Aluminum Alloy AA Research Articles

Cooling Effects on Friction Stir Welded AA2014 Aluminum Alloy: A Macrostructural, Microstructural, and Mechanical Investigation

Cooling Effects on Friction Stir Welded AA2014 Aluminum Alloy: A Macrostructural, Microstructural, and Mechanical Investigation

Impact of tool rotation speed on boundary structure and properties of AA7075 aluminum alloy and Grade 5 titanium alloy joints during friction stir welding

Impact of tool rotation speed on boundary structure and properties of AA7075 aluminum alloy and Grade 5 titanium alloy joints during friction stir welding

Influence of dwell time on microstructure and mechanical properties of Friction Stir Spot welded aluminium dissimilar joints

This research investigates the effect of dwell time on the microstructural and mechanical properties of friction stir spot welded (FSSW) dissimilar joints between AA6061 and AA7075 aluminium alloys, with implications for automotive, aerospace, and structural applications. FSSW was performed on 2 mm thick plates with varying dwell times (2 to 8 s), and the resulting joints were analysed for weld quality using macrographs, microstructure evaluations, and mechanical testing under room temperature conditions. Notably, a 6-second dwell time achieved the maximum lap shear fracture load of 5925 N, attributed to optimised heat input and material flow. However, increasing the dwell time to 8 s led to decreased joint strength due to excessive heat, which affected grain structure and bond integrity. Fracture surfaces examined via Field Emission Scanning Electron Microscopy (FESEM) provided insights into the failure mechanisms associated with each dwell time. These findings underscore the importance of dwell time optimisation in maximizing joint performance for high-strength dissimilar aluminium alloy applications.

The influence of deformation-dependent prior chip boundary on microstructure and tensile properties in a solid-state recycled AA6063 aluminum alloy

The influence of deformation-dependent prior chip boundary on microstructure and tensile properties in a solid-state recycled AA6063 aluminum alloy

Numerical Prediction of Fracture and Perforation Behaviours of Recycled Aluminium Alloy AA6061 Using Taylor Cylinder Impact and Perforation Tests

Numerical Prediction of Fracture and Perforation Behaviours of Recycled Aluminium Alloy AA6061 Using Taylor Cylinder Impact and Perforation Tests

Exploring Marine Biomineralization on the Al-Mg Alloy as a Natural Process for In Situ LDH Growth to Improve Corrosion Resistance.

This study provides a detailed characterization of the AA5083 aluminum alloy, surface, and interface over 6 months of immersion in seawater, employing techniques such as SEM/EDX, GIXRD, μ-Raman and XPS. The purpose was to evaluate the evolution of the biomineralization process that occurs on the Al-Mg alloy. By investigating the specific conditions that favor the in situ growth of layered double hydroxide (LDH) during seawater immersion as a result of biomineralization, this research provides insights into marine biomineralization, highlighting its potential as an innovative and sustainable strategy for corrosion protection.

Studies of Corrosion Inhibition Performance of Inorganic Inhibitors for Aluminum Alloy

In this study, the behavior of sodium silicate (Na2SiO3), manganese sulfate monohydrate (MnSO4·H2O), and ammonium metavanadate (NH4VO3) as corrosion inhibitors for AA6061 aluminum alloy (Al) was investigated. The polarization resistance (Rp) of the Al substrate immersed in 0.1 M NaCl solution was found to be 13 kΩ·cm2. In comparison, the Rp of the Al substrate immersed in 0.1 M NaCl in the presence of Na2SiO3, Na2SiO3/MnSO4·H2O, and Na2SiO3/NH4VO3 inhibitors was found to be 100, 133, and 679 kΩ·cm2, respectively. The best inhibition result was obtained when the mixture of the inhibitors was used with Rp of 722 kΩ·cm2. The maximum percentage of the corroded area calculated from the scanning electron microscopy (SEM) images was found to be 5.7% for Al substrate immersed in 0.1 M NaCl, which decreased to 0.06% when the mixture of the inhibitors was used. The synergetic effects between the three inhibitors were studied, and the results illustrated that the combination of Na2SiO3, MnSO4·H2O, and NH4VO3 provided the best corrosion inhibition properties for Al in aqueous NaCl environments.

Multi-Objective Welding Optimization for AA5052 Using Taguchi-Fuzzy Approach

<div>This study investigates the influence of tungsten inert gas (TIG) welding parameters on the dilution and hardness of AA5052 aluminum alloy. Employing Taguchi’s L27 orthogonal array, the research systematically explores the effects of current, voltage, and welding speed. Analysis of the experimental data utilizes signal-to-noise ratio, analysis of variance (ANOVA), and regression techniques. The study compares a traditional regression model with a fuzzy logic approach for result validation, finding that the latter exhibits marginally better predictive accuracy. Optimal welding parameters are identified as 150 A current, 20 V voltage, and 45 mm/s welding speed, yielding a maximum dilution of 52.81% and hardness of 145.3 HV 0.5. Current emerges as the most significant factor influencing both dilution and hardness. Microstructural examination, hardness profiling, and tensile testing of specimens welded under optimized conditions reveal a characteristic hardness distribution across the weld zones and ductile fracture behavior.</div>

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%.

Aluminum alloys based on response surface methodology optimization and categorization of FSW for AA7075 & AA6082

ABSTRACT The process of fusing two or more metal pieces to enhance their qualities is known as frictional stir welding (FSW). The tensile strength, yield strength, and fracture of the location of the jointed metals vary based on the rotational speed (RS), tilt angle (TA), and welding speed (WS) of the tool. However, a lengthy test cycle and poor precision frequently affect the FSW process’s performance. This paper proposes a response surface methodology (RSM) based optimization of FSW of aluminum alloys AA7075 and AA6082. The primary objective is to improve the mechanical attributes of welded aluminum alloys. The Box-Behnken design (BBD) was chosen for RSM to generate higher-order response surfaces. The microstructure and macrostructure are assessed, as well as whether the fracture location is brittle or ductile, using scanning electron microscopy (SEM) examination. The optimized parameters are found to be RS of 900 rpm, WS of 90 mm/min, and TA of 2°. The ultimate tensile strength (UTS) of 217 MPa and yield strength of 189 MPa are observed with the optimized welding parameters. Additionally, the proposed approach achieves a high R2 and adjusted R2 values of 0.9949 and 0.9877 correspondingly. This research exhibits that the proposed method helps find the optimal welding parameters.

Investigations of surface characteristics on AA5083 alloy with dual treatment

This study compares the mechanical, tribological, and corrosion characteristics of four different substrates: untreated (UNT), untreated substrate then coating (UNTC), LSP-treated (LSPT), and LSP-treated then coating (LSPTC). This study explains how the dual surface treatment LSP and W_HVOF based molybdenum coating on the mechanical properties and corrosion resistance of AA5083 aluminum alloy. Nanoindentation tests revealed significant improvements in hardness and Young's modulus for LSPTC specimens. Surface roughness analysis showed that LSPTC specimen increased roughness, potentially to enhancing coating bonding. Scratch and wear tests demonstrated superior wear resistance for LSPTC specimens due to their higher hardness and reduced friction. Contact angle measurements indicated that LSPTC specimen made the surfaces more hydrophobic. Electrochemical corrosion analysis revealed that LSPTC specimens exhibited the lowest corrosion rates, outperforming untreated and LSPT specimens. FESEM and XRD analyses confirmed the positive effects of LSPTC specimen on microstructure and residual stress, contributing to the improved mechanical properties and corrosion resistance.

A Finite Element Model of Transient Galvanic Corrosion Behaviour of Aluminium Alloy

ABSTRACTThe environment in which aircraft are used is very complex, and factors such as high salinity, high humidity atmospheric conditions and mechanical loads applied to the aircraft during flight can lead to damage to the fuselage materials and compromise the safety of the aircraft. A large number of mechanical structural components in aircraft consist of aluminium alloys, which are susceptible to mechanical loads that erode mechanical properties and endanger the integrity of the aircraft. A time‐dependent numerical model is developed in this study. The model provides insight into the complex effects of mechanical loading on the kinetics of galvanic coupling corrosion of AA7075 (aluminium alloy). Our results clearly show that mechanical loading accelerates galvanic corrosion, and the galvanic corrosion behaviour of aluminium alloys is significantly accelerated when loading induces plastic deformation; changes in the thickness of the thin liquid film affect the galvanic corrosion of the galvanic coupling model, which is suppressed when the film thickness is increased, and, in general, exhibits a stronger tendency to corrode homogeneously; the galvanic corrosion behaviour of aluminium alloys is significantly accelerated as the area of cathode increases; the simulation also reveals a higher localisation rate of the model when the boundary load is applied compared to the no‐load case in the galvanic coupling corrosion behaviour. The numerical methodology illustrated in this study not only serves as a comprehensive tool for interpreting the intricate relationship between mechanical loading and corrosion behaviour, but also provides a framework for a deeper understanding of this multifaceted phenomenon. In practical applications, the model developed in this study can be used to check the safety of aluminium alloy structural components in service, which can be used as a reference for the design of aircraft wing skins.

Surface quality analysis of Abrasive Waterjet Cutting (AWJ) on AA5083 aluminium alloy.

Surface quality analysis of Abrasive Waterjet Cutting (AWJ) on AA5083 aluminium alloy.

Studying the effect of processing parameters on the microstructure, strength, hardness, and corrosion characteristics of friction stir dissimilar welded AA5083 and AA7075 aluminum alloys reinforced with Al-SiC matrix.

The complementary properties of corrosion resistance and ballistic resistance of AA5083 and AA7075, respectively, explain the significance of welding these two alloys in the marine armor industry. This study investigates a novel Al-SiC matrix reinforcement with a different SiC weight ratio in dissimilar friction stir welding of the AA5083/AA7075 joint at different transverse and rotational speeds. The study deduced that the novel matrix can play an important role in improving strength and ductility simultaneously. Maximum strength takes place under conditions of 50% SiC in Al-SiC matrix, 900rpm rotational speed, and 40mm/min transverse speed of value 209.8MPa, which is equal to 90% strength of the base metal AA5083, and the maximum strain takes place at 25% SiC in Al-SiC matrix, 900rpm rotational speed, and 20mm/min transverse speed, with improved strain by 2% than the softer alloy AA5083. Corrosion weight loss decreased by increasing the SiC weight ratio in the Al-SiC matrix, where it improved by 47.9% compared to the base metal alloy of AA5083 at 75% SiC in the Al-SiC matrix, 900rpm rotational speed, and 20mm/min transverse speed.

Improvement of the Localized Corrosion Resistance of AA7075 Aluminum Alloy by Forming Protective Films on Intermetallic Particles

Improvement of the Localized Corrosion Resistance of AA7075 Aluminum Alloy by Forming Protective Films on Intermetallic Particles

Study on the influence of multi-energy field combined surface modification on the subsurface microstructure evolution of AA7075 aluminum alloy

Study on the influence of multi-energy field combined surface modification on the subsurface microstructure evolution of AA7075 aluminum alloy

Evolution of plastic deformation during multi-pass ECAP of an AA6060 aluminum alloy – An experimental flow line analysis

Evolution of plastic deformation during multi-pass ECAP of an AA6060 aluminum alloy – An experimental flow line analysis

Cathodic Electrodeposition of Cerium-Based Conversion Coatings Using Deep Eutectic Solvents Formulations for Corrosion Protection of AA7075 Aluminum Alloys

The paper presents a new approach towards forming Ce-based nanostructures using deep eutectic solvents (DESs) as new green solvents and large-scale media for the chemical and electrochemical synthesis of advanced functional surfaces and nanomaterials. Some experimental results regarding the cathodic electrodeposition of cerium-based conversion coatings onto AA7075 aluminum alloys involving different DES-based formulations are discussed. Electrolytes containing Ce(NO3)3·6H2O dissolved in choline chloride-glycerine and choline chloride-urea (1:2 molar ratio) eutectic mixtures with additions of H2O2 have been proposed and investigated. The influence of the operating parameters, including the applied current density, process duration and temperature on the quality of the formed Ce-containing conversion layers was studied. Adherent and uniform Ce-based conversion layers containing 0.3–5 wt.%. Ce have been obtained onto Al alloy substrates. Higher values of the applied current density and longer process durations led to higher Ce content when a choline chloride-urea eutectic mixture was used. Several accelerated corrosion tests were performed to evaluate the corrosion performance, respectively: (i) continuous immersion in 0.5 M NaCl for 720 h with intermediary visual examinations, recording of (ii) potentiodynamic polarization curves and of (iii) impedance spectra at open circuit potential in 0.5 M NaCl, as well as (iv) salt mist test for 240 h. The influence of an additional post-treatment step consisting in the electrochemical deposition of a hydrophobic Ce-based layer involving ethanolic solutions of stearic acid and cerium nitrate is also considered. Different corrosion performances are discussed, taking into account the used DES-based systems and electrodeposition parameters.

On the drawability prediction of AA5754 aluminum alloy sheet

In order to study the drawability of AA5754 aluminum alloy blank, the numerical predictions of fracture failure behavior caused by cup drawing of metal sheet were carried out by using the GTN model and the thermodynamic-based continuous damage mechanics (CDM) model. The CDM model coupling the nonlinear isotropic and kinematic hardening laws with the isotropic ductile damage model was developed to carry out the numerical computation in the form of the user material subroutines. Although the forming limit curves predicted by GTN model and CDM model are distinctly different, but both of them are feasible to characterize the formability of metal sheets. The numerically predicted drawability of metal sheet is in good agreement with the experimental results in terms of strokes, sheet thinning and fracture failure location. The effects of sheet original thickness and friction coefficient between punch and sheet on the drawability of metal sheet were further investigated in detail.

Investigation of thin layer zinc coating on aluminium 6061 substrate using friction stir additive manufacturing process for material development

The thin layer material deposition on aluminum substrate is always an interesting domain of work. The current research work demonstrates the feasibility of thin layer Zn material deposition on Al 6061 substrate material using friction stir additive manufacturing process. The work delivers a detailed investigation on the numerical simulation and experimental work on the friction stir additive manufacturing process for effective coating of Zn layer of thickness 500 μm on aluminum alloy AA 6061. The investigation revealed that the Zn–Al interface temperature reaches to the maximum value of 762 K which is well above the melting point of the Zinc for its effective deposition on the Al substrate. The macrograph shows that the friction stir additive manufacturing process can achieve a consistent distribution of the deposited material across the Zn–Al interface. The study also delivers the analysis of the phase transformation behaviour of the Zn at the joint interface. The results from Energy Dispersive X-ray Spectroscopy (EDX) and X-ray Diffraction (XRD) confirm the presence of zinc in the deposited material. Additionally, tensile testing reveals about the enhancement in mechanical properties of the deposited material. The study can be considered as the preliminary investigation where the feasibility of deposition of a thin layer is established using the friction stir additive manufacturing process for the development of the bimetallic materials.