Aluminum Alloy Components Research Articles

Improvement of microstructure and mechanical properties of CMT wire arc additive manufacturing Al-Si alloy deposition via interlayer coating TiC nanoparticles

Although cold metal transfer (CMT) wire arc additive manufacturing (WAAM) technology is commonly used in depositing aluminum alloy components, it encounters challenges and areas for improvement, particularly in Al-Si alloys. This study applies layer-by-layer TiC nanoparticle coating in the CMT-WAAM of ER4043 Al-Si alloy, investigating the impact of TiC nanoparticles on forming quality, electrical arc behavior, grain size, and mechanical properties. Results indicate that TiC nanoparticles enhance forming quality by influencing electrical arc behavior and altering the molten pool’s surface tension. Owing to the minor lattice mismatch between TiC nanoparticles and the Al matrix, these nanoparticles serve as non-uniform nucleation sites, encouraging the formation of fine grains. The grain size in CMT-WAAM specimens coated with TiC nanoparticles layer-by-layer decreased from 118.24 µm to 96.13 µm, a refinement of 18.67 %. Specimen hardness increased from 52.58 HV to 64.79 HV, and tensile strength improved by 17.65 %. Additionally, the specimens’ elongation at break was significantly enhanced.

Low-Environmental Impact Surface Treatment on SLM-Produced AlSi10Mg Aluminium Alloy

The need to reduce the cost and, therefore, the processing time of metallic materials has pushed academia and industry toward the use of additive manufacturing (AM) technologies. This paper aims to study the effectiveness of a green electropolishing treatment of AlSi10Mg aluminium alloy components produced using Selective Laser Melting (SLM) technology. The influence of treatment duration in relation to specimen surface polishing and the effect on corrosion resistance were evaluated. Morphological characterizations, roughness measurements and electrochemical tests were performed. Specifically, the study identified a set of parameters to achieve a significant reduction in roughness and an increase in the electrochemical characteristics of the components. Green electropolishing could be a viable post-processing treatment substitute to the classical treatment in which environmentally harmful acids are used.

Novel candidate of metal-based thermal barrier coatings: High-entropy alloy

To obtain compatible properties of low thermal conductivity and high thermal stability, Al0.6CoCrFeNiTi high-entropy alloy was designed as a novel candidate of metal-based thermal barrier coatings (MBTBCs). The corresponding high-entropy alloy coatings were fabricated by both high-velocity oxygen-fuel spraying (HVOF) and atmospheric plasma spraying (APS), and then the dependence of thermal insulation properties on microstructure was investigated. The both coatings exhibit a simple body-centered cubic (BCC) structure, but present obvious difference in microstructure and defect characters which relates to the evolution of in-flight particles. Benefit from the extremely low thermal conductivity, the APS-deposited coating can increase 13.24 °C of the surface temperature of piston crown and yield a temperature reduction of 19.00 °C along the thickness direction, which mean a positivity on enhancing the power efficiency of vehicle engines without sacrificing the strength of aluminum alloy components. In virtue of a decoupling method, the crucial effect of microstructure on thermal conductivity is disclosed, thus interpreting the excellent thermal insulation property of APS-deposited coating dominated by grain refinement and disordered BCC structure. The present results demonstrate a great potential of high-entropy alloy coatings as thermal barrier application and provide an inspiration for future works aiming to design these coatings to meet specific engineering needs.

Enhancing strength, ductility, and fatigue performance of Al-Zn-Mg-Cu-Sc-Zr alloy using a hybrid approach: Wire-arc directed energy deposition and interlayer friction stir processing

Porosity defects are the main issues faced by aluminum alloys manufactured by wire-arc directed energy deposition (WA-DED), which seriously affect the mechanical properties of WA-DED aluminum alloys, especially the fatigue properties. Thus far, there is still no effective solution for the elimination of porosity in high-strength WA-DED aluminium alloys. In this study, an innovative hybrid WA-DED + interlayer friction stir processing (FSP) method was applied to successfully fabricate thick-walled Al-Zn-Mg-Cu-Sc-Zr aluminum alloy component with enhanced strength-ductility and fatigue properties by utilizing a custom 7B55-Sc wire. The porosity defects caused by the WA-DED process were significantly reduced in the FSP effective zone, and the original continuous grain boundary eutectic structures were broken up and dispersed along the grain boundaries. The grains were also further refined with an average size of about 1.1 ± 0.2 μm in the stirring zone (SZ) and 1.6 ± 0.3 μm in the overlapping SZ. The nanoscale intragranular precipitates (IGPs) were mostly composed of both rod-like ηMg(Zn,Cu,Al)2 phases and secondary Al3(Sc, Zr) phases. The yield strength (YS), ultimate tensile strength (UTS) and uniform elongation (EL) in the horizontal and vertical directions were all substantially improved comparing with the WA-DED 7B55-Sc component, especially in the horizontal direction, reaching 387 ± 7 MPa, 511 ± 15 MPa and 14.6 ± 0.5%, respectively. The fatigue property after 1 × 107 cycles for the WA-DED + interlayer FSP 7B55-Sc sample was significantly increased by 81%, reaching 170 MPa in vertical direction compared to 100 MPa of the WA-DED 7B55-Sc component.

Effect of thermal-cold cycling treatment on microstructural stability of Al-Cu-Mg alloy hemispherical component

The microstructural stability of aluminum alloy hemispherical components in gyroscope navigation systems is the determinant for navigation precision. In this work, a thermal-cold cycling treatment (TCT) was applied to evaluate the microstructural stability of the hemispherical components. The results showed that the dislocations and precipitation of Al2CuMg in the component annihilated with the increasing TCT cycles, improving the microstructural stability. After 16 cycles, the dislocation density reached the minimum value of ∼1.51 × 1014 m−2 in the die fillet area (DFA), indicating an earlier stabilization than that in the bottom of the hemisphere (BOH) after 38 cycles. Such a difference was mainly attributed to the initial dislocation density. The high initial dislocation density in the DFA reduced the nucleation work and diffusion activation energy, which accelerated the nucleation of Al2CuMg phases, thereby reducing the stored energy and lattice distortion remarkably. Additionally, the high initial dislocation density increased the superimposed effect of two dislocations of opposite signs, accelerating the annihilation of dislocations. The annihilation of dislocations and precipitation of tiny Al2CuMg phases contributed to the optimized microstructural stability. In this sense, the TCT may serve as an effective method for the fabrication of aluminum alloy components with high stability for gyroscopes.

Health Risk Assessment of Inhalable Dust Exposure during the Welding and Grinding Process of Subway Aluminum Alloy Components

The subway factory industry is developing rapidly in China, but there are some occupational health risk assessments of inhalable dust in this industry. Therefore, this study aimed to explore the contamination level and health risks of dust in an aluminum alloy body workshop of subway factories in Hunan Province, China. A total of 160 dust samples were collected from the welding and grinding areas. The main elements of PM10 were analyzed. The health risks of aluminum dust and PM2.5 were evaluated. The Monte Carlo method was adopted to compare the sensitivity of the Hazard Quota (HQ) of aluminum dust and carcinogenic risk (CR) of PM2.5 to the exposure parameters for workers. The results showed that the PM10 concentration in the grinding area was higher, while the PM2.5 concentration in the welding area was higher. The metal element with a mass fraction of 27.7% was aluminum. In both areas, the probability of the aluminum dust HQ exceeding 1 was approximately 17% and 68%, respectively. The PM2.5 CR exceeded the acceptable upper limit value (1.0 × 10−4). The main risk factor of aluminum dust HQ was concentration, while the main risk factors of PM2.5 CR were concentration and exposure duration. These findings provide basic data for enhancing health risk management in the subway industry.

Prediction Model for the Evolution of Residual Stresses and Machining Deformation of Uneven Milling Plate Blanks.

During aerospace thin-walled component processing, the prediction and control of machining deformation have gained increasing attention. The initial residual stress in the blank is a major factor leading to the occurrence of machining deformation. This paper proposes the concept of uneven milling during the workpiece machining process, which is caused by the variation in local cutting depth resulting in uneven material removal thickness. Based on the elasticity theory, an analytical model is established to predict the evolution of overall residual stress and machining deformation in beam-like aluminum alloy components under uneven milling conditions. The effectiveness of the model is verified through finite element simulations and experiments. The results are as follows: (1) Under uneven milling conditions, the analytical model can accurately predict the distribution of residual stress and the machining deformation within the ZX section of the workpiece. (2) The uneven distribution of bending stress arises from the different curvature radii of various positions after workpiece deformation, leading to a 1 MPa to 3 MPa difference in stress between the middle and both ends of the workpiece. (3) During the layer-by-layer milling process, the magnitude of workpiece deformation is related to the stress state of the material removed, and there is a deformation superposition effect on the lower surface of the workpiece, further exacerbating the overall machining deformation.

Enhanced deep drawing formability and deformation mechanism of aluminum alloy at cryogenic temperature

In this paper, a novel deep drawing forming technique, which involved cooling dangerous areas with high plastic deformation using liquid nitrogen, was introduced to enhance the formability of complex-shaped aluminum alloy components. Uniaxial tensile tests were conducted on Al-Cu series alloys at different temperatures, demonstrating that decreasing the temperature from room temperature (RT) to cryogenic temperature (CT) increased the uniform elongation by over 50%. A deep drawing numerical simulation model was established for a complex-shaped component used in aircraft body opening frame, and a set of forming molds that can control the cooling areas was designed based on the strain distribution. The results of the forming experiment showed that the new deep drawing technique successfully fabricated the component without cracks, whereas the conventional cold forming technique resulted in large-scale cracks at the bottom of the component. The mechanism behind the enhanced ductility of aluminum alloys was analyzed using dislocation slip, grain deformation, serrated flow, and fracture observations.

Laser-directed energy deposition of ZrH2 particles reinforced Al7075 alloy: Cracks elimination and strength enhancement

Metal-based laser additive manufacturing, particularly Laser-Directed Energy Deposition (LDED), holds great promise for producing high-strength aluminum alloy components used in industries such as automotive manufacturing, aerospace, and biomedicine. However, achieving defect-free and superior mechanical strength in high-strength aluminum alloys, especially 7XXX series Al alloys, through LDED remains challenging. In this study, the LDED of ZrH2 particles reinforced Al7075 alloy was investigated. Results indicated that the addition of ZrH2 particles to the Al7075 alloy facilitated the columnar-to-equiaxed transition and effectively prevented hot-crack formation during the solidification process, leading to a crack-free and fine equiaxed-grain microstructure. The as-deposited Zr-modified Al7075 alloy demonstrated a favorable combination of strength and ductility, a yield strength of 266 MPa, a strength of 321 MPa, and an elongation of 21.0% in the Al7075–3%ZrH2 sample, which represents promising performance among the reported LDED-fabricated Al alloys. Contributions of four different strengthening mechanisms to yield strength were calculated, showing that the introduction of ZrH2 particles highlighted the effects of grain refinement and geometrically necessary dislocation strengthening. Moreover, the grain reinforcement mechanism in the Al7075 alloy with ZrH2 particles reinforced was elucidated after adequate material characterizations including SEM, EDS, TEM, and XRD. Needle-like Al3Zr and angular-like Al3Zr were observed in the equiaxed and ultrafine grain regions of the LDED-fabricated Al7075–3%ZrH2 samples, corroborating the truth that Al3Zr serves as heterogeneous nucleation sites during the solidification and plays a significant role in grain refinement. The successful manufacturing of crack-free, equiaxed high-strength 7XXX series Al alloys lays the foundation for LDED production of high-strength aluminum engineering components.

Certification of welder for tungsten inert gas welding in unmanned aerial vehicle systems

Aluminum and its alloys is one of the extensively used non-ferrous metal in aerospace engineering applications due to its excellent properties like higher strength to weight ratio, non-magnetic property, high thermal conductivity, good machinability, recyclability, and excellent formability. However, welding of aluminum and its alloys has always been a challenge due to drastic reduction in strength near heat affected zone (HAZ). Due to softness, ductility, lower melting point of aluminum and its alloys impose additional challenges to weld aluminum alloy components. Due to this, the quality and quantum of skill set needed to weld aluminum alloy joints for flight critical components is much more than that of welding of ferrous materials. The qualification and certification of welder is one of the prime requirements in welding applications especially in aerospace industry. This paper mainly discusses the various aspects involved in qualifying and certifying a welder for tungsten inert gas (TIG) welding process of aluminum alloys, which is treated as one of the special processes. The welder certification is a written verification that weld joints produced by welder meets the prescribed standard of welder performance. It is to verify the ability of an individual to execute a qualified welding procedure specification to produce a sound weld. Aluminum alloy 6xxx series is considered for base metal for sample preparation and weld joint assessment studies, as it is one of the prevalently used aluminum alloy material in unmanned aerial vehicle (UAV) applications. Weld samples are prepared as per internationally practiced standards and welding procedure specification (WPS) is recorded. Various mechanical tests carried out on weld samples during certification process are discussed in the paper. Weld joints are subjected to tensile testing, bending test and macro test. The certifying agencies are involved at every stage to ensure consistency of welder performance.

Experimental studies and modeling of strain rate- and temperature-dependent springback behavior of hot-deformed aluminum alloys

The unloading process of hot-deformed aluminum alloys exhibits obvious strain rate- and deformation temperature-dependent nonlinearity and the springback is generated by internal stress relaxation, which affects the forming accuracy of aluminum alloy components. The strain hardening and dynamic softening during deformation as well as static softening during unloading affect the springback of hot-deformed aluminum alloys. In this study, the homogeneous aluminum alloys samples were used to perform the single-pass isothermal hot compression and unloading tests with different deformation temperatures, loading strain rates and strains. The strain-, strain rate- and deformation temperature-dependent unloading and springback behavior of hot-deformed aluminum alloys were studied. The effects of strain hardening, dynamic and static softening on the springback behavior of alloys were revealed. The relationships between unloading stress, springback strain and instantaneous tangent modulus in unloading were analyzed. A polynomial-type equation was proposed according to the nonlinear unloading stress-strain curves. The microscopic mechanism of nonlinear unloading of hot-deformed aluminum alloys was also clarified based on the physical mechanism of internal stress relaxation and anelastic strain accumulation. A micro-mechanism-based model was developed to describe the springback and internal stress relaxation in unloading after hot deformation of aluminum alloys. The comparison of calculated unloading curves with experimental results indicates that the proposed polynomial-type equation and developed micro-mechanism-based model can describe accurately the nonlinear springback and stress decay in unloading of hot-deformed aluminum alloys, which provide a prerequisite for analyzing the final geometry and residual stress of precision hot-deformed alloy components.

Mechanical and Microstructural Investigations on a Symmetric Mould Processed with Semi-Solid Aluminum RheoMetal<sup>TM</sup>: Analysis of the As-Cast Proprieties

High-pressure die-casting (HPDC) can be a productive process for high-quality cast aluminium alloy components. However, it is also a process prone to generate defects, such as gas porosities and incomplete fillings, resulting in rejections. One way to reduce the reject rate is to employ Semi-Solid Metal processing with HPDC. The most important advantages of Semi-Solid alloys are reduced shrinkage defects, fewer gas porosities, and fewer chances of filling-related problems. To take full advantage of a semi-solid metal slurry, the casting process must be controlled meticulously to reach homogeneous casting quality and high process repeatability. A study has been conducted on cast parts composed of two-dimensional symmetrical cavities. From the mechanical tests, unexpected differences emerged in both tensile strength and fracture elongation, which were confirmed by differences in the microstructure. The paper investigates the reasons for the asymmetry in the proprieties to avoid similar problems in future studies and maximize the effectiveness and repeatability of the high-pressure die-casting process.

Process Optimization, Microstructure and Mechanical Properties of Wire Arc Additive Manufacturing of Aluminum Alloy by Using DP-GMAW Based on Response Surface Method.

Double-pulsed gas metal arc welding (DP-GMAW) is a high-performance welding method with low porosity and high frequency. Periodic shrinkage and expansion of the melt pool during DP-GMAW leads to unusual remelting, and the re-solidification behavior of the weld metal can significantly refine the weld structure. The advantages of DP-GMAW have been proven. In order to better apply DP-GMAW to aluminum alloy arc additive manufacturing, in this paper, the single-pass deposition layer parameters (double-pulse amplitude, double-pulse frequency and travel speed) of DP-GMAW will be optimized using the response surface method (RSM) with the width, height, and penetration of the deposition layer as the response values to find the superior process parameters applicable to the additive manufacturing of aluminum alloy DP-GMAW. The results show that the aluminum alloy components made by DP-GMAW additive are well formed. Due to the stirring of double-pulse arc and the abnormal remelting and solidification of metal, the microstructures in the middle and top areas show disordered growth. The average ultimate tensile strength of the transverse tensile specimen of the member can reach 175.2 MPa, and the elongation is 10.355%.

Study of vibration frequency-fatigue strength action of 6061-T6 aluminum alloy during fillet welding

The research mainly focuses on the fatigue strength characteristics of 6061-T6 aluminum alloy fillet welds under different vibration frequencies. Firstly, by introducing Stress Life Curve (S-N Curve) and Probability Stress Life Curve (P-S-N Curve), the external vibration stress effects of the main load-bearing points in the stress environment of welded joints are analyzed. Subsequently, a vibration test control system is designed to analyze the relationship between vibration frequency and fatigue strength through nominal stress analysis and hot spot stress analysis. The research findings revealed that under the nominal stress analysis method, the P-S-N fitting curve showed a declining trend with an increase in fatigue life for stress variation curves with survival rates of 50 %, 95 %, and 97.7 % at vibration frequencies of 57.5 Hz, 67.5 Hz, and 77.5 Hz. At the same survival rate stress conditions, the fatigue life variation formed by resonance frequency was smaller, and the fatigue life in the resonance state was relatively lower. There is a certain correlation between vibration frequency and fatigue strength, with resonance frequency corresponding to relatively low fatigue life. This research result helps to reveal the fatigue behavior of 6061-T6 aluminum alloy fillet welds under different vibration stresses, providing a reference for the structural safety design of aluminum alloy components.

Dynamic control of aluminum morphology by wire and arc additive manufacturing based on image feedback

The stability of the forming layer shape is a critical factor that impacts the final quality of sample morphology in wire and arc additive manufacturing (WAAM). This paper investigates the forming process and control methods to identify ways to optimize the process and improve the quality of the final product. The study aims to enhance the quality and precision of samples produced by the WAAM process by establishing a morphology control method based on image feedback. The focus is on real-time image acquisition using a CCD and simultaneous extraction of forming process parameter characteristics. Using a central composite experimental design, a prediction model is developed to estimate key process parameters and feature sizes of deposits, including deposition height and width. To further analyze the dynamic characteristics of feature sizes of deposited layers, step response identification is conducted using three process parameters as the system input: forming speed, arc current, and wire feeding speed. The experiments are designed to determine the weight of each process parameter and achieve a high level of response speed and precision. The findings indicate that the feature size of the deposited layer is most sensitive to changes in forming speed, followed by wire feeding speed, while arc current has the least impact on feature size. After verification, the monitoring of the deposition height and width was found to be in good agreement with the prediction model, with an accuracy of over 90%. The results of this study can be used for size measurement and optimization of large aviation aluminum alloy components using WAAM technology and to improve the quality of products produced using these processes.

Microstructural analysis of the influences of platform preheating and post-build heat treatment on mechanical properties of laser powder bed fusion manufactured AlSi10Mg alloy

Platform preheating is a common strategy towards reducing residual stress and distortion of additively manufactured metal components by powder bed fusion – laser beam (PBF-LB) due to the lowered thermal gradient. However, platform preheating can lead to in-situ ageing for aluminium alloy components in the building process, which will affect the mechanical properties. In this work, the microstructures of PBF-LB AlSi10Mg built on preheated (150 °C) and un-preheated (ambient) platforms have been characterized in detail by various electron microscopy techniques in order to better understand the influence of platform preheating on mechanical properties. Furthermore, the influences of T5 ageing and solution treatment plus ageing (T6) on microstructure and mechanical properties have also been examined. Platform preheating to 150 °C improves strength, which is associated with the in-situ precipitation of granular or rod-shaped Si phase and needle-like β'' phase. To the best of our knowledge, this is the first report on the observation of β'' precipitates in PBF-LB Al–Si–Mg alloys in the as-built state. Upon T5 treatment, the ambient platform material exhibits significant age hardening while only marginal age hardening is observed for the 150 °C platform material. Consequently, the materials built at different platform temperatures show similar mechanical properties after T5 treatment. The age hardening response is more pronounced when a rapid solution treatment (RST, 520 °C for 10 min) is adopted instead of the conventional solution treatment (CST, 520 °C for 2 h) owing to the precipitation of a higher number density of needle-like β'' phase during ageing. The T5 treatment improves both yield strength and tensile strength, but the improvements in strength are accompanied by a reduction in ductility. On the other hand, the RST-T6 treatment substantially improves ductility and reduces the tensile strength while maintaining the yield strength for the 150 °C platform material. Based on the microstructural analysis, the influences of platform preheating and post-build heat treatment on mechanical properties of PBF-LB AlSi10Mg are discussed.

Synchronous-hammer-forging-assisted wire arc additive manufacturing Al-Mg alloy

The plastic deformation-assisted wire arc additive manufacturing (WAAM) technology based on the hammer-forging method has essential application prospects in preparing high-dense fine-grain aluminum alloy components. However, the existing interlayer hammer-forging method has limitations, such as insufficient hammering force and high demand for hammering times when obtaining large plastic deformation. To effectively solve these problems, this paper proposed synchronous-hammer-forging-assisted WAAM technology and systematically studied its effects on the macroscopic morphology, microstructure, pores evolution, and mechanical properties of WAAM Al-Mg alloy specimens. The results show that under the synchronous hammer-forging (SHF) condition, a large plastic deformation of 33.97% can be achieved by the 80 N hammer forging force, and the surface flatness of the specimen was significantly improved. The grain size of the specimen was reduced from 105.92 µm in the deposited state to 37.15 µm in the hammered specimen by 64.93% with a significant equiaxed effect. Simultaneously, with the application of SHF technology and the increasing hammer-forging force, the precipitated phase dominated by Al3Mg2 was broken. The pores in the specimen changed from round to narrow and elongated shape with only 0.0065% porosity. The number of pores, equivalent diameter, and surface area were reduced by 68.33%, 13.75%, and 67.24%, respectively. The yield strength and ultimate tensile strength of the hammer-forged specimens reached 250.37 MPa and 315.03 MPa, respectively, which were 36.28% and 8.95% higher than those of the deposited specimens, and still maintained a high elongation rate of 36.11%.

Effect of Intensification Pressure on Eutectic Si Segregation of Al-12Si-1Cu Alloy in Squeeze Casting

Squeeze casting is an advanced technology to produce aluminum alloy components with excellent mechanical property. Due to good fluidity and castability, the Al-Si alloy is the most common aluminum material in squeeze casting. However, the segregation in solid α-Al phase and liquid eutectic Si phase happens during solidification, which leads to microstructural inhomogeneous in the final microstructure. In this study, the eutectic Si segregation of Al-12Si-1Cu alloy under different intensification pressure in squeeze casting was investigated by Optical Microscopy (OM). The results show that increasing intensification pressure promotes the eutectic Si segregation at center zone, while the eutectic Si phase at skin zone is not much influenced. Increasing the intensification pressure from 65 MPa to 140 MPa, the segregation degree of eutectic Si at center zone increases from 0.05 to 0.29, while the segregation degree at skin zone levels at 0.2. Under high intensification pressure, the feeding effect of liquid phase at center zone is prominent, which results to high tendency of eutectic Si segregation in the final microstructure.

Notch-Stress S–N Curves for Welded Aluminum-Alloy Components Subjected to Bending

Fatigue analysis of aluminum-alloy welded joints based on the linear elastic notch-stress approach is presented in this paper. The International Institute of Welding proposes two variants of the approach, one for thick joints, i.e., joints with a plate thickness of 5 mm or more, with a reference radius rref = 1 mm, using the FAT71 notch-stress design curve, and one for thin joints, i.e., joints with a plate thickness of less than 5 mm, with a reference radius rref = 0.05 mm, using the FAT180 notch-stress design curve. In this work, the feasibility of the proposed S–N curves, obtained mainly by fatigue tests on axially loaded joints, was investigated for 4 mm thick joints subjected to bending. The fatigue analysis was performed for two types of joints: a joint with longitudinal fillet-welded attachment and a joint with round sheet fillet-welded attachment. It was shown that a more accurate estimation of the fatigue life of 4 mm thick aluminum joints loaded in bending can be obtained using the FAT71 notch-stress design curve.

Study on the Behavior of Assembled T-Shaped Aluminum Alloy Specimens under Axial Compression

Assembled T-shaped aluminum alloy components represent a new type of structural member in aluminum alloy structures with broad application prospects. In this study, axial compression tests were carried out on 32 aluminum alloy components, considering parameters such as the cross-sectional type and slenderness ratio of the components, to obtain the ultimate bearing capacity and failure mode of the members. The test results show that, for the equilateral assembled T-shaped aluminum alloy components with obvious strong and weak axes, bending instability was most common, and local buckling of the plate occurred when the slenderness ratio of the component was relatively small. For the unequal T-shaped aluminum alloy structures without an obvious strong or weak axis, torsional buckling instability occurred, accompanied by local deformation of the connecting limbs due to mutual compression. A verified finite element model was also established. Based on this model, a parametric analysis was conducted to study the influence of parameters such as initial defects, slenderness ratio, and cross-sectional type on the axial compressive bearing capacity of the assembled T-shaped aluminum alloy components. The experimental and numerical results were then compared with Chinese and European standards, revealing that the standard calculation methods tend to be unsafe. Finally, the calculation parameters for component defects in Chinese and European standards were revised.