AA6061 Alloy Research Articles

Investigating the mechanical performance of innovative bean pod ash particulates reinforced in AA6063 alloy for construction and building applications

Abstract The AA6063, renowned for its corrosion resistance, faces limitations in construction and building applications due to its low mechanical strength. Bean pod ash (BPAp), a byproduct of the agro-waste heat-treatment process, presents an innovative and sustainable alternative to synthetic reinforcements. This study aims to improve the mechanical properties of AA6063 by incorporating BPAp and a hybrid of BPAp and alumina. Four aluminum matrix composites (AMCs), including unreinforced AA6063, were fabricated using a two-step stir-casting process with 10 wt.% BPAp and alumina in varying weight ratios. The microstructure, porosity, hardness, tensile strength, Young’s modulus, and ductility of the AMCs were evaluated. SEM analysis showed uniform BPAp dispersion and porosity below 4%, indicating lightweight AMCs. The composites exhibited enhanced mechanical properties, showing increased hardness (74.70-to-105.04 BHN), tensile strength (118.87-to-207.49 MPa), ductility (5.00-to-12.22%), and Young’s modulus (13.25-to-15.63 GPa). These findings demonstrate that BPAp effectively enhances AA6063 and offers a cost-effective, eco-friendly reinforcement solution. Graphical abstract

Role of Laser Shock Peening in Refining Microstructure and Mitigating Corrosion in AA5083 Alloy

Role of Laser Shock Peening in Refining Microstructure and Mitigating Corrosion in AA5083 Alloy

The Effect of Internal and External MQL Methods Used for Environmentally Friendly Manufacturing on Machining Performance in Drilling AA2024 Alloys: A Comparison for ANN And Taguchi Analyzes

In recent years, the interest in sustainable manufacturing has created an increasing demand for the economical and environmentally friendly Minimum Quantity Lubrication (MQL) method. However, there are not enough studies comparing internal and external MQL applications in drilling operations. The aim of this study is to investigate the effects of internal and external MQL application on drilling performance. Using Taguchi L9 experimental design, AA2024 aluminum alloy was drilled under three different cooling conditions (internal MQL, external MQL, dry), three different cutting speeds (100, 125, 150 m/min) and three different feeds (0.10, 0.15, 0.20 mm/rev). Surface roughness (Ra) was determined as the performance criterion, 30 repetitions were made in each experiment and the average Ra values were calculated for each condition. At the end of the experiments, the lowest Ra value (0.5 µm) was obtained in the internal MQL condition where the lowest cutting speed (100 m/min) and feed (0.1 mm/rev) parameters were used. In the external MQL condition, Ra results close to dry cutting were observed. The ANOVA analysis revealed that the control factor with the greatest effect on Ra values was the cooling condition. In addition, tool wear after the 30th hole was examined with SEM images and minimum deformation was observed in the internal MQL. ANN and Taguchi analyses were applied to the Ra data measured in the experiments. It was observed that the measured Ra data were in agreement with the data estimated using the Taguchi approach by 97% and with the data estimated using the ANN approach by 99%.

Impact of cold upset forging during heat treatment in Al-1.1Si-0.97Mg alloy

Abstract Al-Si-Mg alloys possess superior forgeability attributed to their silicon content and are heat-treatable, allowing for modification of mechanical properties. The AA6082 alloy, renowned for its medium strength and lightweight nature, finds extensive applications in the automotive and aerospace sectors. Researchers utilize thermomechanical processing to tailor microstructure and mechanical properties. This study delves into the effects of cold upset forging on AA6082 alloy behaviour post partial solutionizing and aging heat treatment, with variations in time and temperature. Subsequent analysis investigates microstructural alterations and their relationship with mechanical properties under diverse aging conditions post-forging. This investigation aims to elucidate the structure–property interplay for understanding 6082 alloy’s behaviour in better way. The internal stresses/residual stresses also play a pivotal role to change the AA6082 behaviour during thermomechanical processing. This is also investigated while relating microstructural aspects with mechanical properties and fractography.

Effect of thermo-mechanical age hardening on the strength and electrical conductivity of Copper-AA6063 bimetallic wire.

This research explored the impact of age-hardening treatment on the mechanical response and electrical resistivity of copper-clad AA6063 alloy bimetallic wire, with a focus on microstructural analysis and interface characterization. In this study, AA6063 alloy wire was inserted into an oxygen-free high conductivity copper tube, and a bimetallic wire was fabricated through a wire drawing process that reduced the cross-sectional area in 13 stages. The bimetallic wire underwent a series of thermo-mechanical treatments, including various combinations of wire drawing, solution heat treatment, and artificial aging. The findings revealed that applying solution heat treatment prior to wire drawing, followed by artificial aging after drawing, produced a clean interface free of intermetallic compounds. This processing approach resulted in a Cu-Al bimetallic wire with a strength of 286MPa and an electrical conductivity of 80% IACS. Furthermore, the electrical conductivity-to-density ratio reached 13% IACS/(g·cm⁻³), representing a 16% improvement over oxygen-free high conductivity copper.

Surface properties of friction stir welded dissimilar joints of AA7075 and Mg-WE43 alloys: Effect of positional arrangement

Surface properties of friction stir welded dissimilar joints of AA7075 and Mg-WE43 alloys: Effect of positional arrangement

Mechanical properties of rotary friction and gas tungsten arc welded aa6061 weldments subjected to equal channel angular pressing

AbstractMetal joining can perhaps be said as one of the most indispensable manufacturing processes, with applications across a variety of engineering streams ranging from automobile to day‐to‐day construction activities. The conventional techniques primarily rely on melting the two joining surfaces and solidifying them to create a fresh cast joint. Though the plates being welded are wrought the joints inevitably are cast and hence result in heterogenous mechanical properties between the base metal. In alloy systems with eutectic phase, the high heat input involved in melting the joining surfaces often degrades the strength of the material in the vicinity of the weldment resulting in the formation of a heat‐affected zone. In the welding of heat‐treatable aluminium alloys, heat‐affected zone degradation is often the weakest point of the welded sample The mechanical properties of a weldment can be improved by extensive plastic deformation. Studies show that such strengthening of AA6061 alloys is a combined influence of the grain refinement of the primary matrix as well as the redistribution of the secondary eutectic phase. Weldments fabricated by gas tungsten arc welding and rotary friction welding were subjected to severe plastic deformation, and the effects were studied. Improved mechanical properties thereby providing an alternative solution to post‐weld heat treatment were observed.

Experimental analysis on Bauschinger effects under cryogenically cyclic loading of AA7075 alloy sheets in different heat treatment conditions

Experimental analysis on Bauschinger effects under cryogenically cyclic loading of AA7075 alloy sheets in different heat treatment conditions

A detailed investigation on the mechanical properties and sensitisation resistance of cyclic strengthened AA5083 alloy

A detailed investigation on the mechanical properties and sensitisation resistance of cyclic strengthened AA5083 alloy

Tailing and axisymmetric static laser beam shapes to steer microstructure and improve mechanical properties of autogenously laser welded AA6082 alloy

Tailing and axisymmetric static laser beam shapes to steer microstructure and improve mechanical properties of autogenously laser welded AA6082 alloy

Multi-functional AA6061 alloy hybrid composites via friction stir processing: tailoring properties with TiNi and ceramic nanoparticles

ABSTRACT This study presents a novel approach to developing hybrid aluminum matrix composites by combining the friction stir processing (FSP) of AA6061 with TiNi particles and secondary ceramic reinforcements (TaC, BN, Al2O3). This distinctive combination maximizes the properties of mechanical, tribological, and corrosion resistance. The FSP, when used in combination with TiNi particles, caused a marked reduction in grain size, especially in the presence of Al2O3, owing to enhanced dynamic recrystallization. Thus, the most promising mechanical characteristics among the composites were demonstrated by AA6061/TiNi+TaC, which is 50% higher than base alloy AA6061. Incorporating TiNi particles alone through FSP enhanced wear resistance by 16% and microhardness by 15.4%. Adding TaC nanoparticles further improved wear resistance by 65% and microhardness by 43.8%. BN nanoparticles provided the most significant wear resistance improvement (83% reduction) and a 35.1% increase in microhardness, while Al₂O₃ improved wear resistance by 29% and microhardness by 23.2%. The combination of FSP with TiNi and TaC nanoparticles offers a promising route to achieving a balance of high strength, stiffness, and corrosion resistance, while BN additions prioritize superior wear resistance and low friction.

Wear Study on Various Conditions of AA7075 Metal Matrix Composite with Silicon Carbide (SiC), Boron Carbide (B4C) as Reinforcement for Aerospace Applications

This study aims to investigate the wear behavior of AA7075 alloy with the reinforcement of Silicon carbide (SiC) and Boron carbide (B4C) particles. Process parameters are crucial for component quality improvement, particularly in metal matrix composites (MMCs), a unique class of materials used in a variety of technical applications, such as but not limited to automobiles, marine, and aeronautics.These are frequently utilized in challenging applications due to their significantly better strength to weight ratios, stiffness, and then standard materials. However, it has numerous disadvantages, including high weight ratios, high deformation and stresses, poor fatigue life cycle, early wear and friction, and so on. Up till now, numerous reinforcements have been employed to address these crucial problems. Due to its superior properties, aluminum matrix composites (AMCs) have been used in many different applications. This work attempts to examine the wear behavior of AA7075 alloy reinforced with silicon (SiC) and boron (B4C) particles utilizing the stir casting process AA 7075-(SiC)-(B4C) composites were produced by employing AA 7075 as the matrix material with silicon carbide (SiC) and boron carbide (B4C) particles as reinforcement in various percentages of weight (5%, 10%, and 15%). Parameters of the composites, including wear behavior, coefficient of friction, frictional force, and pin temperature were assessed through graphical representation.

Integrating Digital Twin Technology with AA7050 and AA5083 Alloys for Advanced Resistance Spot Welding Monitoring

Integrating Digital Twin Technology with AA7050 and AA5083 Alloys for Advanced Resistance Spot Welding Monitoring

Experimental and constitutive assessment of tensile flow behavior of AA5083 alloy with microstructural evolution at warm temperatures

The tensile stress-strain response of the AA5083 alloy was investigated over a temperature range of 25 to 300 °C, and strain rate range of 0.001 to 0.1 s−1. A positive sensitivity to temperature along with a small positive correlation with strain rate at elevated temperatures was observed. The developed artificial neural network (ANN) based constitutive model depicted a superior predictability with average absolute relative error of 1.77% as compared to 3.42% and 4.26% for Johnson-Cook (J-C) and Modified Arrhenius (M-A) models, respectively. The detailed microstructural study of strained tensile samples depicted the occurrence of dynamic recovery confirmed by the maximum Kernel Average Misorientation value of 0.84° at 0.01 s−1 strain rate.

Optimization of heat-treated silicon nitride additive parameters on flawless casting of AA7075 alloys: an alternative for conventional green sand

Optimization of heat-treated silicon nitride additive parameters on flawless casting of AA7075 alloys: an alternative for conventional green sand

Cryo-Rolled AA5052 Alloy: Insights into Mechanical Properties, Formability, and Microstructure

Industries operating in extreme conditions demand materials with exceptional strength, fatigue resistance, corrosion resistance, and formability. While AA5052 alloy is widely used in such industries due to its high fatigue strength and corrosion resistance, its strength frequently falls short of stringent standards. For AA5052 alloy, this study explores the combined use of solutionizing and cryo-rolling, followed by annealing, to improve strength. Although several alloys have been reported to undergo solution treatment before cryo-rolling, this study focuses on how post-processing via annealing can lessen the formability constraints usually connected to conventional cryo-rolling. The study sheds light on the ways that solutionizing, cryo-rolling, and annealing interact to affect the alloy’s mechanical characteristics. Microstructure analysis shows that solutionizing improves the grain structure by reducing dynamic recovery, promoting dislocation density, and facilitating precipitate formation. Sheets subjected to solutionizing + cryo-rolling and partially annealed at 250 °C produce optimal results. Interestingly, formability is decreased when cryo-rolling alone is used instead of cold rolling, whereas formability is successfully increased when solutionizing is used. Comparing solutionized + cryo-rolled sheets that are partially annealed at 250 °C to cold-rolled sheets that are annealed at the same temperature, the former show notable quantitative improvements: a notable 17% increase in ultimate strength, a 10% boost in yield strength, and a noteworthy 13% enhancement in microhardness. Formability has improved with the solutionized + cryo-rolled specimens by annealing. This proposed approach led to noticeable gains in formability, hardness, and strength, which would significantly improve material performance for industrial applications.

Study of influence of additive wire-arc manufacturing modes on microstructure of AA7075 alloy

Study of influence of additive wire-arc manufacturing modes on microstructure of AA7075 alloy

An experimental investigation on AA5083 alloy shot peening surface characteristics

The research examines how varying shot peening parameters affect the surface properties of AA5083 aluminum alloy, specifically looking at topography, mechanical traits, and surface morphology. Shot peening treatment is conducted using a custom system with stainless steel shots ranging from 4–8 mm diameter, peening durations of 30–60 min, and shaft speeds of 500–1000 rpm. Surface characteristics are assessed through hardness depth-wise measurement, surface roughness, and tensile properties. The study investigates phase transformation and grain refinements using X-Ray Diffraction (XRD), Electron Backscatter Diffraction (EBSD), and Transmission Electron Microscope (TEM). Full-depth profile and lattice strain study with localized plastic strain are analyzed using XRD, with EBSD estimating the depth of plastically strained regions. A multi-criteria decision-making approach is used to identify the optimal peening parameters based on hardness, tensile strength, and surface roughness, employing analysis of variance (ANOVA) and Grey Regression analysis.

Investigating the effects of ultrasonic assistance on TIG welding of AA7075 alloys: a machine learning-based optimization study using RSM-PSO

Abstract This study explores the impact of ultrasonic assistance on TIG welding of AA7075 alloys, leveraging a machine learning-based optimization approach combining Response Surface Methodology (RSM) and Particle Swarm Optimization (PSO). A central composite design matrix was developed to investigate the effects of process parameters on microhardness and weld defects. A predictive model was constructed, utilizing process parameters as inputs and microhardness as the output. PSO optimization was then applied, followed by experimental validation. The model demonstrated high accuracy, with R-squared values of 0.9808 and 0.9862 for conventional and ultrasonic-assisted TIG welding. Confirmation tests showed an error margin of less than 1%. The optimal process parameters under ultrasonic vibration were identified as welding current (50.38 A), gas flow rate (12.42 l min−1), and filler material (ER5356). The predicted microhardness (153.16 HV) closely matched the actual value (150.71 HV), with an error of 1.6%. Tensile and fractography analyses further validated the optimized welding parameters. This research showcases the potential of integrating ultrasonic vibration with RSM-PSO optimization to enhance weld quality and mechanical properties of AA7075 alloy joints, offering valuable insights for industrial applications.

Enhancing Mechanical Performance and Heat Treatment Response in AA2024 Alloys Through B4C and Alumina

Abstract Aluminum Alloy 2024/Boron carbide (B4C)/alumina composites showed different tensile characteristics after they were strengthened and heated. The T6 thermal cycle performance got better because the samples were made harder through “precipitation hardening” using various amounts of alumina and B4C. After the application of heat, the composite materials had a consistent spread of strengthening elements, and an examination of their energy levels showed Aluminum, Silicon, and Magnesium, along with small amounts of a few other particles. Researchers carefully tested the tensile properties of heat-treated and strengthened steel. The research indicated that both the tensile strength (TS) and yield strength (YS) increased to 210ºC and then started to decrease to 140ºC. The stiffness and elastic modulus of the composites improved due to the addition of reinforcement and heat treatment. This resulted in a significant reduction in El (Elongation) content in the composites. Several factors, such as the diffusion process, grain refinement, heat treatment temperatures, and the mix of strengthening elements, contributed to the enhanced elastic modulus and tensile strength of the composites. Research aimed at optimizing these findings to streamline the development of hybridized composite materials has many applications in the aerospace and transportation industries.