Aerospace Sector Research Articles

Achieving high strength of Al-Cu-Li-Sc alloy over wide temperature range from 25 °C to 300 °C

Modern aerospace and transportation sectors have imposed more stringent requirements for high-strength aluminum alloys. Taking into account factors such as processing, assembly, maintenance, and recycling, there is a desire to develop one high strength aluminum alloy over wide temperature range from 25 °C to 300 °C, however, it is an ongoing challenge topic. Here, a novel Al-Cu-Li-Sc alloy with a reduced Cu content (∼2.8 wt%) was designed, exhibiting great yield strength with 482 MPa at 25 °C, 351 MPa at 200 °C, and 186 MPa at 300 °C, better than present commercial Al-Cu-Li alloys, Al-Cu-Sc alloys, due to the promotion of nucleation of T1 precipitates and their improved coarsening resistance. The novel Al-Cu-Li-Sc also overcomes the shortcoming of commercial Al-Cu-Li alloy which is the rapid degradation of mechanical properties after thermal exposure at 200 °C, as well as exhibiting comparable heat resistance to Al-Cu-Sc alloy after thermal exposure at 300 °C. This study offers a valuable engineering insight to develop light-weight, high-strength and heat-resistant aluminum alloys.

Competence of Carbonaceous Fibers/Nanofillers (Graphene, Carbon Nanotube) Reinforced Shape Memory Composites/Nanocomposites Towards Aerospace—Existent Status and Expansions

Abstract Shape memory or stimuli responsive polymers have established a unique grouping of smart materials. The technical merit of these polymers has been evaluated in aerospace sector, since last few decades. Particularly, the stimuli responsive polymers render inherent competences to recuperate the structural damages in exterior/interior space architectures. In this context, both the thermoplastics as well as thermosetting polymers depicted essential stimuli responsive behaviour. As interpreted in this state-of the-art review, the carbonaceous reinforcement like carbon fibers and nano-reinforcements including nanocarbons (graphene, carbon nanotube) have been employed in the shape recovering matrices. The performance of ensuing shape retrieving aerospace materials was seemed to be reliant on the polymer chain crosslinking effects, filler/nanofiller dispersal/alignment, microstructural specs, interfacial contour and interactions, and processing techniques used. Consequently, the shape actuations of polymer/carbon fiber composites were found to be instigated and upgraded through the inclusion of nanocarbon nano-additives. The ensuing high-tech shape memory composites/nanocomposites have anomalous significance for various aero-structural units (fuselage, wings, antennas, engines, etc.) due to prevention of possible thermal/shock/impact damages. Future implications of carbonaceous shape memory composites/nanocomposites in aerospace demands minimizing the structure-property-performance challenges and large scale fabrication for industrial scale utilizations. In this way, deployment of carbonaceous nanofiller/filler based composites revealed enormous worth due to low density, anti-fatigue/wear, anti-corrosion, non-flammability, self-healing, and extended durability and long life operations. However, there are certain challenges associated with the use of nanocarbons and ensuing nanocomposites in this field markedly the adoption of appropriate carbon fiber coating technique, aggregation aptitude of nanocarbons, additional processing steps/cost, nanoparticle initiated invisible defects/voids, difficulty in machinability operations due to presence of nanoparticles, and corrosion risk of composite structures in contact with metal surfaces. By overcoming these hinderances, nanoparticles modified carbon fiber based composites can be promising towards a new look of upcoming modernized aerospace industry.

Generalized Background Vector Method for Tailored Three-Dimensional Nonperiodic Woven Composite Designs

In critical aerospace applications such as Ceramic Matrix Composite structures, novel three-dimensional nonperiodic textile composite preforms hold great promise for creating advanced composite structures with strategically aligned fiber tows. However, the inherently challenging nature of determining tow locations, a large-scale combinatorial problem, presents a significant obstacle in textile architecture design. This study generalizes the previously developed Background Vector Method (BVM) to address diverse design requirements and constraints, effectively circumventing combinatorial design complexities via a game theoretic approach. This approach allows for the creation of tunable designs for woven architectures with complex geometries, such as channels and tapering features, through simple control parameter adjustments. The method demonstrates exceptional computational efficiency, making it suitable for large-scale nonperiodic textile structures. Case studies including woven sandwich and airfoil structures highlight the generalized BVM’s versatility and effectiveness in addressing complex design challenges within the aerospace sector.

Achieving High Precision and Productivity in Laser Machining of Ti6Al4V Alloy: A Comprehensive Study using a n-predictor polynomial regression model and PSO algorithm

Ti-6Al-4V, the Titanium alloy, has significant utilizations in aerospace, automotive, and marine sectors for its low density and high strength at elevated temperature. But its chemical activity and low thermal conductivity inhibits its machining by conventional method. Nd: YAG laser beam machining (LBM) finds extensive use in rapid and precise cutting of Ti6Al4V. This study has examined the influences of various LBM machining variables, including laser power, gas pressure and stand-off distance, in cutting 5mm thick Ti-6Al-4V plate. In assessing the effectiveness and performance of the LBM process, three response functions—surface roughness, angle of kerf, and material removal rate—have been designated. From the experimental data, different regression models have been established to estimate these response functions in terms of the machining parameters. Based on R2 score and RMSE, multi-dimensional polynomial regression is decided as the most suitable regression model. Subsequently, the Particle Swarm Optimization technique has been applied to identify the optimal machining parameters for reducing angle of kerf and surface roughness, while increasing material removal rate. Three individual single-objective functions underwent optimization, along with a multi-objective function. Furthermore, experimental verification was conducted for the optimal input parameters in the single-objective as well as the multi-objective optimization scenarios, resulting in an accuracy of 97% and 98%, respectively. Such a close agreement emphasizes the accuracy of the developed regression model as well as it signifies the reliability and efficacy of the optimization technique.

Enhanced Mechanical and Thermal Properties in Epoxy-Based Glass Fabric Composites via Nano Silica Integration

ABSTRACT The objective of this study is to improve the mechanical, thermal, and microstructural characteristics of glass fabric composites made of epoxy by adding nano silica fillers. Composites were produced through compression molding, incorporating different concentrations of nano silica (0%, 2.5%, 5%, 7.5%, and 10%). The study encompassed testing the tensile and flexural strength, analyzing thermal properties through TGA and DTA, and characterizing the microstructure using FESEM and FTIR. The findings indicated that composites containing 5% nano silica exhibited the greatest tensile and flexural strengths, enhanced thermal stability, and superior heat dissipation in comparison to composites with different concentrations. The analysis of the microstructure revealed improved distribution of the filler material and decreased voids, resulting in a stronger bond between the matrix and the reinforcement. The findings emphasize the potential of nano silica-enhanced composites in aerospace, automotive, and other engineering sectors. This represents a notable advancement in composite technology for creating strong and efficient materials.

Impact of annealing on the characteristics of 3D-printed graphene-reinforced PLA composite

Manufacturing through additive techniques, especially utilizing the fused filament fabrication (FFF) method, is a transformative technology revolutionizing design and manufacturing. FFF builds parts layer by layer using thermoplastic polymer and polymer composite filaments. However, weak interlayer connections often lead to low interlaminar resistance in printed structures. Recent studies suggest that post-deposition heat treatments can mitigate this issue by reducing internal thermal stresses and enhancing layer adhesion, thereby improving part properties. This research delves into the impact of annealing heat treatment on a composite of Polylactic Acid (PLA) reinforced with graphene. The annealing process was conducted at temperatures of 90, 100, and 120 °C for durations of 60, 120, and 240 min. The annealing response of the graphene-reinforced PLA composite is compared to that of natural PLA for reference, analyzing its effects on electrical, thermal, chemical, and mechanical properties. Chemical characterization was performed using X-ray diffraction (XRD), Raman spectroscopy, and Fourier-transform infrared spectroscopy (FTIR). Thermal properties were analyzed via thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). Electrical properties were assessed by measuring resistance, resistivity, and conductivity. Mechanical properties were evaluated through tensile, flexural, notch sensitivity, impact tests, and hardness measurements. The results demonstrated that annealing of graphene-reinforced PLA and natural PLA did not alter their functional groups but increased their crystallinity. This treatment improved thermal stability, electrical conductivity, and mechanical properties, including tensile strength, flexural strength, and Shore D hardness. However, it reduced impact and notch sensitivity resistances. The increased crystallinity had a greater beneficial impact on some properties than the graphene reinforcement. These findings have potential applications in the automotive, aerospace, electronics, and medical sectors, given the increasing use of PLA in these industries.

A systematic review of the process parameters, mechanical characteristics and applications of polyether ether ketone (PEEK) and its composites by additive manufacturing

Abstract Additive manufacturing (AM) provides an innovative and reliable method of developing medical products with anatomically relevant geometry and mechanical performance, underscoring its significant potential in the medical field. The design of fused deposition modelling (FDM) parameters has a significant impact on the characteristics of the product fabricated utilizing FDM. Numerous studies have assessed the impact of various FDM process parameters on enhancing the print quality attributes of manufactured components, such as mechanical characteristics, production times, dimensional accuracy, and surface finish. Because of the complex features of the FDM process and the contradicting process parameters, the advancement has been slow and poorly coordinated. This work intends to provide a complete review of recent research on PEEK and CF-PEEK printed parts, where the effect of process factors on tensile strength has been described. Furthermore, PEEK, with its potential applications in medical, aerospace, and chemical sectors, serves as an inspiring material for future innovations, offering a promising outlook.

Selective Laser Melting Process Optimization and Mechanical Properties Evolution of AlSi10Mg by determining temperature of the build chamber using Arduino IDE and coding algorithm

Unlike conventional methods that involve removing components from a product, the groundbreaking idea behind additive manufacturing (AM) is the gradual creation of materials. A computer-controlled laser is often used in additive manufacturing to shape and consolidate powder feedstock in a layer-by-layer fashion to arbitrary shapes. The aerospace, defense, automotive, and biomedical sectors have high standards, and AM is now being refined to create complex-shaped functional metallic components out of metals, alloys, and other materials. Lightweight structural components with series similar mechanical characteristics may be produced using Selective Laser Melting (SLM), one of the AM technologies that eliminate the requirement for part specific tooling or downstream sintering procedures, among other things. The low weight and excellent mechanical and chemical qualities of aluminium make it an ideal material for such environmentally designed components. We need further information on how processing circumstances and material qualities affect the microstructural and mechanical properties of AM produced components as well as the metallurgical processes that produce them. Following this, we provide a comprehensive overview of AM's material and process components, including the mechanical and microstructural features of AM-processed parts as well as the physical characteristics of AM-optimized materials. Ultimately, the samples made using SLM-Alsi10Mg demonstrated an ultimate tensile strength of 150 MPa, yield strength of 120 MPa, and an elongation of 20%, as determined by the testing data. Mechanical properties of AlSi10Mg, additive manufacturing, laser powder bed fusion, selective laser melting, and related terms.

Bromine-containing copolymer polycarbonate for simultaneous thermal stability, transparency, and thin-wall flame-retardant polycarbonate

The incorporation of traditional low molecule bromine flame retardants can enhance the flame retardancy of polycarbonate (PC), yet their poor compatibility with PC impairs its transparency and mechanical properties. Here, brominated polycarbonate (B50PC) was synthesized by interfacial polycondensation method using bisphenol A, tetrabromobisphenol A, and triphosgene. The number average molecular weight (Mn) of B50PC reached 14,600, and compared to the low molecule bromine flame retardant tetrabromobisphenol A (TBBPA), its initial decomposition temperature increased by 38.7 % under air atmosphere. The PC composites containing 5 wt% B50PC achieved the V-0 rating in the UL-94 test, with LOI increased by 10.3 %. At the same time, the peak heat release rate (PHRR) was decreased by 28.6 % and the ignition time (TTI) was delayed by 21.3 %. Compared with that of samples with TBBPA, the composite with the same amount of B50PC maintained the original elongation at break of PC and the transmittance remained at 84.9 %. In summary, the composites with B50PC maintains outstanding transparency and mechanical properties while enhancing the flame retardancy. This work has developed a high molecular bromine flame retardant that combines flame retardancy and transparency, offering a strategy for expanding the application of PC in the electronics, construction, and aerospace sectors.

Investigation of surface finish and fatigue life of laser Powder Bed fused Ti-6Al-4V

In this fact-pacing world of technological advancement, the rise of additive manufacturing (AM) has found immense applications of metallic alloys such as Ti6Al4V to manufacture key components in automotive, aerospace and healthcare sectors. However, fatigue characteristics of such additively manufactured metal alloys is noticeably weak, and as such requires post-processing. In this study, AM Ti6Al4V manufactured by Laser Powder Bed Fusion (L-PBF) was treated by Hydrodynamic Cavitation Abrasive Finishing (HCAF) and Laser Cavitation Peening (LCP) to observe the improvement in surface roughness as well as fatigue performance. Our investigations revealed a substantial improvement in surface quality post-HCAF processing. Notably, the surface roughness of AM Ti6Al4V specimens showed a significant reduction of about 91.2 %, post surface treatment. However, Laser Cavitation Peening (LCP) treated sample demonstrates a significantly enhanced fatigue strength of 393 ± 22 MPa at 107, which was 1.75 times better than that of as-built one, i.e., 224 ± 16 MPa. This difference can be attributed to the distinct surface modification mechanisms of each technique. LCP, utilizing laser-induced shock waves, likely induces large compressive residual stresses, leading to better fatigue resistance.

High-performance thermoplastic nanocomposites for aerospace applications: A review of synthesis, production, and analysis

Thermoset polymers are cured under natural or synthetic created conditions and retain their solid form when exposed to heat. Unlike thermosets, thermoplastics melt when exposed to heat after production. Thermoplastics are preferred as raw materials because they can be easily shaped after production, have a high shelf life and are recyclable. In this regard, the prominence of high-performance engineering polymers in recent years has led to the preference of alternative polymers to thermosets. High-performance engineering thermoplastics include thermoplastics such as polyphenylene-sulfide (PPS), polyether-ether-ketone (PEEK), polyether-ketone-ketone (PEKK), polyphenylene-ether, polysulfone,polyoxadiazole, polyimide, polyether-amide, polyether-amide-imide, polynaphthalene, and polyamide-imide. These polymers exhibit application potential in aerospace, defense, automotive, marine, energy, and medical sectors. In challenging conditions such as high pressure, temperature, and corrosive environments, they possess high service temperatures, enhanced mechanical and physical properties, preferable chemical resistance as well as out-of-autoclave and rapid processing properties. In this review article, nanomaterial production methods (bottom-up and top-bottom) are mentioned. In the following sections, PPS, PEEK, and PEKK thermoplastics are explained, and carbon- and boron-based nano additives used in constructing nanocomposites are investigated. In the last section, PPS, PEKK, and PEEK polymer nanocomposites are investigated.

Enhanced broadband infrared radiation from rare earth orthochromites for High-Temperature radiative heat transfer

The development of broadband, high-performance infrared radiation materials is crucial for energy conservation and applications in aerospace and industrial sectors. Rare earth orthochromites, such as PrCrO3, exhibit good thermal stability and high infrared emissivity beyond the 6 μm wavelength range. However, their large bandgap limits their infrared emissivity before 6 μm, significantly impacting their potential applications. Herein, we have successfully enhanced the thermal emissivity of PrCrO3 by manipulating oxygen vacancies (OV) and accompanying impurity levels, leading to the synthesis of five rare earth orthochromites. Compared with pristine PrCrO3, co-doping of Ca, Co, and Mn introduced oxygen vacancies (OV) and impurity energy levels, effectively reducing the band gap and improving emissivity in the wavelengths below 6 μm. In particular, the infrared emissivity of (Pr0.3Y0.3Ca0.4)CrO3 in the wavelengths of 0.78–2.5 μm reaches 0.89, which is double than that of pristine PrCrO3. Furthermore, its thermal stability is excellent, as demonstrated by thermal shock experiments at 1500 ℃ for five cycles. More importantly, the developed orthochromites can be applied as a coating on substrates such as alumina ceramic sheets, exhibiting an average infrared emissivity of 0.95 and remarkable radiative heat transfer capability. This research contributes to the advancement of high-performance infrared radiation materials by vacancy engineering.

Technologies for Mechanical Recycling of Carbon Fiber-Reinforced Polymers (CFRP) Composites: End Mill, High-Energy Ball Milling, and Ultrasonication.

Carbon fiber reinforced polymer (CFRP) composites have very high specific properties, which is why they are used in the aerospace, wind power, and sports sectors. However, the high consumption of CFRP compounds leads to a high volume of waste, and it is necessary to formulate mechanical recycling strategies for these materials at the end of their useful life. The recycling differences between cutting-end mills and high-energy ball milling (HEBM) were evaluated. HEBM recycling allowed us to obtain small recycled particles, but separating their components, carbon fiber, epoxy resin, and CFRP particles, was impossible. In the case of mill recycling, these were obtained directly from cutting a CFRP composite laminate. The recycled materials resulted in a combination of long fibers and micrometric particles-a sieving step allowed for more homogeneous residues. Although long, individual carbon fibers can pass through the sieve. Ultrasonication did not significantly affect HEBM recyclates because of the high energy they are subjected to during the grinding process, but it was influential on end mill recyclates. The ultrasonication amplitude notably impacted the separation of the epoxy resin from the carbon fiber. The end mill and HEBM waste production process promote the presence of trapped air and electrostatics, which allows recyclates to float in water and be hydrophobic.

Review of aging mechanisms, mechanical properties, and prediction models of fiber‐reinforced composites in natural environments

AbstractFiber‐reinforced composites are widely used in civil engineering, aerospace, automotive, and medical sectors. However, these composites undergo aging due to factors such as temperature, humidity, load, and so on, during their usage. As a result, their performance deteriorates, and predicting their durability under real service conditions is a significant challenge. In order to better understand the durability of fiber‐reinforced composites, this article summarizes their microscopic aging mechanism under natural aging conditions and analyzes the changing rules of tensile, bending, and shear properties of composites under seven typical climate types, including tropical desert climate, temperate continental climate, temperate oceanic climate, Mediterranean climate, seasonal climate, tropical rainforest climate, and seawater immersion. This article reviews various durability prediction models, such as the Arrhenius model, prediction models based on residual modulus of elasticity and residual strength, and median strength regression analysis. To enhance the accuracy of aging life prediction during the natural aging process of composites, it is important to consider the influence of loads under real service conditions, incorporate different climatic types, utilize comprehensive mechanical property indices, establish an equivalent conversion relationship between natural aging and accelerated aging, and create a database with unified test standards.Highlights The aging mechanisms of FRP after exposure in natural aging environments are discussed. The tensile, bending, and shear properties of FRP after exposure under seven climate types are discussed. The predictive models are proposed for the FRP used in natural aging. The future research needs are proposed for the FRP used in natural aging.

Radiation absorption, Hall and ion-slip current – driven MHD convection with spanwise cosinusoidally fluctuating temperature: a perturbative study

This study investigates the impact of radiation absorption, Hall and ion-slip current on magnetohydrodynamic free convective fluid flow past an infinite vertical porous plate with viscous dissipation and chemical reaction in the presence of Spanwise Cosinusoidally fluctuating temperature by time. Its significance extends across a wide array of applications, including advanced heat transfer systems for electronics, optimization of material processing kinetics, and fostering innovation for tailored material properties, with far-reaching implications spanning aerospace and renewable energy sectors. The governing equations, subject to stipulated boundary conditions are analyzed using the multiple regular perturbation method. The results are visually presented to evaluate the influence of various parameters on system dynamics. Graphical representations illustrate the physical significance of parameters including velocity, temperature, concentration, skin friction, mass transfer rate and heat transfer coefficients. The findings reveal that increased values of Hall and ion-slip current effects correlate with acceleration of velocity and skin friction. Moreover, higher radiation absorption parameter values lead to enhancements in velocity, temperature and Nusselt number. Conversely, different chemical reaction rates and Schmidt number values result in declines in velocity, concentration and Sherwood number. Additionally, incremental values of the Eckert number improve velocity and Nusselt number but have a reverse impact on temperature. The findings of this research align with those from prior examinations.

Recent Advances in Laser Surface Hardening: Techniques, Modeling Approaches, and Industrial Applications

The article provides a comprehensive review of the latest developments in the field of laser surface hardening (LSH) and its modeling techniques. LSH is a crucial process for enhancing the surface properties of metals, particularly their hardness and wear resistance, without compromising their bulk properties. This review highlights the fundamental principles of LSH, the types of lasers used, and the key parameters influencing the hardening process. It delves into various modeling approaches, including finite element method (FEM) simulations, analytical models, and empirical models (using statistical methods), emphasizing the integration of advanced computational techniques such as machine learning and artificial intelligence to improve the accuracy and efficiency of LSH simulations. The review also explores practical applications across different industries, showcasing how LSH models have been used to solve real-world challenges in the automotive, aerospace, and tool manufacturing sectors. Finally, it addresses current limitations and outlines future research directions, suggesting potential areas for further advancements in the modeling and application of LSH processes.

Parametric Investigation of Die-Sinking EDM of Ti6Al4V Using the Hybrid Taguchi-RAMS-RATMI Method

Ti6Al4V is a widely used alloy due to its excellent mechanical qualities and resistance to corrosion, which make it fit for automotive, aerospace, defense, and biomedical sectors. Due to its high strength and limited heat conductivity, it is difficult to machine. Both the workpiece’s and the electrode’s conductivity are important factors that impact the electro-discharge machining (EDM) process. In this case, the machining efficiency is also influenced by the electrode selection. As a result, choosing the right electrode and machining parameters is essential to improving EDM performance on the Ti6Al4V alloy. Research on EDM for Ti6Al4V is limited, with little focus on electrode material selection and shape. The impact of EDM settings on MRR, TWR, and surface roughness is complex, and a comprehensive optimization strategy is needed. Copper electrodes are widely used, but further investigation is needed on EDM’s effects on Ti6Al4V’s surface properties and surface integrity. Addressing these research gaps will improve the understanding and application of EDM for Ti6Al4V, focusing on parameter optimization, surface integrity, and thermal and mechanical effects. By employing copper tools to optimize four crucial EDM process parameters—peak current, duty cycle, discharge current, and pulse-on time—this research aims to increase surface integrity and machining performance. A comprehensive Taguchi experimental design is used to systematically alter the EDM settings. By optimizing parameters using tolerance intervals and response modelling, the recently developed RAMS-RATMI approach improves the dependability of the EDM process and increases machining efficiency. With the optimized EDM settings, there were notable gains in depth of cut enhancement, surface roughness minimization, tool wear rate (TWR) reduction, and material removal rate (MRR). The results of the surface integrity examination showed fewer heat-affected zones, fewer microcracks, and a thinner recast layer. Analysis of variance was used to verify the impact and resilience of the optimized parameters. Superior machining performance, higher surface quality, and increased operational dependability were attained with the Ti6Al4V-optimized EDM process, providing industry practitioners with insightful information and useful recommendations.

FLAx‐REinforced Aluminum (FLARE): A Bio‐Based Fiber Metal Laminate Alternative Combining Impact Resistance and Vibration Damping

Fiber metal laminates (FMLs) have mainly been used in aerospace applications with synthetic fibers. To improve their environmental credentials and address issues regarding the end‐of‐life of these materials, a shift to FMLs based on natural fibers can be a promising course of action. However, regarding them as conventional FMLs overlook some of the unique benefits of natural fibers. Therefore, this study pioneers the examination of FLAx‐REinforced aluminum (FLARE) for its combined impact resistance and vibration damping. Dynamic mechanical analysis and vibration beam tests demonstrate that the metallic layer predominantly influences the damping behavior of FLARE. The loss factor notably decreases with aluminum addition (by 80% compared to the flax composite), approximated via an inverse mixture rule. Low‐velocity impact tests highlight the role of aluminum layers in energy absorption and the composite strength as a critical factor in impact resistance. FLARE exhibits 25% less specific energy absorption compared to its glass fiber counterpart. A quasi‐static analytical model suggests the potential of FLARE for practical applications. With its balance of properties and considering its potential advantages at end‐of‐life, allowing recycling of aluminum, and its expected lower carbon footprint, FLARE renders potential beyond the aerospace sector, e.g., in other forms of transportation.

Combining Ultrafast Laser Texturing and Laser Hardening to Enhance Surface Durability by Improving Hardness and Wear Performance

Aluminum alloy 7075 is utilized widely across marine, aerospace, and automotive sectors. However, its surface wear resistance has hindered its application in certain tribological environments. Addressing this challenge, the current study examines a hybrid laser method to increase surface wear resistance by combining two techniques: ultrafast laser texturing and laser‐based surface hardening. Ultrafast laser processing is conducted using 3 W laser power, 100 kHz pulse repetition rate, 4 mm s−1 scanning speed, and three different scan patterns. After the texturing operation, laser‐based surface hardening is then performed on these textures using a continuous wave laser. The laser heat treatment is conducted using laser powers of 400 and 500 W with three different scan speeds of 1, 2, and 3 mm s−1. Microhardness evaluations show a notable increase in hardness, with the hardest sample exhibiting a 17.8% increase compared to the pristine sample. The laser‐textured and laser heat‐treated samples exhibit a significant reduction in the average coefficient of friction and wear volumes compared to samples that were laser‐textured but not laser heat‐treated. The investigated laser processing strategy offers a promising approach for surface modification, enhancing both mechanical properties and wear resistance of aluminum alloy 7075 surfaces.

Enhanced mechanical and tribological properties of ultrasonically assisted stir-cast AA7075 metal matrix composites in challenging corrosive environments

Aluminum-based metal matrix composites (AMMCs) find extensive applications in aerospace, defence, automotive, and various sectors on account of remarkable mechanical properties, lightweight nature, and excellent dimensional stability. In this research, AA7075 matrix material was reinforced with tungsten carbide ceramic particles with various 0, 5, 10, 15 and 20 weight percentages (wt%) with the use of Ultrasonic assisted stir casing setup. The stir casted AA7075 MMCs were subjected to XRD, SEM, and density test to investigate the presence of elements, microstructure and density. The tensile, micro hardness, and wear test were performed on AL7075 based MMCs after conducting NaCl based spray test at the condition of spray pressure of 1.2 kg cm−2, spray duration of 120 h and PH value of 8.2 to determine the wear resistance, micro hardness and Ultimate Tensile Strength. The XRD test confirmed the presence of secondary phases such as Al2Cu, W2C, and MgZn2 with Al and WC phases. The SEM test confirmed the uniform dispersion and no more cluster formation upto 15 wt% WC addition and agglomeration of WC was occurred in the addition of 20 wt% of WC. The enhancing of wt% of WC improved the corrosion resistance, Micro hardness, UTS, wear and up to 15 wt% addition and decreases by the 20 wt% WC addition. The higher tensile strength 312 MPa was obtained from AA7075/15 wt%WC composite. The lower wear rate 0.11 mg m−1 was obtained from AA7075/15 wt%WC at 1000 m sliding distance with 1.2 m s−1 sliding velocity. The improved mechanical and tribological properties were mainly depended on strengthening mechanisms such as load transfer mechanism and dislocation strengthening mechanism.