Aluminum Brass Research Articles

Effects of Materials and Riblets on Erosion Mitigation Induced by Multiple Collapses of Cavitation Bubbles

The current research investigates the effects of materials and riblets on cavitation-induced erosion morphology, depth, and cross-sectional area through experimental approaches. To achieve these aims, the erosion of pure aluminum (1xxxAl or Al) and alpha brass (CuZn37 or CZ108), in the presence and absence of bio-inspired sawtooth riblets, was examined after exposure to multiple collapses of single cavitation bubbles with a wall distance of 1.8 (dimensionless). The results indicate that the erosion morphology resembles a rounded cone with a circular cross-section. Brass provides 21.6% more erosion resistance compared to that of Al in terms of material properties. Furthermore, the erosion for both Al (depth by 3.8% and width by 18.3%) and brass (depth by 7.9% and width by 27.4%) decreases in the presence of riblets compared to the results for flat surfaces. The greater erosion resistance of brass compared to Al is attributed to the superior mechanical stability of brass, making it a potentially suitable alloy for use in propellers and hulls in the shipping industry. In summary, the results reveal that riblet-equipped materials with high mechanical durability are promising erosion-resistant materials for the shipping industry. However, the potential for chemical reactions in a cathodic environment should be addressed to provide a comprehensive perspective in regards to reducing corrosion intensity.

The Effect of Cow Bone Particulate on the Mechanical Properties and the Microstructure of Aluminium Brass

This study investigates the mechanical properties and microstructural characteristics of aluminium brass composites reinforced with varying percentages of cow bone particulate (CBP). The analysis includes stress, strain, elongation at yield, Brinell hardness, and impact resistance measurements, complemented by microstructural examination. The results show that increasing CBP content enhances the stress capacity and hardness of the composites, with stress values rising from 2.2123 N/mm² at 0% CBP to 3.9951 N/mm² at 3% CBP, and Brinell hardness increasing from 52.98 BHN to 103.63 BHN. Conversely, strain values decrease from 16.8% to 13.26%, indicating a reduction in ductility. Impact resistance also diminishes with higher CBP content, from 43.52 joules at 0% CBP to 32 joules at 3% CBP. Microstructural analysis reveals that CBP particles are distributed both as clusters and fine isolated particles within the brass matrix, influencing grain size and boundary strength. These findings suggest that while CBP reinforcement enhances the hardness and stress resistance of aluminium brass, it also introduces brittleness, affecting the material’s overall ductility and impact resistance. The study provides valuable insights into the potential applications and limitations of CBP-reinforced aluminium brass composites.

Development of the Wimshurst Machine as a Learning Media on Static Electricity Material for Junior High Schools

This research aims to produce a learning media development product in the form of a Wimhurst machine teaching aid that can be used by teachers and students in the physics learning process. This media is expected to improve the knowledge and scientific thinking skills of grade 8 junior high school students in physics lessons on static electricity. This research was conducted in March-June 2014 at the Physics Department Laboratory, FMIPA-UNJ. The research carried out is research and development. This machine (the media) can show electric charge jumps directly from the friction between aluminum foil (sector) and brass as a rake. The results of the Wimhurst machine are learning media in the form of teaching aids that can help teachers in conveying material and can develop science process skills. The results of testing the Wimhurst machine teaching aids can attract students' interest in studying static electricity, so that students can easily understand the concept of static electricity.

A combination of aluminium strip and brass mesh to process a refined structure composite via accumulative roll bonding: A characterization study

In the present study, a dissimilar composite consisting of commercially pure aluminium and 70–30 brass alloy was manufactured using the accumulative roll bonding process. For microstructural evaluations, optical microscopy, scanning electron microscopy, and electron back-scattered diffraction were employed. It is indicated that after the 3rd ARB pass, the bonding between the reinforcements and matrix strengthened. However, after the 5th pass, the formation of micro-cracks along the Al/brass interface was observed. These cracks accompanied by the separation of matrix/particle led to fracture of the composite from the base metal as confirmed by fractography of the failed specimen. Also, the average diameter of Al grains was estimated to range from 1.2 μm (between brass particles) to 850 nm (near brass fragments). The micro-texture study of the selected areas indicated the evolution of P and Q components known as recrystallization texture near the brass particles. Above all, mechanical evaluations were conducted using Vickers microhardness and tensile tests. Results revealed a dramatic increase in the composite ultimate strength and hardness and then saturation as compared to that of Al without brass fragments. However, a sudden drop in hardness occurred for the composite at the 3rd pass.

Monitoring Elastoplastic Deformation in Ductile Metallic Materials Using Sideband Peak Count-Index Technique

Abstract Ductile metallic materials such as aluminum alloy, brass, and steel are widely used in engineering structures. Monitoring elastoplastic deformation in these materials is important for structural health monitoring (SHM) to ensure the safety of structures made of metallic materials. This article presents a newly developed and promising nonlinear ultrasonic (NLU) technique called sideband peak count-index (or SPC-I) for monitoring the early stages of elastoplastic deformation in ductile metallic alloy Al6061. Experimental results presented in this article show that the elastic range of the Al6061 SPC-I values shows slight changes due to the inherent inhomogeneities (imperfect grain boundaries or dislocations at the grain boundaries under loadings) of Al6061. Then the SPC-I value changes rapidly as the material enters the plastic range zone. Compared to the linear ultrasonic (LU) parameters (wave velocity and attenuation changes), the SPC-I shows a noticeable advantage (higher sensitivity) for monitoring the early stages of the elastoplastic deformation in these ductile metallic specimens investigated in this study. It is concluded that the SPC-I technique is useful for monitoring deformations in ductile metallic materials, especially in their plastic zone. This work extends the applicability of the SPC-I technique for monitoring elastoplastic deformations in metallic specimens that have not been reported in earlier works and can provide some guidelines for SHM related to elastoplastic deformation in metallic structures.

Development of a low-cost non-destructive test system for measurement of elastic modulus

Conventional measurement processes to determine elastic modulus of samples such as tensile or flexural test and bending test are typically unidirectional and destructive in nature for the measured samples. The industrial grade and commercially available Non-Destructive Test (NDT) measurement instrument based on the impulse excitation technique is meanwhile expensive. This project involves designing and developing a low-cost NDT system for the measurement of elastic modulus based on the impulse excitation technique. Secondly, it is to compare the performance of the measurement system with the tensile test. The performance of the NDT prototype will be put to test by using different type of specimens such as aluminium alloy, copper, brass, and carbon steel. Each type of specimen will carry be tested three times to get the average of the data. After all the data collection of the NDT measurement system, the tensile test will be carried out. A comparison for the measurement of the elastic modulus will be conducted between the NDT system, tensile test, and theoretical results. The expected outcome for this project is to develop a NDT for the measurement of the elastic modulus. This project also aims to reduce the industrial waste, reduce the cost of the sample test and maintain the accuracy and the performance of the NDT system compared with the tensile test.

COMBINED EXTRUSION OF GLASSES WITH A CONICAL BOTTOM. EXPERIMENTAL VERIFICATION OF THEORETICAL FORMULAS WITH FREE TRADITIONAL EXTRUSION WITH HARDENING

Cold free traditional extrusion of cups with a conical bottom made of a hardening material is considered. The methods for performing specific calculations of the deforming force for various geometric parameters of free extrusion are demonstrated in detail. Comparison with experimental data obtained by extrusion of aluminum alloy AD1 and brass L63 shows the high accuracy of the derived calculation formulas.

Significance of underwater friction stir welding on the weld integrity of thin sheets of aluminum (AA1050-O) and brass (CuZn34) joints

Classical friction stir welding (C-FSW), because of its solid-state joining nature, offers several benefits over traditional fusion welding for joining dissimilar materials. C-FSW conducted in open air, are affected by several weld flaws and thick Intermetallic Compounds (IMCs) that reduce the weld joint quality. In this study, FSW of thin sheets of aluminum alloy (AA1050-O) and brass (CuZn34) in lap joint configuration was performed in air and underwater. The main objective of this study was to investigate the feasibility of underwater-FSW (UW-FSW) for obtaining aluminum and brass (Al-Brass) joints at different values of shoulder plunge depth (SPD) and tool rotational speed (N). To determine the effect of welding temperature at different values of SPD and N on the formation of weld joints, K-type thermocouples were used. Underwater welding reduced the welding temperature and thermal cycle time. The optical images of C-FSW joints revealed the presence of kissing bonds, wavy patterns, cracks, tunnels, and void defects. In UW-FSW, the faster cooling rate significantly reduced these weld flaws. Electron backscattered diffraction (EBSD) and transmission electron microscopy (TEM) were used for the microstructural characterization. EBSD and TEM results show fine microstructure and precipitates in UW-FSW specimens. The X-ray diffraction results demonstrated that the weld joint interface primarily consisted of Al-Cu & Cu-Zn IMCs in the form of Al4Cu9, Al2Cu, AlCu3, AlCu4, CuZn5, and Cu5Zn8. The amount of IMCs was less in the joints produced by UW-FSW. The obtained results were used to understand the variation in the weld strength of C-FSW and UW-FSW joints at different values of SPD and N. To further evaluate the interface of the Al-Brass weld joint, energy dispersive spectroscopy (EDS) and scanning electron microscopy (SEM) were employed. EDS confirmed the presence of brass fragments in the stirred zone of aluminum substrate. TEM and SEM images illustrated fine precipitates and formation of thin IMC layers in UW-FSW. The tensile test result shows that the UW-FSW remarkably improved the joint strength. The percentage increase in the joint tensile strength for UW-FSW was found 42%, 30% and 50% higher than C-FSW for lower, medium and high heat input welding conditions. The lower heat input in UW-FSW significantly suppressed the formation of weld flaws and IMCs, which collectively improved the tensile strength of the weld joint.

A novel technique for identifying unknown workpiece material through machining/turning

ABSTRACT Dry machining is becoming increasingly popular due to concern regarding the safety of the environment. This research-cum-review article presents a novel technique for identifying unknown grades of aluminum alloy and brass workpieces (since the supplier did not provide the alloy details) by dry turning experimentation and logic; this paper also comparatively analyzes the resulting cutting forces and power. Dry turning experiments have been conducted on aluminum alloy and brass workpieces at a feed of 0.04 mm/rev and a cutting speed of 42 m/min. Turning was performed at depths of cut (DOC) of 0.5, 1.0, and 1.5 mm with an HSS cutting tool by use of a center lathe. The determination of the cutting forces involved the use of a dynamometer linked with a computer facilitated with the LABVIEW software package. The resulting DAQ output has been analyzed to calculate cutting forces and power at various DOC. The resulting machining data are compared with literature for a range of aluminum alloys and brasses. Logic philosophy has been applied to identify the workpiece alloys grades based on specific cutting energies.

Measuring Deformation of Deep Drawing of Various Alloys by Image Processing Using Matlab

Measuring deformation mostly is based on the contact type of measurements which utilize the gauges and instruments. But this type of contact will lead to error in the precise measurement because of errors by the contact, measuring instruments, and human. So, feel proud to introduce image processing in the field of measurement. Here, in this study deals the measurement of deformation of deep drawing specimen by image processing which is called as contact free method. This is invasive method of measurement in two dimensions.Deep drawing process is an important sheet metal forming in which flat sheet metal had been forced through the die in association with the forward punch force and opposing blank holder force. As the blank passes through the tool set converts 2D bank into 3D cup formation. The process of achieving the required diameter of the cup can be produced in single stage or multistage operation. In this study, experimental study had been conducted on single stage deep drawing process for assessment of deformation and strain in aluminum alloy, copper alloy and brass alloy. Cylindrical cup deep drawing experimental tests were performed with blank of 60 x 60 square plate with 1 mm thickness. Eventually this new approach will help to optimize the geometry parameters deep drawing specimen correlation with the Matlab results.

KAJIAN PENGARUH JENIS MATERIAL TERHADAP KUALITAS UKURAN PADA PROSES PENEKUKAN PELAT DENGAN METODA ANOVA

Abstract
 In previous research, it has been proven that the measurement technique, setting and use of quality measuring instruments can increase the quality of measurements during the bending process of steel plates (ST.37). However, this research has not examined the types of materials other than steel, even though other materials apart from ST.37, for example aluminum plates, brass plates and steel plates are widely used, especially in the manufacturing industry.. Therefore, the aim of this research is to analyze the effect of the type of material on the quality of the measurement in the bending process. This study uses an experimental method, combined with a theory that supports the discussion of the problem. The materials used are 3 different types of material plates (aluminum plate, brass plate and steel plate). The parameters observed include the measurement technique, setting and use of measuring instruments. Each material received 10 repetitions of the measurements. These three parameters were analyzed using ANOVA statistics, in order to determine the quality of the measurement of each material and the most dominant factors affecting the quality of the measurements.
 Keywords: Plates, measurements, bending processes, and statistics.

Characteristics of Mechanical Properties and Microstructure of Micro Friction Stir Spot Welding of AA1100 and Brass

Friction stir spot welding (FSSW) is a type of solid state welding that has been widely developed using both similar and dissimilar materials. Aluminum AA1100 (99% Al) and brass (Cu-Zn) with a thickness of 0.42 mm are used in this welding joint.

The influence of the backing plate materials on microstructure and mechanical properties of friction spot extrusion brazing of AA2024-T3 aluminum alloy and Brass sheets

In this study, the impact of the backing plate materials on microstructural and mechanical features during friction spot extrusion brazing of AA2024-T3 aluminum alloy and brass sheets by inserting Zn as an interlayer was investigated. Results indicated that the change of the backing plate material influentially affected the microstructure of the reaction layers at the interface of the AA2024/Zn/brass joint. Besides, it was found that the Zn interlayer could restrict the creation of deleterious intermetallic compounds at the interface. Moreover, the attained data revealed that the weld produced by the steel backing plate raised the fracture load of the joint in comparison to the other weld obtained by the copper backing plate by 35% even though the peak temperature was enhanced with a change in the backing plate material from copper to steel. The improvement in the tensile result of the steel backing plate-produced joint is owing to the good metallurgical bonding (complete filling of the pre-threaded hole) and presence of a larger amount of Al-Zn eutectic phase at the brazed zone.

Green corrosion inhibitor: Cymbopogon schoenanthus extract in an acid cleaning solution for aluminum brass

Abstract The purpose of this study was to see if Cymbopogon schoenanthus aerial extract (CSA extract) could reduce the corrosion of aluminum brass in acid cleaning solutions in the distillation plant. For this assessment, measurements of weight loss and polarization technique have all been used. We discovered that at 250 ppm, the efficiency of CSA extract was excellent (97%). Polarization assessments confirmed that the organic compounds in CSA extract were effective mixed-type corrosion inhibitors. HPLC and FTIR analysis were used to explore the key chemical components of CSA extract. CSA extract caused the corrosion process to have a higher energy barrier. Observations of SEM and FT-IR spectra confirmed that CSA extract prevents corrosion attacks at the aluminum brass’s surface.

Protective layer dissolution by chlorine and corrosion of aluminum brass condenser tubes of a nuclear power plant

The pitting and erosion corrosion of aluminium brass (Al-brass) condenser tubes in a seawater cooled nuclear power station was investigated. Inadequate ferrous sulphate dosing and relatively excess chlorine concentrations have caused the corrosion of the Al-brass tubes. Microscopic studies and surface chemical analysis were carried out to understand the mechanism of corrosion. Optical, stereozoom and SEM microphotographs showed intense pitting and typical errosion corrosion pattern of Al-brass. XRD analysis showed that the major corrosion product was copper chloride (parachamite). Detailed XPS study has provided valuable supportive data to eloborate on the mechanism of Al-brass chemical corrosion.

Failure Criterion and Parameter Calibration Methods of Aluminum Brass Alloy based on J-C Model

As the impact resistance of metal varies from different material property, therefore, the failure criterion has been adopted as theoretical or empirical formula to describe the capacity of ultimate load and deformation for materials. The paper has improved Johnson-Cook failure criterion equation and identified parameters of failure criterion through combination of experimental data, analogue simulation and numerical fitting, so as to lay the foundation for simulated analysis.

Electrochemical Investigation of Under-Deposit Corrosion Behavior for Aluminum Brass in Artificial Seawater

The under-deposit corrosion behavior and mechanism of aluminum brass (HAl77-2) were investigated in artificial seawater with a custom double electrolytic cell. The experiments included linear polarization, electrochemical impedance spectroscopy, and multielectrode arrays analysis. The electrochemical results revealed a pronounced effect of temperature on the under-deposit corrosion behavior of HAl77-2. The corrosion of HAl77-2 inside the CaCO3 scale is aggravated with increasing temperature. However, the increasing frequency of the corrosion rate of HAl77-2 gradually decreased after 333 K. Moreover, in the desalination of artificial seawater, the corrosion rate of HAl77-2 in the occulated area initially increased and subsequently decreased with increasing Cl− concentration. The scanning electron microscopy and energy dispersive spectrometry analysis showed a remarkable appearance of selective localized corrosion on the surface of HAl77-2.

Determination of a Load Causing the Appearance of Plastic Deformation in a Tensile Plate with a Crack

The problem of stretching a plate with a central or lateral crack is considered. The previously obtained solution, which determines the stresses in the plate in the vicinity of the central crack, is used to predict the load at which plastic deformation appears in the plate with a lateral crack. The Mises condition is used as a criterion for plasticity. The calculation results are compared with the experiment carried out on plates made of aluminum alloy, brass and steel.

Comparative Study on the Cavitation Erosion and Sliding Wear of Cold-Sprayed Al/Al2O3 and Cu/Al2O3 Coatings, and Stainless Steel, Aluminium Alloy, Copper and Brass

The paper investigates the cavitation erosion (CE) and sliding wear (SW) resistance of cold-sprayed Al/Al2O3 and Cu/Al2O3 composites and studies them in relation to a set of metallic materials such as aluminium alloy (AlCu4Mg1), pure copper (Cu110), brass (CuZn40Pb2) and stainless steel (AISI 304). The coatings were deposited on stainless steel by low-pressure cold spray (LPCS) using Al (40 wt.%) and Cu (50 wt.%) blended with Al2O3 (60 and 50 wt.%, respectively) feedstocks. CE resistance was estimated by the stationary sample method according to the ASTM G32 standard. The SW test was conducted using a ball-on-disc tester with compliance to the ASTM G99 standard. Results obtained for the LPCS coatings show that the Cu/Al2O3 coating exhibits a denser structure but lower adhesion and microhardness than Al/Al2O3. The Al/Al2O3 and Cu/Al2O3 resistance to cavitation is lower than for bulk alloys; however, composites present higher sliding wear resistance to that of AlCu4Mg1, CuZn40Pb2 and stainless steel. The CE wear mechanisms of LPCS composites start at the structural discontinuities and non-uniformities. The cavitation erosion degradation mechanism of Al/Al2O3 relies on chunk material detachment while that of Cu/Al2O3 initiates by alumina removal and continues as layer-like Cu-metallic material removal. CE damage of metal alloys relies on the fatigue-induced removal of deformed material. The SW mechanism of bulk alloys has a dominant adhesive mode. The addition of Al2O3 successfully reduces the material loss of LPCS composites but increases the friction coefficient. Coatings’ wear mechanism has an adhesive-abrasive mode. In both CE and SW environment, the behaviour of the cold-sprayed Cu/Al2O3 composite is much more promising than that of the Al/Al2O3.

Dissimilar friction stir lap welding of aluminum to brass: Modeling of material mixing using coupled Eulerian–Lagrangian method with experimental verifications

The intermetallic compounds formation and inter-material mixing have a critical impact on achieving a sound joint with fine mechanical properties in the case of dissimilar metal friction stir welding. In this investigation formation of intermetallic compounds as well as material flow that results in inter-material mixing during friction stir lap welding of aluminum and brass are studied. First, the 2.5-mm-thick aluminum sheet was laid on the same-thickness brass sheet and then, friction stir lap welding was applied using a tool with 4-mm pin length and 6-mm pin diameter. Next, experimental investigations were performed using scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, microhardness, and tensile shear test to probe the chemical compositions and intermetallic formation in the stir zone. Moreover, the coupled Eulerian–Lagrangian method is employed to simulate the stir zone formation during the process to further study inter-material mixing. In this method, the workpiece is modeled using Eulerian formulation, while Lagrangian formulation is utilized to model the tool. The model successfully predicts the stir zone formation and inter-material mixing in the aluminum–brass interface. Results shows that by increasing tool rotational speed from 500 to 2000 r/min the amount of inter material mixing significantly increases. Therefore, to achieve a joint with the highest strength in friction stir lap welding of aluminum–brass, the rotational speed should be lowered as much as it can produce defect-free joint.