Aluminum Alloy AA Research Articles

Realization of Friction Stir Welding of Aluminum Alloy AA5754 Using a Ceramic Tool

When engaging in the friction stir welding of aluminum/aluminum joints, the conventional use of tools made of hard metal and steel involves a complex and costly production process. These tools experience wear over welding distances and require frequent replacement to ensure the consistency of the welded seams. The exploration of silicon nitrite as a tool material emerges as a promising alternative in this scenario. The heightened hardness of non-oxide ceramics anticipates a diminished wear rate compared to traditional welding materials, translating into an extended operational lifespan. Nevertheless, the adoption of ceramics introduces challenges initially perceived as detrimental to friction stir welding. The inherent brittleness of silicon nitrite makes it susceptible to breakage under specific loads, and thermal stresses within the component can lead to failure. To mitigate these vulnerabilities, a ceramic material with high thermal shock resistance and a low proportion of sintering additives was used. Employing these accurately designed tools friction stir welding (FSW) was performed on sheets of AA5754, followed by a comprehensive examination of their microstructural and mechanical properties. It was demonstrated that a joint efficiency of 88% can be achieved, and that an increase in hardness within the stir zone occurred as a consequence of grain refinement. Furthermore, the Portevin–Le Chatelier effect, which is characteristic of this alloy, was influenced by the FSW process.

Optimising the quality of several welds in a metal-inert gas arc joining of AA6082 and AA7075 using the grey-based Taguchi technique

In recent times, welding procedures have become increasingly crucial for fabrication and manufacturing businesses. Gas metal arc welding, also known as metal inert gas (MIG) welding, has attracted much attention because of its versatility. Its benefits include low capital needs, high deposition rates, high productivity, and simplicity in adjusting to automation. It has drawn much interest because of its versatility in welding metallic materials and ease of automation. This work's objective is to maximise the multi-performance properties of the aluminium alloys AA6082 and AA7075's MIG-welded butt junction by using a hybrid grey-based Taguchi technique. During MIG welding, With the L9 Taguchi orthogonal array, the welding speed, gas flow rate, and current were optimised. Weld joint integrity has been evaluated using the fusion zone's Vickers microhardness, per cent elongation, tensile strength, and yield strength. The ideal welding current for the MIG process is 140 A, the perfect welding speed is 10 mm/min, and the excellent gas flow rate is 18 lit/min. The material showed 159.68 MPa of tensile strength, 112.79 MPa of yield strength, 16.79% of percentage elongation, and 70.95 HV of hardness under optimal conditions. With a 63.99% contribution to the process, welding speed greatly affected the weldments' overall performance. The confirmatory test confirmed the optimisation procedure also demonstrated that optimising numerous welded joint performance factors may be achieved effectively with the grey-based Taguchi approach.

Effect of vibration frequency on mechanical properties and microstructure of metal inert gas welded dissimilar AA5083 and AA6061 aluminum alloy joints

This study explores how the frequency of vibrations affects the physical, mechanical, and residual stress properties in dissimilar metals welding between AA5083 and AA6061. The vibration-assisted welding process involves the application of vibration frequencies; 0 Hz, 10 Hz, 30 Hz, and 50 Hz. Weld joints were then examined for their microstructure, tensile strength and impact strength. They were also examined using X-ray diffraction to quantify surface residual stress. The findings suggest that welding with a 50 Hz vibration frequency produced weld metal characterized by a fine and consistent equiaxed microstructure. This welded joint exhibited exceptional mechanical property, boasting an ultimate tensile strength (UTS) of 197.87 MPa, an elongation of 15.28 %, and an impact strength of 8.10 J (J). Moreover, this welded joint displayed the lowest surface residual stress within the weld metal, measuring at 110.9 MPa. The application of high-frequency vibrations during aluminum welding promotes a more homogeneous mixing of molten metals between AA5083 and AA6061 in the weld metal. These vibrations also result in increased internal pressure within the molten weld metal, causing dissolved gas bubbles like H2, O2, and N2 to break and release.

Research on Process Characteristics and Properties in Deep-Penetration Variable-Polarity Tungsten Inert Gas Welding of AA7075 Aluminum Alloy

In this study, a new deep-penetration variable-polarity tungsten inert gas (DP-VPTIG) welding process, which is performed by a triple-frequency-modulated pulse, was employed in the welding fabrication of 8 mm AA7075 aluminum plates. The electric signal, arc shape, and weld pool morphology of the welding process were obtained by means of high-speed photography and an electric signal acquisition system under varying parameters of the intermediate frequency (IF) pulse current. The principle of the arc characteristics and the dynamic mechanism of the weld melting during the process are explained. In addition, the macroforming, microstructure, and microhardness of the welded joints were investigated. The results indicate that, with an intermediate frequency pulse of 750 Hz, the arc displayed a higher energy density and a more effective arc contraction, which improved weld appearance and penetration. Moreover, the impact and stirring action of the arc refined the microstructure grains of the weld center. Therefore, this new welding method is feasible for welding medium-thickness aluminum alloy plates without a groove.

Evaluation the effect of multi-pass friction stir processing on the wear, mechanical properties, and microstructure of the AA1050/ZrO2 surface nanocomposite

This work presents surface nanocomposites of aluminum alloy AA1050, reinforced with zirconium oxide (ZrO2) nanoparticles developed through multipass friction stir processing (FSP). This article attempts to study the effects of the number of passes on the wear rate, microhardness profile, tensile properties, and macrostructure of surface nanocomposites. The results demonstrate that an improved distribution of ZrO2 nanoparticles is obtained following each FSP pass, and that the number of passes increases with a decrease in stir zone (SZ) grain size. Consequently, it was found that applying FSP passes continuously enhances the materials' microhardness and tensile characteristics. In the microstructure development of the stir zone during the ZrO2 nanoparticle FSP, dynamic recrystallization (DRX) was an essential mechanism. The main reason for this is that surface nanocomposites with homogenous ZrO2 particle dispersion and no discernible particle clustering in the stir zone were shown by microstructural studies conducted through FSP, which significantly reduced the matrix grain size. The AA1050 base metal (BM) has an ultimate tensile strength, yield strength, and hardness of 59.2 MPa, 24 MPa, and 30.1 respectively. The nanocomposite generated by 5 FSP passes exhibits improved yield stress (55 MPa), tensile strength (94.5 MPa), and microhardness (86.5 HV), but its tensile ductility decreased from 34% to 23.8% when compared to the base metal. Tensile strength that is higher is the outcome of fine dimples' ability to pin the dislocation movement during tensile loading. According to fractographic studies, the ductile–brittle mode replaced the dimple-shaped ductile fracture mode.

Effect of wire deposition rate on macro and microscopic characteristics of laser weld-brazed AA5083 aluminum alloy to galvanized steel joints and their corrosion response

ABSTRACT In this study, dissimilar metals, such as aluminium (AA5083) and galvanised interstitial free steel, were laser-brazed in a flange configuration using eutectic filler aluminium wire (4047, Al-12%Si). To investigate the effects of wire deposition rate on the characteristics of laser-brazed joints and to understand the factors contributing to corrosion in these joints. The wire deposition rates were varied while keeping other laser parameters constant. Changes in wire deposition rate were observed to affect the flow behaviour of molten metal leading to variations in the geometrical characteristics of the brazed joints and interfacial reactions as revealed by macroscopic examination. A series of corrosion tests, including electrochemical, immersion, and salt spray tests, were conducted on the laser-brazed joints. It was demonstrated by Immersion corrosion tests that the wire rate influenced the corrosion results for the laser-brazed joints. However, the salt spray test showed no substantial effect on corrosion with respect to different wire deposition rates. Furthermore, the electrochemical results indicated significant changes in the corrosion response of the brazed zone due to the presence of chemically dissimilar phases. A correlative discussion between laser parameters, observed microstructure, and their effects on the corrosion performance of the brazed samples is presented.

A Two-Scale Texture Modelling of AA1050 Aluminum Alloy after Accumulative Roll-Bonding (ARB)

Texture evolution during accumulative roll-bonding (ARB) is complicated because of the change in the through-thickness position that results from repeated cutting–stacking and roll-bonding. In this study, a macro–micro two-scale modeling was carried out to investigate the behaviors of texture evolution during ARB. The finite element method (FEM) was used to predict the strain history at a macro-scale, while a crystal plasticity FEM was used to reproduce the texture at a micro-scale. The texture evolution along three different cutting–stacking paths was traced and investigated. The patterns of texture transition between the rolling-type, shear-type, and random-type textures were studied by using area fractions of texture components, the distribution of textures, and the distribution of crystal rotation angles.

Subgrain Size Modeling and Substructure Evolution in an AA1050 Aluminum Alloy during High-Temperature Compression.

For materials with high stacking fault energy (SFE), such as aluminum alloys, dynamic recovery (DRV) and dynamic recrystallization (DRX) are essential softening mechanisms during plastic deformation, which lead to the continuous generation and refinement of newborn subgrains (2° ˂ misorientation angle ˂ 15°). The present work investigates the influence of compression parameters on the evolution of the substructures for a 1050 aluminum alloy at elevated temperatures. The alloy microstructure was investigated under deformation temperatures ranging from 300 °C to 500 °C and strain rates from 0.01 to 0.1 s-1, respectively. A well-defined substructure and subsequent subgrain refinement provided indication of the evolution laws of the substructure under high-temperature compression. Corresponding experimental data on the average subgrain size under various compression conditions were obtained. Two different independent average subgrain size evolution models (empirical and substructure-based) were used and applied with several internal state variables. The substructure model employed physical variables to simulate subgrain refinement and thermal coarsening during deformation, incorporating a corresponding dislocation density evolution model. The correlation coefficient (R) and root mean square error (RMSE) of the substructure-based model were calculated to be 0.98 and 5.7%, respectively. These models can provide good estimates of the average subgrain size, with both predictions and experiments reproducing the expected subgrain size evolution using physically meaningful variables during continuous deformation.

Effect of the vanadium layer on the wear resistance of the 1050 aluminum alloy coated by cathodic cage plasma deposition

This study investigated the wear resistance of AA1050 aluminum alloy coated using plasma deposition with a vanadium cathode cage and evaluated the effect of subsequently applying a plasma nitriding process to the coated sample. The treatments were carried out at 400°C for 3 hours. To evaluate the composition, thickness and wear resistance of the layers formed, X-ray fluorescence (XRF), scanning electron microscopy (SEM) and fixed ball micro-abrasive wear tests were applied. The treatments altered the wear mechanisms, with the treated samples also showing the two- and three-body wear modes, compared to the aluminium alloy, which only showed the two-body wear mode. The sample coated using only the cathodic cage deposition technique obtained a greater layer thickness (7.6 μm) and better wear resistance, with a reduction of around 83% in the worn volume compared to the 1050 aluminum alloy. However, the subsequent plasma nitriding process proved to be detrimental to the tribological properties of the coating formed, reducing the layer thickness (3.2 μm) and decreasing wear resistance.

Characterization of Portevin–Le Chatelier effect in aluminum alloy AA5052 under strain-controlled tensile test via digital image correlation and acoustic emission

Characterization of Portevin–Le Chatelier effect in aluminum alloy AA5052 under strain-controlled tensile test via digital image correlation and acoustic emission

Exploratory data analysis & EDS analysis on tool chip adhesion under dry and nano minimum quantity lubrication machining environment

Adhesion, abrasion, plowing and transverse displacement are the major causes of origin of friction. During dry machining of ductile materials, chips are fused with the rake face of the cutting tool and contribute to the formation of the built up edge. Built up edge protects the rake face of the tool from wear, but makes the machined surface rough. To improve the tribological properties and to decrease the tool-chip adhesion, cutting fluids are used. Cutting fluids are added to the machining zone to minimise cutting temperature and friction, but they result in environmental and health degradation. Surface texturing of tools is a potential way to modify the tribological properties of mating surfaces in order to increase the tribological qualities and decrease the tool-chip adhesion. The performance of surface textured tools depends upon orientation, dimple depth, width and pattern. Under lubrication regime, microholes in surface textured tools acts both as lubrication reservoir and traps wear debris to reduce abrasive wear. Nano Minimum Quantity Lubrication (nano-MQL) is an advanced lubrication technique used in machining processes, specifically designed to minimize the use of lubricants while maintaining effective lubrication. This method involves delivering an extremely small amount of high-performance lubricant directly to the cutting zone. The MoS2 lubricant with sunflower oil is typically in the form of nanodroplets, which are much smaller than conventional minimum quantity lubrication (MQL) droplets. The Exploratory Data Analysis (EDA) methodology enables the identification of patterns, trends, and outliers within the collected data, offering insights into the complex interplay of factors affecting the machining of Aluminium Alloy AA2024. At a spindle speed of 3500 rpm the feed force decreases by 37% under dry environment when compared with nano-MQL environment. Under dry environment average surface roughness reduces by 27% when compared with nano-MQL environment.

Microstructural analysis and defect characterization of additively manufactured AA6061 aluminum alloy via laser powder bed fusion

AA6061 is a widely used aluminum alloy with significant applications in the aerospace and automotive industries. Despite its popularity, the utilization of additively manufactured AA6061 through the laser powder bed fusion (LPBF) process has been hindered by the pronounced formation of pores and cracks during rapid solidification. This study quantitatively investigated defects, including pores and cracks, and microstructures, including texture, grain size, subgrain structure, and precipitates, of LPBF-manufactured AA6061 across a broad spectrum of laser power and speed combinations. A high relative density of more than 99 % was achieved with a low-power and low-speed condition, specifically 200 W and 100 mm/s, with minimal cracks. Large pores, akin to or exceeding melt pool dimensions, emerged under either low or high energy densities, driven by the lack of fusion and vaporization/denudation mechanisms, respectively. Solidification cracks, confirmed by the fractography, were propagated along grain boundaries and are highly dependent on laser scanning speed. Elevated power and speed exhibited finer grain size with refined subgrain cellular structures and increased precipitates at interdendritic regions. The cooling rate and thermal gradient estimated from thermal analytical solutions explain the microstructures’ characteristics. Nano-sized Si-Fe-Mg enriched precipitates are confirmed in both as-built and heat-treated conditions, whereas T6 heat treatment promotes a uniform distribution with coarsening of those precipitates. The low-power and low-speed conditions demonstrated the highest yield strength, consistent with defect levels. A minimum of 102.3 % increase in yield strength with reduced ductility was observed after heat treatment for all examined conditions. This work sheds light on printing parameters to mitigate the formation of pores and cracks in additively manufactured AA6061, proposing a process window for optimized fabrication and highlighting the potential for enhanced material properties and reduced defects through process control.

Life cycle assessment of the rolling process of thin aluminum sheets

ABSTRACT Primary aluminum recycling has been demonstrated to play a pivotal role in sustainable manufacturing. Nevertheless, among all the Life Cycle Assessment (LCA) studies existing in the literature on aluminum products, very few focus on the rolling stage. In this work, LCA of two semi-finished products, plates and coated strips, made of AA8011 aluminum alloy have been carried out. Inventory data were collected by the Laminazione Sottile plant, except for coil coating data for pharmaceutical caps, which were collected in the Italcoat plant. For both semi-finished products, hot rolling and fusion mostly affect the environmental impact of the manufacturing. Moreover, results show that the substitution of virgin primary aluminum with secondary aluminum results in a remarkable minimization of the environmental impact. Indeed, a 50% reduction of primary aluminum results in about a 70% reduction of GWP to produce AA 8011 coated strips.

AA5754 aluminium alloy springback reduction by post forming electro plastic effect (PFEPE)

Post Forming Electro Plastic Effect (PFEPE) has been proposed as a promising technology for mitigating forming forces and addressing springback challenges in the metal forming industry. However, several research gaps remain unaddressed for the industrialization of this technology. Firstly, there is a lack of experimental validation regarding the impact of stress reduction on springback. Secondly, the potential effect of the skin-effect on the current metrics of stress reduction needs to be evaluated. Additionally, a post-forming electrically assisted elastoplastic material model is necessary for further technology development in stamping processes. This study tackles these challenges by utilizing AA5754H22 as a reference material and integrating a comprehensive experimental campaign with finite element numerical models and empirical material model developments. Our findings confirm that PFEPE facilitates a significant reduction in springback, achieving approximately a 100% reduction. Although the skin-effect introduces non-uniform current flux density distribution, its impact at the macroscopic level is negligible for the studied thin samples. While the numerical results of springback fails to accurately replicate experimental results, the developed material model aligns well with experimental trends.

Impact of cooling methods on the corrosion behavior of AA6063 aluminum alloy in a chloride solution

Abstract In this work, the AA6063 Al alloy was processed by cooling at four different conditions. The impact of the type of cooling method on the corrosion behavior of the produced alloys after 1 and 24 h in 3.5% NaCl solutions was carried out. Various electrochemical measurements, such as cyclic potentiodynamic polarization (CPP), chronoamperometric, and electrochemical impedance spectroscopy (EIS) measurements, were employed. The CPP data revealed that the intensity of corrosion of the alloys is highly influenced by the cooling method. The change in the chronoamperometric current at −650 mV (Ag/AgCl) over time indicates the possibility of pitting corrosion, particularly after 24 h, where the recorded currents showed a continuous increase over time. The scanning electron microscopy images taken for the surfaces of the alloys after corrosion confirmed that the lowest deterioration occurring on the surface was for the AA6063 alloy that was quenched in water. The EIS plots also demonstrated that AA6063 alloy exhibits different corrosion resistances when different cooling methods are applied. All measurements indicated that the corrosion resistance increases in the following order: the quenched alloy in water > the air-cooled alloy > the furnace-cooled alloy > the as-received alloy. The exposure for 24 h decreases the corrosion damage of all alloys via the formation and thickening of a top layer of corrosion products on its surface over time.

An investigation on the corrosion behaviour of B4C-reinforced AA5083 aluminium alloy in sodium chloride solution using electrochemical impedance spectroscopy

An investigation on the corrosion behaviour of B4C-reinforced AA5083 aluminium alloy in sodium chloride solution using electrochemical impedance spectroscopy

Simple incorporation and calcination of Zn-Al LDH during PEO processing in near-neutral pH solutions

Plasma electrolytic oxidation (PEO) process was employed for preparing oxide coatings on AA2024 aluminum alloy in solutions containing Zn-Al layered double hydroxide (LDH) particles. Sodium hexametaphosphate aqueous solution was selected as the standard solution, based on its almost neutral pH value considered as important for the LDH stability. Different additives to the standard solution were examined including 2-mecaptobenzothiazole (MBT) and different Zn-Al LDH compounds. The formed coatings underwent characterization regarding their morphology, chemical and phase composition, as well as assessment of their photocatalytic and corrosion protection efficiency. Coating thickening and compactness evolution were noted for all coatings with LDH additions to the standard solution. Obtained coatings are well-crystallized featuring γ-Al2O3 and two Zn-containing crystalline phases, namely ZnO and NaZnPO4, originating mainly from the LDH addition to the solution. PEO coatings obtained in this study demonstrated very reasonable photocatalytic activity for immobilized photocatalyst, reaching 51 % after 6 h under UV irradiation. The inclusion of Zn-Al LDH substantially boosted the impedance modules at low frequencies by two orders of magnitude compared to bare AA2024 alloy when exposed to a 3.5 % NaCl solution.

On the Relationship between Thermomechanical Processing Parameters and Recrystallization Texture in AA1100 Aluminum Alloy

In this study, 48 hot-rolling processing conditions were designed to investigate the influences of thermomechanical processing parameters on the recrystallization behavior and texture development. The hot-rolling experiments were conducted using the thermomechanical simulator Gleeble 3800 at temperatures of 275, 300, and 350 °C with strain rates of 5 and 90 s−1 up to 60 and 85% reduction. The microstructure and texture analysis were measured by using the EBSD technique on a large area. Experimental results show that the Cube component maintains a volume fraction between 10% and 20%, below the 40% recrystallization fraction, but the volume fraction of Cube significantly increases between 20% and 50% above the 40% recrystallization fraction. However, the fractions of Rotated Cube (RC) and Goss components remain below 10%.

Anticorrosion mechanism of epoxy coating containing mesoporous resorcinol-formaldehyde hollow nanosphere loaded with 8-Hydroxyquinolin

Mesoporous resorcinol-formaldehyde hollow nanosphere (MRFHN) with erythrocyte like shape was prepared successfully. The average diameter, shell thickness, and specific area of MRFHN are 223 nm, 42 nm, and 73.2 m2/g, respectively. The average loading capacity of 8-Hydroxyquinoline (8-HQ) in MRFHN is 33 % and the sucked 8-HQ can release continuously from MRFHN. MRFHN loaded with 8-HQ (MRFHN@8-HQ) was introduced into epoxy coating to enhance its anticorrosion performance. The results show that epoxy coating pigmented with MRFHN@8-HQ has a higher anticorrosion performance than neat epoxy coating. Especially, epoxy coating containing 4 wt% of MRFHN@8-HQ presents the best anticorrosion performance and self-healing function, and its coating resistance is still maintained at 109 Ω cm2 even after 50-day immersion in 3.5 wt% NaCl solution. Meanwhile, the scratch on coating surface is covered by a thin layer of 8-HQ which can prevent the AA2024 aluminum alloy from corrosion even after 50-day neutral salt spray test. 8-HQ can release from MRFHN and form a compact inhibiting layer on AA2024 aluminum alloy surface, thus the corrosion of AA2024 aluminum alloy is suppressed effectively. MRFHN@8-HQ can be used as a high performance anticorrosion pigment to give epoxy coating a long term protection.

The influence of various welding wires on microstructure, and mechanical characteristics of AA7075 Al-alloy welded by TIG process

Owing to their exceptional mechanical properties, the various welding wires used to combine aluminum can meet the needs of many engineering applications that call for components with both good mechanical and lightweight capabilities. This study aims to produce high-quality welds made of AA7075 aluminum alloy using the GTAW technique and various welding wires, such as ER5356, ER4043, and ER4047. The microstructure, macrohardness, and other mechanical characteristics, such as tensile strength and impact toughness, were analyzed experimentally. To check the fracture surface of the AA7075 welded joints, the specimens were examined using optical and scanning electron microscopy (SEM). A close examination of the samples that were welded with ER5356 welding wire revealed a fine grain in the weld zone (WZ). In addition, the WZ of the ER4043 and ER4047 welded samples had a coarse grain structure. Because the hardness values of the welded samples were lower in the WZ than in the base metal (BM) and heat-affected zone (HAZ), the joints filled with ER5356 welding wire provided the highest hardness values compared to other filler metals. Additionally, the ER4047 filler metal yielded the lowest hardness in the weld zone. The welding wire of ER5356 produced the greatest results for ultimate tensile stress, yield stress, welding efficiency, and strain-hardening capacity (Hc), whereas the filler metal of ER4043 produced the highest percentage of elongation. In addition, the ER4047 fracture surface morphology revealed coarser and deeper dimples than the ER5356 fine dimples in the welded joints. Finally, the highest impact toughness was obtained at joints filled with the ER4047 filler metal, whereas the lowest impact toughness was obtained at the BM.