6063-T6 Aluminum Alloy Research Articles

Improving heat transfer in an air-cooled engine by redesigning the fins

Heat transfer modelling and simulation were carried out in a single-cylinder, four-stroke, air-cooled engine to evaluate the heat transfer rate of the engine block. The modelling studies of cylinders with different numbers of fins and different geometry were performed using the SolidWorks computer platform. The tested components were made of 6063-T6 aluminium alloy castings. The simulation concerned different numbers of fins as well as changing the geometry of fins with circular and rectangular perforations. The results of the studies showed the possibility of improving the power to mass ratio for cylinder efficiency and heat transfer rate. It was shown that a large number of fins leads to an increased heat transfer rate, but it affects the overall engine efficiency due to the increase in the total engine mass. Circular perforation is a better design solution than rectangular perforated fins with the same cross-section. Circular perforation provides a lower engine cylinder mass and gives more than 4 % better heat transfer rate. The perforation size was tested using circular perforations with a diameter of 7.14 mm, 8.5 mm and 10 mm. With a 7.14 mm diameter perforation the heat transfer rate increases slightly compared to the other tested ones, while a 10 mm diameter perforation provides the best mass reduction.

Fatigue performance of a fastener hole treated by a novel electromagnetic strengthening process

In this study, a novel non-contacting electromagnetic cold expansion process was proposed to improve the fatigue performance of hole component using a single power supply and a single coil. The stress state and deformation of the 6063-T6 aluminum alloy hole component during the electromagnetic strengthening process were investigated through numerical simulation. The residual stress around the hole edge was measured using XRD. Fatigue testing was performed to verify the effectiveness of the process on improving the fatigue life of the hole component. Results showed that the proposed electromagnetic strengthening process could effectively improve the fatigue life of the hole component. Fatigue life of the specimen via electromagnetic treatment is 3.42 times of that of the original specimen at a maximum stress of 120 MPa. Simulation results indicated that the generation of compressive residual stress was attributed to the falling stage of the pulse current, and the maximum compressive residual stress was −102 MPa.

Effect of Process Parameters on Strength and Surface quality of Friction stir welded AA 6063-T6 Aluminum Alloy

Effect of Process Parameters on Strength and Surface quality of Friction stir welded AA 6063-T6 Aluminum Alloy

Mechanism of grain refinement in FSW joints of 6063-T6 aluminum alloy under different rotational speeds

Abstract The inherent properties of aluminum alloys often result in defects like deformation and porosity in joints and welds created through conventional fusion welding. Our paper investigates the impact of varying rotational speeds in the friction stir welding of 4mm thick 6063-T6 aluminum alloy, focusing on microscopic grain refinement and mechanical property alterations in T-joints. Using mechanical stretching and numerical simulation methods, we observed that the initial weld joint is robust, with minimal flying edges and a distinct fish-scale pattern on the surface. Moreover, the grain sizes in the weld’s core area are notably smaller than those in the region affected by the upper axial shoulder. The mechanical properties of the joint experienced a first increase and then a decrease in mechanical properties when the friction stir welding rotational speed, was increased from 600r/min to 1500r/min. Moreover, in 1000r/min rotational speed, the material welded tensile strength and yield strength of the best tensile strength compared to the raw material to enhance the 21MPa, yield strength of 30MPa, elongation close to the raw material of 89.86%.

Comparative study of anodizing and chromate conversion coatings in enhancing the wear and corrosion properties of 6063 Al alloy

ABSTRACT The present study compares the corrosion and tribological performance of anodic oxide (AO) and chromate conversion (CC) coatings deposited on 6063-T6 aluminum alloy. The goal is to determine how these treatments benefit the performance of the underneath substrate. The corrosion protection properties of the coatings were evaluated by potentiodynamic polarization measurement in 3.5 wt. % NaCl solution. The friction and sliding wear behavior of coatings were studied by pin-on-disk test and their erosion behavior was examined by air jet solid particle erosion test. The surface structure, chemical composition, roughness, wettability, and hardness of specimens were also characterized. The results showed that the AO coating with porous surface morphology was found to be thicker, rougher, and harder along with greater wettability, when compared to CC coating. Furthermore, the AO coating with polarization resistance of 6.64 × 103 Ω.cm2 enhanced the corrosion resistance of the substrate more than 8 times. In addition, the AO coating under dry and wet sliding conditions reduced the aluminum alloy substrate wear rate by about 80% and 52%, respectively. However, due to being more brittle, the AO coating lost more weight than the CC coating during the solid particle erosion test.

Effect of post-welding coating process on the organization and properties of MIG-welded T-joints of 6063-T6 aluminum alloy

Abstract With the rapid development of the precision industry, aluminum alloy structural parts have been widely used. However, in the welding process of aluminum alloy, there are problems such as welding deformation and weld tumor defects due to the special physical characteristics of aluminum alloy. Therefore, this paper mainly focuses on 6063-T6 aluminum alloy as the research object to analyze the effect of the coating process on the organizational properties of MIG welded T-joints of 6063-T6 aluminum alloy. First, based on the Simufact welding finite element analysis platform, the establishment of a three-dimensional welding simulation model, the simulation calculations and test results for comparison, the peak temperature and temperature change trend of each measurement point between the two. Secondly, according to the T-joint welding process, welding numerical simulation of 6063-T6 aluminum alloy rear compartment structural parts to obtain the rear compartment assembly welding residual stress is mainly concentrated in the vicinity of the weld. Finally, the impact of welding current on the organization and properties of T-shaped welded joints of 6063-T6 aluminum alloy was discussed. The results show that the coating process has a good strengthening effect on the mechanical properties of welded joints. Compared with the pre-coating process, the welded joint tensile strength increased by 14.93%, and the welding coefficient of 73% of the parent material heat-affected zone microhardness increased by 21.82% compared to the pre-coating process. In this paper, the finite element theory of the coating process and MIG welding, T-joint organization between the found welding heat-affected zone after the coating process can make Mg, and Si atoms continue to be enriched, and mechanical properties strength is enhanced.

Study on Morphology, Microstructure and Properties of 6063-T6 Aluminum Alloy Joints in MIG Welding

In this paper, a metal inert gas (MIG) shielded welding method was used for high-quality welding of 6063-T6 aluminum alloy sheet with a thickness of 2.5 mm. The welding process of MIG welding was accurately simulated and the welding temperature field and thermal cycle curve were calculated using a combination of Gaussian body heat source and double ellipsoidal heat source. As the welding current increased from 75 A to 90 A, the reinforcing phase precipitated under the microstructure of the joint gradually became larger and re-solidified into the body, resulting in a reduction in mechanical properties. When the welding current is 85 A, the pitting resistance of weld forming and weld area reaches its optimum. At this time, the tensile strength of the joint is up to 110.9 MPa, the elongation is up to 16.3% and the Vickers Microhardness is up to 46.9 HV.

Low-speed finite element frontal impact analysis on aluminum alloy bumper made of 6063-T6

In this research, a low-speed impact numerical simulation has been performed on a 6063-T6 Aluminum alloy bumper welded by MIEA technique using ANSYS® LS-DYNA® Workbench™ 19.2, according to the requirements of the Federal Motor Vehicle Safety Standards and Regulations. For the numerical simulation, mechanical properties were obtained from quasi-static tensile tests in 6063-T6 aluminum alloy joints, these joints were manufactured using the MIEA (modified indirect electric arc) technique and a MIG welding process and post-weld heat treatment (PWHT). For the numerical impact simulation, the following parameters have been used: mass of the impactor of 1000 kg, speed of the impactor 4 km/hr and material of the impactor AISI 4130 steel. The simulation study showed that aluminum alloy joints used in bumper beam has excellent mechanical strength under low-speed impact conditions. Among the mechanical properties that have been recovered due to PWHT are the following: it was possible to harden the fusion zone, that is, there was an increase in hardness values from 80 HV0.1 to 98 HV0.1, the heat affected zone was eliminated, obtaining hardness values of approximately 110 HV0.1, a recovery in yield strength (59%) was observed, that is, in welding condition (170 MPa) and welding condition plus PWHT (270 MPa). In terms of tensile strength, a recovery (42%) was observed, going from welding condition (214 MPa) and welding condition plus PWHT (304 MPa). Tensile strength also had an increase ranging from 214 MPa to 304 MPa. This represents an increase of 42 pct. Finally, the simulation showed that the welding zone on the bumper has very good resistance to low speed impact since no permanent deformations were observed, that is, after the impact the bumper returns to its initial position.

Microstructural and mechanical analysis of 6063-T6 aluminum alloy joints bonded by friction stir welding

Microstructural and mechanical analysis of 6063-T6 aluminum alloy joints bonded by friction stir welding

A study on the microstructures of resistance spot welded Al 6063 T6 and SS 304

The micro structural and mechanical activity of resistance spot welds (RSW) conducted on 6063-T6 aluminium alloy sheets and SS 304 stainless steel welded at various welding parameters is investigated in this report. In order to determine the effect of welding parameters on the efficiency of the welds, micro structural examinations and hardness assessments were carried out. In order to define their strength and the microstructures of the base and welded components, the welded joints were subjected to static tensile-shear testing. Present work focused on evaluating the mechanical properties for RSW welding aspects of SS 304 and AL6063 T6 materials of 1 and 1.5 mm thick.

Properties of High Speed Friction Stir Welded 6063-T6 Aluminum Alloy

Friction stir welding (FSW) is as known as a revolutionary welding technology, which has come to the foreground in recent years. The low welding speed affects the efficiency of friction stir welding (FSW) and hinders the large-scale commercial application of FSW. In order to improve the welding speed and promote the application of FSW, 6063-T6 aluminum alloy plates were friction stir welded with welding speed of 3000 mm/min. The properties of welds were also tested and analyzed. The results show that the alloy plates can be successfully welded by FSW with high speed welding speed, and the tensile strength of weld can reach over 71 % that of the base material.

Numerical Study of the Section Moment Capacity of Complex-Shaped Aluminum Mullions

Curtain wall systems made of an aluminum frame and infilled with glass panes are extensively used in present day high-rise buildings. The vertical members of the aluminum frame, known as mullions, are complex-shaped and are primarily subjected to bending action when the curtain wall panels are exposed to wind pressure or suction loading. This paper investigates the section moment capacity of 6063-T6 aluminum alloy mullion sections subjected to wind actions using a numerical study. An experimental study conducted to determine the section moment capacity of the mullions is summarized in this paper. The results from an experimental study on the mechanical properties of 6063-T6 aluminum alloy mullions are then presented including a suitable stress–strain model. Finite element models were developed to determine the section moment capacities of tested mullion sections, and the details of the finite element modeling procedure and the results are presented in this paper. The developed models included mullions used in the structural and captive glazing systems subjected to both wind pressure and suction loading and were validated using the available test results. Finite element analysis (FEA) results were compared with the predictions from three design methods, the limiting stress method (LSM), the direct strength method (DSM), and the total moment capacity approach (TMCA), based on which the most suitable design method is recommended

Microstructure Evolution and Mechanical Property Characterization of 6063 Aluminum Alloy Tubes Processed with Friction Stir Back Extrusion

Friction stir back extrusion (FSBE) is a technique for lightweight metal extrusion. The frictional heat and severe plastic deformation of the process generate an equiaxed refined grain structure because of dynamic recrystallization. Previous studies proved that the fabrication of tube and wire structures is feasible. In this work, hollow cylindrical billets of 6063-T6 aluminum alloy were used as starting material. A relatively low extrusion ratio allows for a temperature and deformation gradient through the tube wall thickness to elucidate the effect of heat and temperature on the microstructure evolution during FSBE. The force and temperature were recorded during the processes. The microstructures of the extruded tubes were characterized using an optical microscope, energy-dispersive x-ray spectroscopy, electron backscatter diffraction, and hardness testing. The process reduced the grain size from 58.2 μm to 20.6 μm at the inner wall. The microhardness of the alloy was reduced from 100 to 60–75 HV because of the process thermal cycle.

Performance evaluation in CNC turning of AA6063-T6 alloy using WASPAS approach

PurposeSurface roughness and vibration during machining are inevitable which critically affect the product quality characteristics. This paper aims to suggest the implementation of a multi-objective optimization technique to obtain the favorable parametric conditions which lead to minimum tool vibration and surface roughness of 6063-T6 aluminum alloy in computer numerically controlled (CNC) turning.Design/methodology/approachThe case study has been accomplished according to response surface methodology RSM’s Box–Behnken design (BBD) matrix using Titanium Nitride-coated Tungsten Carbide insert in a dry environment. As the experimental results are quite nonlinear, a second-order regression model has been developed for the responses (surface roughness and tool vibration) in terms of input cutting parameters (spindle speed, feed rate and depth of cut). The goodness of fit of the models has also been verified with analysis of variance (ANOVA) results.FindingsThe significance efficacy of input parameters on surface roughness and tool vibrations has been illustrated through multi-objective overlaid 3D surface plots and contour plots. Finally, parametric optimization has been performed to get the desired response values under the umbrella of weighted aggregate sum product assessment (WASPAS) method and verified confidently with confirmatory test results.Originality/valueThe results of this study reveals that hybrid RSM with WASPAS method can be readily applicable to optimize multi-response problems in the manufacturing field with higher confidence.

Microstructural Characteristics and Mechanical Properties of Water Cooling Bobbin-Tool Friction Stir Welded 6063-T6 Aluminum Alloy

In this study, a novel welding method called water cooling bobbin-tool friction stir welding (WBT-FSW) was developed. 4 mm-thick 6063-T6 aluminum alloy sheets were successfully jointed by WBT-FSW. Comparative studies on macro/microstructural characteristics and mechanical properties of the WBT-FSW and conventional bobbin-tool friction stir welding (BT-FSW) joints were carried out. The results indicated that the water mist cooling can significantly decrease the welding temperature and improve both the weld formation and the mechanical properties of the joint. The tensile strength of the WBT-FSW joint was 11.4% higher than that of BT-FSW joint.

Friction and Wear Properties of Plasma Sprayed YSZ/Ni-Cr-Al Coated 6063-T6 Aluminum Alloy

AbstractIn this study T6 heat treated 6063 aluminum alloys were used as substrate material. In order to form a bond between the substrate and the main coating, all samples were coated with Ni-Cr-Al powders. 8 wt% Yttria Stabilized Zirconia powders (YSZ) were coated with plasma spray technique. Thickness of YSZ was 150 μm and bond coating was 36 m. XRD and SEM-EDS analyses were performed to characterize the coating layers. These YSZ coated and uncoated samples were subjected to wear testing under different spindle speed, loading and working distance. Wear test results were compared with the kinetic friction coefficients and weight loss values. Wear marks on YSZ coated and uncoated samples were investigated by SEM analysis. By coating with plasma spray technique, the wear resistance of Al alloys was increased without changing the friction coefficient. It was found that spindle speed had significant effect over the wear properties than the load applied. By YSZ coating, wear properties were increased 10 times.

Microstructures and mechanical properties of resistance spot welded joints of 16Mn steel and 6063-T6 aluminum alloy with different electrodes

The dissimilar resistance spot welding of 16Mn high strength steel and 6063-T6 aluminum alloy was studied by using different welding electrodes and welding parameters. The aluminum alloy nuggets consist of cellular crystals, cellular dendrites and equiaxed dendrites with tangled dislocations and fine Mg2Si particles. There exist intermetallic compound layers including Fe2Al5 layer at steel side and Fe4Al13 layer at aluminum side in the interface zone, and their evolution process has been summarized. The excessive Fe-Al intermetallic compounds deteriorated the steel-aluminum joint strength. The welding electrode morphology and welding parameters had great effects on the steel-aluminum joints. When F-type electrodes were used, the tensile shear load and indentation ratio of the joint are 2534N and 28.0%, respectively under the condition of optimized welding parameters. When optimized electrodes were used, the tensile shear load of the joint reached 3623N and the indentation ratio decreased to 18%, which is related to improving welding temperature distribution. It is more favorable to use the optimized electrodes for increasing the steel-aluminum joint strength and improving its appearance quality.

STUDY OF FATIGUE CRACK GROWTH IN 6063-T6 ALUMINUM ALLOY

The present study relates to fracture mechanics and its aim is to validate the experimental analysis with analytical analysis and find out a relationship between loading parameters and crack growth rate for 6063-T6 Aluminum Alloy. All analysis was done on Side edge notch specimen. The constant U was found to depend on stress ratio R. Variation in load range affects the crack growth rate constant m. For constant load range its variation was negligible, constant C was almost constant at variable load range. Variation of maximum load affects constant C.

Experimental and numerical analysis of tube-core claddings under blast loads

An investigation into the response of a sandwich cladding panel under blast loading is presented. The sandwich cores are composed of square thin-walled metallic tubes. Three primary panel layouts are identified, consisting of panels with four, five and nine tubes within the core. Annealed mild steel and 6063-T6 aluminium alloy tubes are selected as the core material. Hemispherical indentation triggers are used to induce progressive, symmetric buckling. A series of experimental blast tests are conducted on the proposed panels. A ballistic pendulum is used to measure the impulse transferred to the panel. At smaller blast impulses, irregular buckling modes are observed for both the steel and aluminium tube-core panels primarily due to variable trigger performance. For blasts which utilize the full stroke of the tubes, symmetric buckling modes are observed. In all cases panel crush distance increases with increasing impulse and decreases with an increasing number of tubes in the panel core. Further to this, at equal charge mass, the aluminium tube cores show significantly higher crush distance than identical steel tube panels. Analytical predictions of panel response give satisfactory agreement with experimental and finite-element results provided the response is within the pre-compaction regime. Finite-element results using ABAQUS/Explicit also show satisfactory correlation with experimentally obtained global response. Numerical analysis shows that energy absorption is primarily confined to the core tubes with only minimal plastic strains developing in the top plate. A numerical parametric study is conducted to determine influence of load uniformity on panel response. Energy absorption efficiency is found to be highly sensitive to the uniformity of the load, primarily in panels with fewer core tubes and thinner top plates.

Joint Strength Optimization of Adhesively Bonded Patches

Aircraft face damage from impact with objects or birds or due to ageing that leads to fatigue cracks. The conventional methods of repairing aircraft metallic structures generally include the use of a plate joined by screws or rivets. Although these methods are efficient in the short term, they introduce stress concentrations leading to the initiation of new cracks that are difficult or impossible to detect by non-destructive methods. For these reasons, it is necessary to develop new methods to improve the behaviour of the structure (especially for long term) and its manufacture cost. One of the solutions that have been studied by the aeronautical industry is the use of patches bonded with structural adhesives. However, adhesively bonded patches have problems of stress concentration at the edges where crack initiation is prone to occur. This problem can be reduced by the use of a taper and a spew fillet at the end of the patch and by the use of a mixed adhesive technique where a ductile adhesive is placed at the edges of the patch. Double strap specimens from 3 mm thick 6063-T6 aluminium alloy sheet were analysed. Aluminium and straps (or patches) with an internal taper, an adhesive spew fillet, and dual adhesives were experimentally tested. The results obtained were explained by a finite element analysis. A taper angle is beneficial only for the brittle adhesive. The use of two adhesives is advantageous for the taperless configuration.