Aluminum Alloy Research Articles

Influence of the Cooling Temperature on the Surface Quality in Integrated Additive and Subtractive Manufacturing of Aluminum Alloy

The surface quality of parts processed by laser additive manufacturing, especially laser-based directed energy deposition (LDED), makes it difficult to meet actual use requirements. In addition, defects generated during the long-term additive manufacturing process need to be removed in time. Therefore, laser additive and subtractive manufacturing is of great significance for additive manufacturing. The main difference between laser additive-subtractive manufacturing and pure subtraction is that a cooling temperature is required due to the laser process. Therefore, this work studies the temperature variation regularity during LDED and the milling processes, as well as the surface roughness, cross-sectional microstructure, and tool wear under different cooling temperatures for milling. The results show that there is a “turning point temperature” in LDED, and the value of the turning point temperature gradually increases with heat accumulation, which affects the initial temperature of the subtractive manufacturing. When subtracting, a high initial temperature improves surface quality and reduces tool wear, but an excessively high temperature will cause the aluminum alloy to adhere to the tool. Then, the smear metal is difficult to effectively remove, deteriorates the milling quality, and aggravates tool wear. It is found that the higher the cooling temperature generated, the wider the thermally insulated shear band. The insulated shear band may affect the quality of the additive and subtractive manufacturing. Finally, it is determined that the milling temperature of aluminum alloy in this work condition is about 100 °C.

Efficacy of Stationary Shoulder Friction Stir Welding to Minimize the Abnormal Behavior of Grain Growth in 7075 Aluminum Alloy

Efficacy of Stationary Shoulder Friction Stir Welding to Minimize the Abnormal Behavior of Grain Growth in 7075 Aluminum Alloy

Investigation on the microstructure and mechanical properties of 5356 aluminum alloy wire in continuous casting direct rolling process

Investigation on the microstructure and mechanical properties of 5356 aluminum alloy wire in continuous casting direct rolling process

Effect of Process Parameters on the Mechanical Properties of Simultaneous Double-Sided Friction Stir Welding Joints

Currently, conventional single-sided friction stir welding is primarily suitable for joining thin plate aluminum alloys, and its application to thick plates is still challenging in terms of welding efficiency and joint mechanical properties. Simultaneous double-sided friction stir welding (SDS-FSW) is a high-efficiency joining technique specifically developed for welding thick plates. However, there is little research on the influence of SDS-FSW process parameters on the joint mechanical properties. In this study, a 12 mm thick AA6061-T6 aluminum alloy and dual robot welding equipment are used to conduct SDS-FSW experiments exploring the influence of rotational speed ω\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\omega$$\\end{document} and welding speed v on the mechanical properties and microstructure. The results show that when the welding parameters are ω\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\omega$$\\end{document} = 800 r/min and v = 60–80 mm/min, smooth and defect-free thick plate aluminum alloy SDS-FSW joints can be obtained, and the macroscopic morphology of the joints is distributed in a “dumbbell” shape. The grain size in the weld nugget zone increases with increasing welding heat input. The microhardness distribution in the joint displays a “W” shape, and the hardness value of the weld nugget zone can reach 67% to 86% of that of the base metal (BM). The junction between the thermo-mechanically affected zone and the heat affected zone is the weakest region of the joint, with the lowest hardness being approximately 51% of that of the BM. When the welding parameters are ω\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\omega$$\\end{document} = 800 r/min and v = 140 mm/min, the SDS-FSW joint has the highest tensile strength, reaching 78.43% of the BM strength and exhibiting ductile fracture characteristics. This research indicates that acceptable weld strength in thick aluminum alloys can be achieved via the SDS-FSW joining mechanism, highlighting its significant potential for industrial applications.

Thermal Management of Friction-Drilled A356 Aluminum Alloy: A Study of Preheating and Drilling Parameters

Friction drilling is a non-conventional process that generates heat through the interaction between a rotating tool and a workpiece, forming a hole with a bushing. In this study, the effect of the preheating temperature, rotational speed, and feed rate on the induced temperature during the friction drilling of A356 aluminum alloy was investigated. This study aimed to analyze the influence of friction-drilling parameters on the thermal conditions in the induced bushing, where it focused on the relationship between preheating and the resulting heat generation. The analysis of variance (ANOVA) approach was carried out to optimize the friction-drilling parameters that contributed most to the induced temperature during the friction-drilling processing. Experiments were conducted at various preheating temperatures (100 °C, 150 °C, 200 °C), rotational speeds (2000 rpm, 3000 rpm, 4000 rpm), and feed rates (40 mm/min, 60 mm/min, 80 mm/min). The induced temperature during the process was recorded using an infrared camera, where the observed temperatures ranged from a minimum of 154.4 °C (at 2000 rpm, 60 mm/min, and 100 °C preheating) to a maximum of 366.8 °C (at 4000 rpm, 40 mm/min, and 200 °C preheating). The results show that preheating increased the peak temperature generated in the bushing during friction drilling, especially at lower rotational speeds. The rotational speed rise led to an increase in the induced temperature. However, the increase in the feed rate resulted in a decrease in the observed temperature. The findings provide insights into optimizing friction-drilling parameters for enhanced thermal management in A356 aluminum alloy.

Enhancement of aluminium alloy (AL7075) composite by the addition of crs particle via stir casting technique

Enhancement of aluminium alloy (AL7075) composite by the addition of crs particle via stir casting technique

Numerical simulation on 90° impact test of aluminium alloy wheel with the effect of tyre

Car wheels are crucial to automobile safety, requiring a rigorous test before production. A 90° impact test simulates the frontal impact and its influences on the wheel structure, replicating dynamic driving conditions. A novel modelling approach is illustrated for the 90° impact test simulation and investigates the feasibility of excluding the tyre. Firstly, the test performs and validates five impact simulations, with the maximum deformation error being 7.04%. Subsequently, with additional tests, the effectiveness of the modelling approach is evaluated. Lastly, the effect of tyres has been analysed from an energy perspective. The results indicate that the tyre significantly influences the simulation results and should be included in the finite element (FE) model, which differs from the 13° impact test.

Considerations on the Behaviour and Resistance of Aluminium Alloys to Cavitation Erosion

Considerations on the Behaviour and Resistance of Aluminium Alloys to Cavitation Erosion

Control of surface edge roughness for aluminum alloy mirror based on sub-aperture polishing

Control of surface edge roughness for aluminum alloy mirror based on sub-aperture polishing

Effects of mandrel velocity on residual stresses created in cold expansion process of adjacent holes for AA6016-T6 and AA1100 aluminum alloys

Cold expansion is a mechanical method for creating residual stresses. This method is a proven technique to increase the fatigue life, and checking the residual stress on it, is of particular importance. A cold expansion process is widely used to generate beneficial residual stresses into an annular region around the hole. In the present research work, AA 6016-T6 and AA 1100 aluminum alloys which are two strain rate sensitive materials, were subjected to cold expansion process with different mandrel velocities. In fact, the effect of mandrel velocity on the created residual stresses has been investigated. The constants of the Johnson-Cook material model have been determined for them and the process has been investigated, experimentally and numerically. The obtained results revealed that the values of the residual stresses created in the sheets depend on the velocity of the process especially at the edge of the sheets holes. By increasing the mandrel velocity from 5 to 500 mm/min, depending on the distance from the hole to the edge of the sheet, it is possible to enhance the hoop residual stress by 37.3–41.2% in AA 1100 aluminum alloy and by 37.6–38.1% in AA 6016-T6 aluminum alloy. This research showed that in all cases, the radial residual stresses created around the holes are negative. Also, it was cleared that due to the existence of material constraints and the movement of the sheet material, the amount of hoop residual stress created in the mid-thickness is more than the exit face and in the exit face is also more than the entrance face, exactly unlike the size of their zones.

Enhancing performance through friction welding of dissimilar aluminium 2014 and 7075 hybrid metal-matrix composite: insights into material characterization, crystallographic texture, and mechanical properties

Abstract Welding high-strength, age-hardenable aluminium alloys from the 2XXX and 7XXX series poses challenges when using fusion-based welding processes. Common issues such as hydrogen porosity, hot cracking, stress corrosion cracking, and solidification cracking can lead to a reduction in mechanical properties due to the loss of strengthening precipitates and alloying elements. Consequently, friction stir welding (FSW) has emerged as a promising solid-state welding technique for joining dissimilar aluminium alloys and composites, particularly in aerospace applications where a combination of strength, corrosion resistance, and other desirable properties is required. This study investigates the FSW of dissimilar aluminium alloys, specifically AA2014 and a hybrid metal-matrix composite of AA7075 reinforced with silicon carbide and graphite particles. The microstructural and mechanical properties of the welded joints were characterized, revealing an average grain size of 2.39 μm ± 1.2 in the stir zone (SZ). A high angle grain boundary volume fraction of 47.25% was observed in the SZ, compared to 2.01% in the AA7075 composite and 15.03% in the AA2014 base metal. The presence of shear textures and the distribution of cube, S, and H textures indicate a homogeneous mixing of the base materials and a high shear strain rate during welding. The hardness of the SZ increased by 13%, and the ultimate tensile strength, yield strength, and elongation of the joint were measured at 251 MPa, 183 MPa, and 6.44%, respectively. The flexural strength of the joints improved significantly, with the CW13 sample showing a 67% increase compared to CW1. The dissimilar joint CW13, welded at 12.5 mm min−1, achieved a maximum joint efficiency of 95%.

Tribological Properties of 7A04 Aluminum Alloy Enhanced by Ceramic Coating

The 7A04 Al alloy is a commonly used lightweight metal material; however, its low wear resistance limits its application. In this study, the wear resistance of this alloy was improved by preparing micro-arc oxidation (MAO) coatings, MAO/MoS2 composite coatings, and hard-anodized (HA) coatings on its surface. The friction and wear behaviors of these three coatings with diamond-like coated (DLC) rings under oil lubrication conditions were investigated using a ring–block friction tester. The wear rates of the coatings on the block surfaces were determined using laser confocal microscopy, and the wear trajectories of the coatings were examined using scanning electron microscopy. The results indicated that, among the three coatings, the MAO/MoS2 coating had the lowest coefficient of friction of 0.059, whereas the HA coating had the lowest wear rate of 1.47 × 10−6 mm/Nm. The MAO/MoS2 coatings exhibited excellent antifriction properties compared to the other coatings, whereas the HA coatings exhibited excellent anti-wear properties. The porous structure of the MAO coatings stored lubricant and replenished the lubrication film under oil lubrication. Meanwhile, the introduced MoS2 enhanced the densification of the coating and functioned as a solid lubricant. The HA coating exhibited good wear resistance owing to the dense structure of the amorphous-phase aluminum oxide. The mechanisms of abrasive and adhesive wear of the coatings under oil lubrication conditions and the optimization of the tribological properties by the solid–liquid synergistic lubrication effect were investigated. This study provides an effective method for the surface modification of Al alloys with potential applications in the aerospace and automotive industries.

Research on numerical simulation and prediction of tool wear in cutting ultra-high-strength aluminum alloys

Research on numerical simulation and prediction of tool wear in cutting ultra-high-strength aluminum alloys

Simple Scaling as a Tool to Help Assess the Closure-Free da/dN Versus ΔKeff Curve in a Range of Materials

Recent studies have proposed a simple formula, which is based on Elber’s original approach to account for R-ratio effects, for determining the crack closure-free ΔKeff versus da/dN curve from the measured R-ratio-dependent ΔK versus da/dN curves. This approach, which is termed “Simple Scaling,” has been shown to collapse the various R-ratio-dependent curves onto a single curve. Indeed, this approach has been verified for a number of tests on metals, polymers, and a medium-entropy alloy. However, it has not yet been used to help assess/determine the closure-free ΔKeff versus da/dN curve. The current paper addresses this shortcoming and illustrates how to use this methodology to assess the ΔKeff versus da/dN curves given in the open literature for tests on a number of steels, aluminum alloys, STOA Ti-6Al-4V, a magnesium alloy, and Rene 95. As such, it would appear to be a useful tool for assessing fatigue crack growth.

Mechanical Behaviour of 7075-T6 Aluminium Alloy: Integrating Digital Image Correlation and Finite Element Analysis for Uniaxial and Biaxial Load Scenarios

The objective of this study is to investigate the mechanical properties of 7075-T6 Aluminium (Al) alloy under both uniaxial and biaxial loads. The study will be conducted using a combination of experimental and numerical methods. The experimental method used is the digital image correlation (DIC) technique, which was utilized to capture the deformation and strain fields of the material specimen under tensile test. A tensile machine was employed to apply uniaxial and biaxial loads on the sample. The strain and deformation distribution of the results was generated on the DIC and correlated software. The numerical method involved the use of a commercial finite element software to create a finite element model and simulate the mechanical behaviour of the material under the same loading conditions. The results obtained from the experimental and numerical methods were compared to validate the accuracy of the numerical model. The outcomes demonstrated that under uniaxial loading, localized necking and fracture were observed, while biaxial loading resulted in shear deformation and fracture. This research contributes to the development of more accurate models for predicting the mechanical behaviour of the model samples under different loading conditions.

Impact of lattice designs and production parameters on mechanical properties of AlSi10Mg in laser powder bed fusion

Abstract This study investigates the impact of lattice designs and production parameters on the mechanical properties of AlSi10Mg fabricated using Laser Powder Bed Fusion (L-PBF). The research explores the production and performance of gyroid, diamond, and lidinoid lattice structures under varying scanning speeds (600, 900, 1,200 mm s−1). Key findings indicate that scanning speed significantly influences mechanical properties and energy absorption capabilities. The gyroid lattice structure produced at 600 mm s−1 exhibited the highest compressive strength (76.51 MPa) and energy absorption (28.57 MJ m−3). SEM-EDS analysis revealed no substantial structural defects, while porosity and microstructural deformations were observed at higher scanning speeds. Finite element simulations demonstrated localized buckling and fissure formation in lattice structures under compressive loads. The study highlights the critical role of production parameters in optimizing the mechanical performance of L-PBF-manufactured AlSi10Mg, offering insights into achieving cost and time efficiencies in additive manufacturing processes. This comprehensive analysis contributes to advancing the application of L-PBF in producing complex, high-performance aluminum alloy components for industrial use.

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

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

Investigation of various process attributes in an ingotless rolling-extrusion process imposed on waste aluminum alloy rods

Investigation of various process attributes in an ingotless rolling-extrusion process imposed on waste aluminum alloy rods

Research on deep drawing process of parabolic aluminum alloy part by one-pass rubber bladder hydroforming

Research on deep drawing process of parabolic aluminum alloy part by one-pass rubber bladder hydroforming

Quantitative Analysis of Frictional Forces and their Impact on Drilling Efficiency in Aluminum Alloy Machining

Quantitative Analysis of Frictional Forces and their Impact on Drilling Efficiency in Aluminum Alloy Machining