Alloy AA2024-T3 Research Articles

Numerical investigation of patch geometry effect on the fatigue life of aluminum panels containing cracks repaired with CFRP composite patch using XFEM and CZM approach

This study investigated numerically the effect of using composite patches with various geometric shapes to improve the fatigue life of aluminum panels of AA7075-T6 and AA2024-T3 containing cracks and compared with the available experimental results. The Cohesive Zone Model (CZM) and Extended Finite Element Method (XFEM) were applied to static and fatigue analyses. Four types of rectangular, trapezoidal, left-oriented and right-oriented triangular composite patches were used in the numerical analysis. With the combination of XFEM and CZM methods, and using the Paris equation, the fatigue crack propagation and fatigue life of aluminum panels containing cracks can be reasonably predicted. A composite patch with a suitable shape and geometry, fatigue life of the repaired panel can be improved considerably. With a 204% improvement in fatigue life in comparison to the unrepaired panel, the repaired sample made of aluminum alloy AA2024-T3 alloy achieved the most significant improvement in fatigue life. In AA7075-T6 alloy samples repaired with composite patches, the samples repaired with rectangular and trapezoidal patches experienced the highest fatigue life increases, respectively with 342 and 290% compared to the unrepaired samples. The comparison of numerical simulation results with the available experiment results shows a good agreement.

Ultrasound-Enhanced Friction Stir Welding of Aluminum Alloy 6082: Advancements in Mechanical Properties and Microstructural Refinement

This study examines the effects of ultrasound-enhanced friction stir welding (USE-FSW) on the mechanical properties and microstructural characteristics of aluminum alloy AA6082-T6, commonly used in automotive, aerospace, and construction industries. The investigation included tensile and bending tests, as well as detailed microstructural evaluations using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and energy-dispersive X-ray spectroscopy (EDS). The results indicate that USE-FSW led to an approximately 26% increase in tensile strength compared to similar samples produced by conventional friction stir welding (CFSW). Additionally, the elongation at break improved by around 52%, indicating better ductility. Flexural strength also showed a notable improvement of over 70%. Microstructural analysis revealed a finer grain structure in the stir zone, contributing to these mechanical enhancements. However, the changes in texture and grain orientation were relatively modest, as shown by EBSD and Kernel Average Misorientation (KAM) analyses. Overall, USE-FSW offers incremental improvements in weld quality and mechanical performance, making it a promising technique for producing joints with slightly enhanced strength and ductility.

Synergetic effect of hybrid surface treatment on the mechanical properties of adhesively bonded AA2024-T3 joints

ABSTRACT Improving the surface properties of AA2024-T3 aluminium alloys is crucial for achieving durable and sustainable joints. For this purpose, AA2024-T3 alloys were first sandblasted at 4, 5 and 6 bar pressures using aluminium oxide and glass sphere abrasives. Then, the sandblasted samples were subjected to the chemical surface treatment resulting in a hybrid surface process. The surface properties of sandblasted and hybrid surface-treated AA2024-T3 alloys were characterised by 3D image analysis, contact angle and roughness measurement. Additionally, single-lap joints were fabricated using adhesives with low and high viscosity. The effect of changes in the viscosity of adhesives and the surface properties of the AA2024-T3 on the mechanical properties of the joints has been analysed in detail. It was found that both sandblasting and hybrid surface treatments applied to AA2024-T3 alloys caused significant improvement in the mechanical properties of the joints. AA2024-T3 alloys, which were chemically surface treated after being sandblasted with glass spheres at 6 bar pressure, were joined using low and high viscosity adhesives, and the failure load of these joints increased by approximately 110% and 68%, respectively, compared to untreated samples. In the case of aluminium oxide usage, the increase rates were determined to be 93% and 43%.

Comparative Investigation of Friction Stir Welds Reinforced with Graphene Nanoplatelets and Copper in AA6082-T6 Alloy

Comparative Investigation of Friction Stir Welds Reinforced with Graphene Nanoplatelets and Copper in AA6082-T6 Alloy

Hot Ductility Behaviour of AA7075-T651 Aluminium Alloy

Abstract This study focused on examining the hot ductility characteristics of aluminium alloy 7075-T651. Hot ductility is the capacity of a substance to undergo deformation at high temperatures without fracturing. Aluminium alloys typically demonstrate favorable hot ductility, rendering them appropriate for a wide range of high-temperature applications. The investigation entails performing hot tensile tests for AA7075-T651 aluminium alloy at different deformation temperatures (350°C-525°C), followed by fractography to ascertain the fracture mode. The ductility of the AA7075-T651 alloy was greatly enhanced during this procedure. The findings indicate that the hot working range of the aluminium alloy 7075-T651 can be expanded to 525°C instead of a liquidus start temperature of 477°C with a maximum of 30% ductility. The fractography results demonstrate that the fracture mode remains ductile. The AA7075-T651 aluminium alloy exhibits excellent thermal stability, allowing it to be hot worked at temperatures as high as 525°C without experiencing any sudden alterations in its characteristics or fracture behaviour.

A generalized, computationally versatile plasticity model framework - Part II: Theory and verification focusing on shear anisotropy

Shear-dominated deformation (SHDD) is pivotal in sheet metal forming; however, comprehensive modeling of plastic anisotropy in SHDD, specifically shear anisotropy considering both yield stress and plastic flow, has been inadequately addressed in existing literature. In this work, a generalized constitutive framework is introduced on the basis of stress triaxiality-dependent state variable to accurately emulate plastic anisotropy and the physics-based shear constraint in SHDD. The framework is capable to seamlessly integrate with existing yield criteria, preserving computational efficiency and versatility. Notably, the yield function, anisotropic parameters, and their optimization or analytical determination for the non-shear deformation state remain unaltered. When integrated with the Hill48 yield function, featuring either one or two anisotropic parameters within the generalized constitutive framework, precise characterization of yield strength and plastic flow in SHDD is achieved. The applicability of the framework extends to various anisotropic yield functions such as the widely employed Yld2k-2d and the sixth-order polynomial (Poly6) function as a class of associated flow rule-based yield functions, and one non-quadratic yield function for non-associated flow rule scenarios. Experimental validation with two engineering sheet metals, high-strength dual-phase steel DP980 and high-strength aluminum alloy AA7075-T6, was conducted. Comparative analyses with several recently proposed yield criteria, especially Poly6-18p, highlighted the efficiency of the proposed constitutive framework. Furthermore, this study explores intrinsic shear constraints, particularly the absence of through-thickness strains under in-plane shear stress. Additionally, it offers an enhanced description of plastic anisotropy in shear yield stress within the general framework, providing valuable insights into the complexities of SHDD.

Friction stir welding of AA2024-T3 and SS304 alloys: microstructural analysis, microhardness evaluation, and tensile performance

This study examines the feasibility of friction stir welding (FSW) for dissimilar butt joints formed between 3 mm thick 2024-T3 aluminum alloy and AISI 304 stainless steel. It explores the impact of operational parameters, particularly traverse speeds of 20 and 40 mm min−1, a fixed tool rotation speed of 450 rpm, a tool pin offset of 1.5 mm, and a tool shoulder diameter of 18 mm, on microstructure, microhardness, and tensile strength. A traverse speed of 40 mm min−1 resulted in a lower peak temperature of 257.75 °C, while optimal conditions at a speed of 20 mm min−1 led to peak temperatures of 356.5 °C. This higher temperature facilitated material deformation, improved flow, enhanced mixing, and contributed to grain refinement, with an average grain size of 4.2 μm. Vickers microhardness tests revealed a maximum hardness of 339 Hv at a traverse speed of 40 mm min−1 and 413 Hv at 20 mm min−1. The ultimate tensile strength (UTS) reached 338 MPa, resulting in a joint efficiency (JE %) of 76.81% for the weld performed at optimal conditions.

Experimental investigation into friction stir welding of AA6061-T6 and magnesium AZ31B alloy using copper backing plate

Aluminium-magnesium alloys are lightweight and possess superior properties, making them ideal for applications in aerospace, railway, automotive, and marine structures. However, these alloys are challenging to fabricate using traditional fusion welding due to various metallurgical issues. This study investigates the feasibility of joining 3 mm thick dissimilar alloys of aluminium AA6061-T6 and magnesium AZ31B using the friction stir welding (FSW) process with copper as a backing plate. The effects of FSW process parameters, including tool rotational speed (380, 545, 765 rpm), weld speed (20, 31.5, 50 mm min−1), and tilt angle (1°, 2°, 3°), on tensile properties were examined using Taguchi-based grey relational analysis. Temperatures were recorded during the FSW process under different conditions on both sides of the joint. The highest tensile strength of 130.72 MPa, with a joint efficiency of 67.85%, was achieved at a tool rotational speed of 765 rpm, a welding speed of 50 mm min−1, and a tilt angle of 2°. Analysis of variance (ANOVA) for the grey relational grade indicated that the tilt angle had the highest percentage contribution of 43.60%. This study demonstrates the significant influence of FSW parameters on the mechanical properties of aluminium-magnesium joints and highlights the optimal conditions for achieving high joint strength and efficiency.

Microstructure-sensitivity of CPFEM models on fretting fatigue crack initiation of AA2024-T351 alloy

The AA2024-T351 alloy is widely used in civil engineering, machinery, and aerospace industries for bolts, rivets, and thin plate components. When in service within these fields, the components are susceptible to performance degradation and fracture failure due to fretting fatigue. In this study, a crystal plastic finite element method (CPFEM) model incorporating microstructure sensitivity is employed to predict the fretting fatigue crack initiation (FFCI) location and lifetime. The submodel method is utilized to simulate various microstructures in the contact region of the specimen under fretting fatigue. This research focuses on two fatigue indicator parameters (FIPs): accumulated plastic slip p and FIPFS, used to determine the hotspots for crack nucleation on the contact surface and subsurface in fretting fatigue. The study explores the impact of different grain size and orientation on crack nucleation and analyzes how various microstructural characteristics influence the crack initiation lifetime. The findings indicate that the influence of grain orientation distribution in fretting fatigue on the initiation location of contact surface cracks is not significant, but it has a notable impact on subsurface cracks. Different grain textures combinations exhibit a more pronounced anisotropy based on the accumulated plastic slip p than FIPFS. Additionally, the effect of grain orientation distribution on the FFCI lifetime is influenced by the average grain size, showing remarkable influence within a specific range of grain sizes.

Microstructure and Corrosion Study on Friction Surfaced Aluminum Alloy Coatings over Mild Steel

In this study, the low-carbon steel (AISI 1018 mild steel) substrate is coated with the aluminum alloys AA6082-T6, Al-20Zn, and Al-2Si-15SiC to improve its corrosion resistance by the friction surfacing (FS) technique. To produce a high-quality coating, friction surfacing process variables including spin speed, speed of travel, and the rate of feed are crucial. This experiment examines twelve friction-surfaced plates with different parameter combinations. Scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) examinations were carried out in order to comprehend the microstructure and chemical composition of the coating deposits and the area in contact between the coated surface and the substrate. Microstructure investigation reveals that the intermetallic combination of Fe-Al at the coating interface region is an effect of the elemental diffusion of Fe to aluminum at the contact interface. Then a uniform and fine-grained coating deposit is observed as a result of the continuous recrystallization of the consumable rod under frictional stress and heat generation. According to the outcomes of the microhardness test, the coated surface is roughly 15–16% harder than the consumable rod. The coating bond strength was measured using a ram tensile test, and it ranged from 102 MPa to 135 MPa. Finally, evaluation of corrosion behavior through immersion testing and pitting corrosion testing reveals that the coatings made of Al-20Zn and Al-2Si-15SiC exhibit good corrosive resistance in an alkaline environment.

Sealing of cerium oxide coating primers on anodized AA2024-T3 alloy by boiling in Lourier buffers

Although their exceptional re-passivation ability, Al-alloys are susceptible to corrosion due to the amphoteric nature of the alumina passivation films. This issue is exacerbated by the disruption of these films by intermetallics on the surfaces of highly doped ones, like AA2024-T3 aircraft alloy. The combination of anodized aluminium oxide (AAO) and cerium conversion coatings (CeCC) shows promise as a coating primer. However, the defective structures of CeO2 and Al2O3 require additional sealing. This research proposes sealing the CeCC/AAO layer by boiling it for 10 minutes in two relatively neutral Lourier buffers, adjusted to pH 7.75, and in a mixture of them. The samples underwent a series of analyses to compare the impact of the sealing procedure on surface topology, properties (e.g., colour and wettability on two samples from each set), and corrosion protective ability. It was assessed after 24 hours of exposure to 3.5 % NaCl model corrosive medium on six samples from each set. The assessments included electrochemical impedance spectroscopy (EIS) and potentiodynamic scanning (PDS) techniques. The results indicate that the borate buffer improves the corrosion protection of the coating primers more effectively than the phosphate and mixed ones.

Influence of Process Parameters on Residual Stresses in Dissimilar Friction Stir Welding of Aluminum Alloys

Foreseeing how welded structures will behave requires careful consideration of the residual stresses that the friction stir welding (FSW) process introduces. These residual stresses can cause severe deformation and compromise the ability of friction stir welded structures to bear imposed external loads. This work uses a Sequentially Coupled Thermo-mechanical finite element simulation to quantitatively evaluate the influence of such residual stresses coming from the FSW process. This modelling method examines the thermal and post- weld stress distributions during the friction stir welding of dissimilar AA2024-T3 and AA5086-O alloys. The procedure entails an initial thermal analysis followed by a mechanical analysis to determine the distribution of residual stresses across the entire dissimilarly welded alloys. The study examined how alterations in FSW operational parameters, such as rotational and translational speeds, influence both the thermal conditions and residual stress distribution. The findings highlighted that both temperature and residual stress exhibited higher values on the retreating side of the specimen compared to the intended advancing side. As the tool rotational speed rose, the magnitude of longitudinal residual stress dropped, however it showed an increase with greater tool translational speeds. Moreover, the simulated outcomes demonstrate the substantial impact of welding fixtures on the profiles and magnitudes of residual stresses.

Analyzing the synergistic effects of hard ceramic TiB2 and rare earth oxide La2O3 on mechanical behaviour, wear resistance, and residual stress of AA6061-T6 hybrid composite fabricated via ultrasonic-assisted stir casting

This investigation involves the fabrication of an aluminium metal matrix composite using AA6061-T6 alloy as the matrix, incorporating 2 wt% of hard ceramic (TiB2, 14 μm particle size) and 0.5 wt% of rare earth oxide (La2O3, 40–50 nm particle size) reinforcement powders through ultrasonic assisted stir casting. The study examines the microstructure, residual stress, and mechanical properties alongside performing pin-on-disk wear tests. Taguchi's optimization and ANOVA are used to optimize the wear rate of the composite using three control parameters: Load, Sliding Distance, and Sliding Speed. Results from optical micrography and field emission scanning electron microscopy (FESEM) with energy-dispersive spectrometer (EDS) analysis confirm the uniform distribution of TiB2 and La2O3 particles within the AA6061-T6 volume when ultrasonic stirring is employed. The composite's microhardness is found to increase by 25.15 %, and its tensile strength by 31.32 % compared to the base alloy due to a higher dislocation density. ANOVA highlights Load as the primary influencer, contributing 69.54 %, followed by Sliding Distance (17.45 %) and Sliding Speed (12.56 %). The optimal parameters for minimizing wear rate are found to be Load (20 N), Sliding Distance (1500 m), and Sliding Speed (2.5 m/s). Scanning Electron Microscope (SEM) images of worn surfaces reveal various mechanisms such as abrasion, delamination, and adhesion, with abrasion being the dominant mechanism. Residual stress increases with the addition of TiB2 and La2O3 particles in the matrix, showing transitions from tensile to compressive stress from the inner to the outer surface of the composite casting.

Comprehensive analysis of mechanical properties, wear, and corrosion behavior of AA7075-T6 alloy subjected to cryogenic treatment for aviation and defense applications

It is important that the parts to be used in the aviation and defense industry have high wear, fatigue and corrosion resistance. AA7075-T6 alloys are increasingly used in every field due to their advantageous physical and mechanical properties. However, some of the materials of this alloy types exhibit excellent fatigue strength and ductility, but their surface hardness and surface roughness after processing may be poor. For this reason, the wear resistance of AA7075-T6 aluminum alloy expected to be improved in order to increase their corrosion resistance properties. In this work, cryogenic treatment was applied to AA7075-T6 alloy and the mechanical characteristics, wear and corrosion behaviors of these samples were examined. As a result of the experiments, it was determined that cryogenic treatment improved the wear behavior of AA7075-T6 alloy. The untreated sample was found to have the highest wear rate, whereas the sample with deep cryogenic treatment (DCT) had the lowest wear rate. The hardness of the DCT process increased by 5.79 %, according to macro hardness measurements, making the AA7075-T6 alloy harder from 80.16 HRB to 84.8. The SEM images revealed that, the shallow cryogenic and deep cryogenic operations had substantial effects on the microstructure by modifying the size and distribution of precipitates in the AA7075-T6 alloy. In addition, tensile and hardness tests were carried out to assess the mechanical characteristics of the samples. Accordingly, the maximum tensile strength and hardness values were obtained in the deep cryogenically treated sample. The tensile strength of the DCT sample was approximately 544.18 MPa, a considerable 11.5 % increase above the untreated sample's 488.07 MPa strength. In potentiodynamic polarization testing, the DCT treated sample was determined to have the maximum corrosion resistance. Among the materials tested, the DCT sample showed the strongest corrosion resistance, with a corrosion potential of −0.689 V and a corrosion rate of 0.021 mm/year. Wear rate analysis revealed that DCT samples experienced the least material loss, demonstrating improved abrasion resistance. Enhanced hardness and the formation of stable oxide tribo-layers contributed to these superior wear characteristic.

The effect of rolling direction and strain rates on the tensile properties of AA2024-T3 aluminum alloy

The AA2024-T3 alloy is a lightweight and durable material commonly used in the aerospace industry. This study investigates the impact of the rolling direction (RD) and strain rates on the alloy’s tensile properties. Tensile tests have been performed on samples oriented parallel and transverse to the rolling direction at varying strain rates (5, 25, and 125 mm/min). Samples parallel to the rolling direction have exhibited higher strength compared to those in the transverse direction (TD). At a strain rate of 5 mm/min, the maximum tensile strength in RD samples has been 530.72 MPa, while in TD samples, it has been 505.76 MPa. At 25 mm/min, the tensile strength has been 498.31 MPa in RD and 482.91 MPa in TD. At 125 mm/min, the tensile strength has been 508.52 MPa in RD and 480.36 MPa in TD. The increase in strain rate has had a complex effect on the mechanical properties. The total elongation values have also varied with strain rate, with the highest total elongation observed at 5 mm/min (0.168) in both RD and TD directions. These findings have highlighted the significant impact of the rolling direction and strain rate on the mechanical properties of the AA2024-T3 alloy, which should be considered in design and manufacturing processes.

Influence of post-weld explosive treatment on low cycle fatigue of AA7075-T651 friction stir welded joint

In this investigation the friction stir welded joint of 5 mm thick AA7075-T651 alloy has been subjected to the post-weld explosive treatment. To assess the influence of the proposed treatment on the joint properties, a comprehensive analysis was conducted, including microstructural examination, microhardness testing, static tensile tests, low-cycle fatigue testing, and fracture surface observations. The strain amplitudes of 0.35 %, 0.4 %, 0.5 %, and 0.6 % with asymmetry coefficient R = 0.1, were used for the examined samples. It was concluded that the explosively treated FSW joints are characterized by a lower amplitude of plastic deformation, a reduced number of cycles to failure and show a tendency for cyclic softening. The differences in the fatigue crack propagation primarily concern the initiation area of the crack near the hardened surface. Explosive treatment did not influence the location of material decohesion, which occurs in the low-hardness zone.

Multifunctional polyurethane-based coating with corrosion resistance and anti-icing performance for AA2024-T3 alloy protection

In this study, we present the development of advanced anticorrosive icephobic coatings tailored for AA2024-T3 surfaces. These coatings were engineered using polyurethane, incorporating fluoropolyol and isocyanate modified with hydroxyl-terminated silicone oil and fluoroalkyl polyhedral oligomeric silsesquioxane (F-POSS) particles. Surface characterization involved contact angle and sliding angle measurements, as well as atomic force microscopy. The icephobic efficacy was evaluated through a battery of tests including differential scanning calorimetry, delay of freezing time measurement, impact and non-impact ice adhesion measurement (push-off and centrifuge), and the ice accretion method. Electrochemical impedance spectroscopy served to evaluate the anticorrosion performance of the coatings. The integration of silicone oil and F-POSS led to notable improvements in contact angles, increasing from 92° to 127°. The lowest sliding angle (6°) was obtained for the coating containing both silicone oil and F-POSS. Topographical images showed the essential role of F-POSS in providing a rough surface structure. The optimal coating formulation consisted of 10 wt% F-POSS particles and 5 wt% silicone oil, resulting in a water contact angle of 127°, a sliding angle of 9°, approximately 42 days of surface protection, and an impedance value of 4.8 × 108 Ω·cm2. Remarkably, this coating demonstrated exceptional durability in terms of icephobic properties, maintaining a push-off ice adhesion strength of 9.3 kPa even after 15 icing/de-icing cycles, confirming its desirable icephobic performance.

Use of threaded cylindrical pin tools to reduce macroscopic defects in dissimilar welded joints of AA7075-T6 and AZ31B alloys by the FSW process

The continued increase in greenhouse gas emissions has had dire consequences for the global climate. In order to reduce such emissions, several efforts have been made by researchers in the transport sector, such as the development of electric motorization, the development of hybrid engines, the use of biofuels and the use of light alloys. The use of light alloys such as aluminum and magnesium in vehicles can reduce the emission per kilogram of vehicles drastically, however, it is still necessary to develop effective and more agile methods of the dissimilar joints of these materials. Some authors have studied the friction stir welding of AZ31B magnesium alloys and AA7075-T6 aluminum alloys in order to determine better process parameters to enable this bond, however, few articles have been published in order to evaluate the influence of tool geometry on such properties. In this sense, this article aims to evaluate the influence of friction welding tool pin geometry as smooth cylindrical pin, threaded cylindrical pin, conical and hexagonal pin configurations in the formation of the mixed zone of welds manufactured by the FSW process. For this purpose, AZ31B and AA7075-T6 alloys were welded by FSW with welding speed of 75 mm/min, tool rotation speed of 565 rpm, offset of 0.5mm and inclination of the tool geometry in relation to the plates to be welded of 3º, the joints were evaluated for their macro and microstructures and Vickers hardness with a load of 100 gf. It was possible to observe that the joints welded with the threaded cylindrical pin tool presented stir zones free of macroscopic defects, similar hardness values for the four tools studied and the presence of a thin layer of intermetallics between TMAZ and SZ on the AZ31B side.

Effect of Friction Stir Processing Parameters on Microstructure and Mechanical Properties of Aluminum Alloy AA6061-T6: Experimental and Statistical Study

Effect of Friction Stir Processing Parameters on Microstructure and Mechanical Properties of Aluminum Alloy AA6061-T6: Experimental and Statistical Study

Effect of welding speed on microstructural evolution and strengthening mechanism of friction-stir welded 7075 aluminum

In present study, we aimed to analyze the microstructural characteristics and strengthening mechanism of AA7075-T6 alloy after the friction-stir welding speeds from 150 to 350 mm min−1. The continuous dynamic recrystallization underwent actively with higher welding speed, leading to equiaxial and fine grains, as evidenced by misorientation distribution, grain orientation spread, and aspect ratio. Regarding the textural evolution of the stir zone, the weld at lower welding speed retained the deformation texture (e.g., Brass), while the higher welding speed showed the development of recrystallization texture (e.g., Goss). The weld at 250 mm min−1 revealed superior weldability for strength of over ∼80 % owing to both grain refinement and accumulated dislocations despite the dissolution of precipitate such as ηˊ.