Aluminum Alloy Matrix Research Articles

Insight on corrosion behavior and mechanism of AA2219 friction stir welded joint in N2O4 medium

This paper investigated the corrosion behavior of AA2219 friction stir welded joints in N2O4. The results showed that with the extension of immersion time, corrosion behaviors such as pitting, intergranular corrosion, and exfoliation corrosion occurred in both base material and weld nugget zone, but there are differences in corrosion sensitivity, and the corrosion behavior mechanism and corrosion sensitivity differences were further analyzed. Pitting was caused by the dissolution of the aluminum matrix near the intermetallic Al2Cu. In addition to the potential differences, intergranular corrosion was also related to grain boundary misorientation and differences in grain boundary precipitates. Corrosion products observed visually at the intergranular corrosion position were helpful in understanding the corrosion mechanism. This work is the first to systematically investigate and report the evolution in corrosion behavior and mechanism of AA2219 FSW in N2O4, which can be a reference for the study of aerospace aluminum alloy materials.

Improvement in effectiveness of diamond in strengthening the porous aluminium composite

In this study, an aluminum (Al) alloy matrix reinforced with uncoated and titanium (Ti) -coated diamond were developed using powder metallurgy technique where polymethylmethacrylate (PMMA) particles were employed as space holders. The weight % of uncoated and coated diamond varied as (0, 6, 9, 12, 15, and 20 wt.%). Microstructural and elemental analysis was examined using scanning electron microscopy and energy dispersive spectroscope, respectively. The relative density and porosity that were in the range of 0.72–0.92 and 31–44% respectively, were measured using Archimedes principle. The compressive properties were measured and correlated with microstructure observations. The microstructure of the composite samples revealed presence of well-defined macro pores with good interfacial integrity. The X-ray diffraction revealed the presence of strengthening phases such as Al2Ti, Mg2Sn, AlB12, Cu5Sn6, Al12Mg17 and MgB2 phases formed as a result of addition of metal additives in Al matrix. Further improvement in the strength was obtained by using Ti-coated diamond particles as reinforcement. As Ti formed a good interface between the Al alloy matrix and the diamond thereby preventing the formation of undesirable carbide phases. There was an improvement in plateau stress and energy absorption capacity of 82 and 88% as compared to unreinforced porous sample. The maximum values obtained for the plateau stress and energy absorption capacity were 45.12 MPa and 13.68 MJ/m3 respectively for 9 wt.% of Ti-coated diamond reinforced composites. Uncoated diamond reinforced composites, on the other hand, reduced the strength of porous Al alloy matrix due to the formation of brittle intermetallic compound such as carbides (Al2C3) at the interface. As a result, the coated diamond particle surface modifies and improves the wettability of the Al alloy matrix and diamond interface.

Modified plasticity constitutive model for extruded aluminum alloys

Aluminum alloys have been increasingly used in a wide range of construction applications, especially in important public buildings. A plasticity constitutive model that can accurately describe the elastoplastic behavior of aluminum alloys under complicated stress states is of great importance in precisely simulating aluminum alloy structures under complicated working conditions. Also, a precise plasticity model serves as the foundation for studying the ductile fracture of metals, and is therefore crucial for structural analysis involving large deformation, such as progressive collapse analysis. The classic J2 plasticity model based on the von Mises yield criterion is the most commonly utilized model for ductile metal materials. However, it ignores the effect of stress state on metal plasticity behavior, making it inapplicable to aluminum alloy materials under various complicated stress states. This study experimentally demonstrated that stress triaxiality and Lode angle have a noticeable effect on the plasticity behavior of extruded aluminum alloys (6061-T6, 6082-T6, and 6063-T5). Accordingly, a plasticity constitutive model suitable for extruded aluminum alloys under complicated stress states was proposed and validated, including a full-range hardening law and a new yield criterion. In addition, the parameter calibration method for this new model was detailed. Finally, comparisons between the experimental and numerical results proved the high accuracy of the proposed model in predicting the actual response of a structural extruded aluminum alloy under complicated stress states. Compared with previous studies, the proposed model can not only consider the effects of stress triaxiality and Lode angle, but it can also provide a more reasonable description of yield surface under considerably high or low stress triaxiality.

Comparative Analysis of Finite Element Simulation and Experiment on the Polished Surface Quality of Hard Anodized Film of Aluminum Alloy

According to the abrasive morphology and distribution of sandpaper surface, the finite element model of hard anodic oxide film polishing was established by using ABAQUS finite element software, and the hard anodic oxide film and aluminum alloy matrix were defined respectively. The effects of hard anodic oxide film polishing process, polishing surface quality and polishing parameters on the polishing force were simulated. The polishing surface quality and polishing force simulated by finite element model were verified by experiments. The results show that in the polishing process, the residual stress of polishing surface is mainly distributed in the range of 0.0034mm, and the chips produced by polishing are mainly broken and long strips with microscopic morphology, and polishing mainly depends on the front part of abrasive particles in the feeding direction of sandpaper. Under the action of abrasive particles of sandpaper, the results of finite element simulation and test show that there are certain grooves on the surface of oxide film. The finite element simulation of the normal polishing force of hard anodic oxide film is consistent with the polishing test results. During the process of polishing hard anodic oxide film, the normal polishing force increases as the polishing speed increases; the normal polishing force increases as the polishing removal amount increases; the polishing removal amount parameter has a greater degree of influence on the polishing force.

Characterization, LCA and FEA for an efficient ecodesign of novel stainless steel woven wire mesh reinforced recycled aluminum alloy matrix composite

The production of metal matrix composites generally requires higher energy and raw materials consumption, while generating more waste than conventional material processing. The possibility of reusing recycled aluminum as an alternative in the production of metal matrix composites has led to the interest in this research as it can contribute to aluminum waste and raw reduction as well as to environmental impact mitigation. This paper provides an in-depth investigation of a brand-new metal matrix composite that is produced by gravity casting. In turn, the process is based on recycled aluminum EN AW 6082 for the matrix that is reinforced with stainless steel AISI 304 woven wire mesh that is intended for industrial and commercial use. A detailed description of the production procedure is reviewed, as are the vales of toughness, yield and tensile strengths that were determined by standardized tensile and Charpy tests. Life Cycle Assessment and Finite Element Analysis were used to determine, respectively, the environmental impact and the residual stresses generated during the production of the specimens for the above mentioned tests. Five different opening and wire diameter configurations for the AISI 304 woven wires were studied in this work. In a comparison to recycled aluminum alloy EN AW 6082 without reinforcement, the best results were provided by the 2.177 mm × 0.6 mm configuration. These results were the following: (1) Yield, tensile strength and toughness showed an increase of 245.5%, 13.62% and 175.0% respectively. (2) Life Cycle Assessment increased 8.31% for the highest environmental impact obtained (Human Toxicity). (3) The Finite Element Analysis showed that the residual stresses increased in their compressive values in −10.83 MPa, −9.925 MPa and −3.84 MPa, respectively, for the stainless steel wires, aluminum matrix and wire/matrix interfaces. From the mechanical properties, the environmental impacts and the residual stresses that were obtained, one can conclude that this study has demonstrated a technically feasible practical approach to the use of the recycled aluminum alloy EN AW 6082 using AISI 304 stainless steel woven wires as materials in the metal matrix composites production. This could lead to a substantial reduction in the volume of aluminum used and, consequently, provide environmental and economic benefits.

Research of Gantry Frames of Different Materials Based on ANSYS Workbench

According to the production requirements of a packaging production line in a distillery, this article designed a suction tray gantry with a width of 1922mm, a length of 5000mm, and a height of 940mm using Solidworks software. Through ANSYS Workbench, the performance advantages and disadvantages of the gantry made of structural steel and aluminum alloy under the maximum load of 100Kg required by the enterprise are analyzed. Finally, through the comparison of their stress, total deformation, and total weight, it is concluded that the total weight of the gantry made of aluminum alloy material is about 660kg lighter than that of the gantry made of structural rigid material when the difference between the stress and total deformation is not significant, and the cost is cheaper. Therefore, the aluminum alloy material is finally selected to make the gantry.

Spreadsheet to analyze the comparative of elasticities properties of aluminum alloy materials

Physics learning contains mathematical processes with various equations to interpret concepts or phenomena in the quantitative concept. Each material with different values owns material mechanical properties such as elasticity. Spreadsheets can help mathematical processes become more effective and efficient. The output of spreadsheets can be interpreted as graphs or diagrams that make it easier to understand concepts and compare the elasticity of each material. The material studied in this study is an aluminum alloy in terms of its elemental content. Spreadsheet analysis presents the values of the elasticity properties of each material in graphical form. The elasticity properties studied are the modulus of elasticity (Young modulus), yield strength (Yield strength), and maximum strength (Ultimate strength).

A bifunctional epoxy coating doped by cerium (III)-8-hydroxyquinoline: Early self-reporting and stimuli-responsive inhibition on corrosion of Al substrate

Recently, anti-corrosion coatings with auto-inhibition and self-reporting on their premature flaws are becoming more and more attractive. In this work, we engineered a cerium nitrate/8-hydroxyquinoline (Ce-HQ) hybrid pigment to endow epoxy coatings with corrosion self-inhibiting and fluorescent self-reporting performances via molecule design. The Ce-HQ pigments were synthesized by physical mixture and then dispersed into the commercial epoxy coating. Once the epoxy coating gets degraded, the underneath aluminum alloy matrix may corrode to produce Al3+ ions, which can compete with Ce3+ ions in the Ce-HQ complex, and then chelate with dissociative 8-HQ to form fluorescent Al-HQ complex, due to the higher bonding strength of Al3+ with 8-HQ than Ce3+ ions. Thus, not only the responsive releasing of Ce3+ ions and 8-HQ can inhibit the underlying Al alloy, but the newly formed Al-HQ complex could indicate the location and severity of coating flaws through fluorescent emission under UV light. Electrochemical impedance evidenced that the composite epoxy coating containing 1 % mass Ce-HQ presents high corrosion resistance even after 504 h of salt spray test, showing 90 % corrosion refraining efficiency. This work may enlighten an approach to developing self-healing and self-diagnosis coating for premature corroded Al alloy beneath coatings via reactive release and fluorescent visualization.

Interfacial reaction kinetics of (Al63Cu25Fe12) 99Ce1 quasicrystal reinforced 6061 aluminum matrix composites

Due to its superior overall characteristics and effective interface wetting, quasicrystal reinforced aluminum matrix composite is regarded as a type of material with significant development potential. The procedure of hot pressing and sintering was used to create a quasicrystal particle reinforced 6061 aluminum matrix composite made of (Al63Cu25Fe12)99Ce1. Investigated in the composite were the element diffusion and the microstructure of the contact between the reinforcement and matrix. The findings demonstrate that mutual diffusion between reinforcement and matrix leads to the formation of the I-phase, Cu9Al4 phase, Al23CuFe4 phase, and ω-phase. Always present in the reinforcement, which has a strong link to the matrix, is the Al13Ce2Cu13 phase. At the same time, the diffusion kinetics of the transition layer between the quasi-crystalline phase and the matrix during the hot pressing process was revealed, and the most suitable thickness of the transition layer was determined to be 4.85 µm, which plays a great role in the improvement of the composite properties. The study of the microstructure and interfacial dynamics of (Al63Cu25Fe12)99Ce1 quasicrystal-reinforced 6061 aluminum matrix composites has laid the foundation for the creation of long-life, high-strength aluminum alloy materials with excellent properties.

Influence of carbon and glass fiber reinforced composite adhesive on the strength of adhesively bonded joints

Abstract Today, due to the frequent use of composite materials used in the aerospace and automotive industries, an intensive study is carried out on the joining methods of these materials. One method of joining composite or aluminum alloy materials is adhesive bonding. Studies on the development of the strengths of adhesively bonded joints focused on adhesive type, the bonding method, and hybrid joints. In the present study, a different method was used to increase joint strength. This study experimentally and numerically investigated the mechanical properties of single-lap joints bonded by a composite adhesive – obtained by adding fiber fabric to the adhesive. Adhesively bonded single-lap joints were produced using DP460 toughened adhesive type as the adhesives; AA2024-T3 aluminum alloy was used as the adherend, and carbon fiber and glass fiber fabric were used as the added fiber. In addition, for the numerical analysis of the presented study, the bulk properties of the composite adhesives were obtained. As a result, the use of fiber-reinforced adhesive in bonding joints significantly increases the failure load of the joint, as it prevents the progression of cracks formed in the joint. However, the increase rate in the failure load changes depending on the adhesive thickness and the type of fiber fabric. As follows, the failure loads of the fiber-reinforced joints increase between 5% and 41% compared to the non-fiber-reinforced joints. In addition, it was observed that the results obtained from the numerical analysis and the results obtained from the experiments were consistent with each other.

Effect of the Deposition Process on High-Temperature Microstructure and Properties of the Direct Energy Deposition Al-Cu Alloy

The excellent microstructure and mechanical properties of Al-Cu alloy deposited using the Direct Energy Deposition (DED) process has been shown in previous studies, which is the most likely aluminum alloy material to meet the load-bearing requirements of hypersonic aircraft. However, its high-temperature performance and the law of microstructure transformation during the high-temperature process still need to be determined. In this paper, DED Al-Cu alloy samples were prepared using the Cold Metal Transfer (CMT) process, CMT Pulse process, and CMT Pulse Advanced process. The effect of different deposition processes on the microstructure and mechanical properties of the deposits was investigated at 200 °C for 30 min. The results show that the Al-Cu alloy’s main strengthening phase θ′ is excessively transformed into the equilibrium θ phase after the high-temperature process, which is the main reason for the degradation in the DED Al-Cu alloy’s properties at high temperatures. Different deposition processes have almost no effect on the high-temperature performance of the DED Al-Cu alloy, and the deposition process can be selected according to the product’s structure.

Conservation of waste melon shell and fly ash utilized as reinforcements for aluminum alloy matrix in terrestrial ecosystem acquired green hybrid composites

AbstractNowadays, the environmental ecosystem is protected and maintains sustainability for waste material management like agriculture product end waste and industrial waste. The main scope of this research is to gather the agriculture end product of melon shell ash waste and industrial fly ash waste utilized as organic reinforcements for making a lightweight with superior strength green hybrid composite for fourth‐generation terrestrial ecosystem applications. The various volume percentage of waste melon shell ash and fly ash are governed by the ratio of 0:0, 1:4, 2:4, 3:4, and 4:4, respectively. The green aluminum alloy (Al6061) hybrid composite is synthesized via a semi‐solid stir technique. The developed green hybrid composites are subjected to physical and mechanical studies followed by ASTM standards. The developed composite contained a 4:4 ratio of melon and fly ash and found a light weight of 2.75 ± 0.11 g/cc with improved tensile strength and hardness percentages of 8.35% and 21.38% compared to cast aluminum alloy. This research may help basic knowledge for future investigations on modern green composite manufacturing via agricultural and industrial wastage.

Study of effect of provision of cut-outs on axial collapse behaviour of circular aluminium tubes

Geometrical modification of thin-walled tubular structure is one of the innovative ways in the development for vehicle safety design. This research is developed in accordance with the need of investigation on behaviour of tubular structures with geometrical modifications like cut-outs under dynamic loading technique. Diamond and elliptical cut-out shapes are provided in multiple number arranged circumferentially in a single row on a tube surface. Tubes with cut-outs are loaded axially at three different velocities, corresponding to three different strain rates. Energy absorption characteristics like energy efficiency, specific energy absorption, peak collapse force, mean collapse force and efficiency of peak force reduction at the initiation of tube deformation are calculated and compared using finite element (FE) based ABAQUS/Explicit® software. Split-Hopkinson Pressure Bar (SHPB) is modelled in the FE software to understand the material behaviour under high strain dynamic loading. Johnson-Cook material model parameters are incorporated in the study to understand the strain rate sensitive behaviour of aluminium alloy material. Results revealed that providing diamond and elliptical cut-outs on tube is much efficient than providing circular cut-outs on tube, in terms of percentage peak load reduction as well as energy efficiency of structure. It was observed that number of cut-outs influences the polygonal deformation pattern of tube with cut-outs. Overall study significantly helps to achieve the aim of improving vehicle crashworthiness characteristics by implementing cut-outs in a crash frame.

Characterization of wear and fatigue behavior of aluminum piston alloy using alumina nanoparticles

Abstract Due to their excellent thermal conductivity, lightweight, and ease of processing, aluminum alloys are the material of choice for piston manufacture in internal combustion engines. Nanoparticles (NPs) of alumina (Al2O3) with a size of 25 nm were incorporated into an aluminum piston alloy to examine the effect of the NP addition on wear resistance and fatigue behavior. The stir casting method has been utilized to manufacture experimental samples of the composite material by altering the particle weight ratio of aluminum to the matrix alloy to 2, 4, and 6 wt%. The surface morphology of the samples has been examined using an electronic scanning microscope. The results of the wear and fatigue tests indicate that the addition of Al2O3 to the composite enhanced its fatigue resistance and wear strength, with the exception of 6 wt% weight ratio. The best improvement in wear resistance and fatigue strength occurs at 4 wt% Al2O3 particles, which are 12.13 and 67.5%, respectively, more significant than the pure metal and other composites. The mechanical properties of the alloy samples have been enhanced by adding Al2O3 NPs of 25 nm size into the piston’s aluminum matrix alloy. Stir casting was employed to produce the needed composites by incorporating Al2O3 NPs at varied weight percentage ratios of 0, 2, 4, and 6 wt% into the master alloy. Before the composite alloy reached 6 wt%, including Al2O3 NPs, the alloy’s hardness and tensile strength improved, according to the experiment results.

Research of Ceramic Aluminum New Material and Its Application on Certain Naval Gun

The ceramic aluminum new material is a kind of high performance material, which has attracted much attention due to their excellent properties such as high elastic modulus, good wear-resistance and high strength. These properties have made ceramic aluminum materials attractive candidates for various application fields. As the weapons equipments have entered the golden development period, the demand for high performance composite materials is crucially strong. It was estimated that the new materials was used to produce the brackets and cradles on certain naval gun, which account for more than 31% of all gun materials. The results showed that the properties of the ceramic aluminum new material were better than those of the conventional cast aluminum and matrix aluminum alloy. Under the condition of the same structure, the weight of the ceramic aluminum new material was about 6.5% and the maximum deformation was about 15.5% less than that of the ordinary aluminum alloy. Under the condition that the maximum deformation was basically the same and the stress was not considered, the weight of ceramic aluminum alloy was about 6.3% less than that of the ordinary aluminum alloy.

Analysis of mechanical properties enhancement on composites of AA7175 by multi walled carbon nano tube (MWCNT)

Developed to meet the demands of appealing contemporary materials, nanocomposites are polyphase materials that include a matrix and nano-reinforcement. The major types of nanocomposites are as follows. They are categorized as fiber-reinforced nanocomposites, laminar nanocomposites, and particulate nanocomposites based on the reinforcing component, whereas they are classed as metal matrix, ceramic matrix, and polymer matrix nanocomposites based on the matrix ingredient. Due to its advantages over polymer and ceramic matrix, metal matrix nanocomposites (MMNCs) are the most common type of nanocomposites employed in industrial applications. To improve the physical, mechanical, thermal, and electrical properties of conventional materials, nanocomposites are often formed by reinforcing nanoscale tubes, fibres, particles, or sheets. To keep up with technological advancements, drive market changes, and bridge technological gaps by revolutionizing the product, innovative nanocomposites must be used in advanced engineering applications. The high-strength, light-weight aluminium alloy matrix nanocomposites (AMNCs) are able to replace traditional materials to a greater extent in cutting-edge applications including the automotive, aircraft, marine, defense, leisure, and electronic industries. In this study deals with the property enhancement analysis by means of the assistance of Multi Walled Carbon nano tube (MWCNT) nano particles encouragement in AA7175 aluminium alloy. The main focus of this investigation on the tensile related mechanical properties such as tensile strength, percentage of elongation and yield strength. The composites were created with the mass fractions of 5.0 wt%, 4.0 wt%, 3.0 wt%, 2.0 wt% and 1.0 wt% of MWCNT with 95.0 wt%, 96.0 wt%, 97.0 wt%, 98.0 wt% and 99.0 wt% of AA7175 aluminium alloy. These composite mechanical properties were compared with the pure AA7175 aluminium alloy. Among the comparison of these composites values 3.0 wt% of MWCNT produce the greater results on the considered composites. The composite sample recorded high Ultimate Tensile Strength of 431.12 MPa, low Percentage of elongation of 9.58% and high Yield strength of 396.63 MPa.

Computational evaluation of automotive camber component for light‐weight design

AbstractDue to global warming, environmental issues are one of the most interesting issues in the world. Especially for automobiles that emit pollutants, the issue of lightweight design is one of the important research areas. Thus, this study deals with the lightweight design of a camber link, an automotive suspension component, through finite element analysis. With reference to the camber link made of steel (SM45C) material that has been proven by commercialization, we will replace it with A356 aluminum alloy material to reduce the weight. Here, the design was changed through finite element analysis to reinforce the reduction of rigidity due to material substitution. In particular, we propose a method of designing a camber link considering the safety factor by analyzing the change of stress applied to the suspension. The weight reduction of about 14 % was achieved through static analysis using the weight factor. Using the dynamic optimization method through static analysis using the weight factor and stress ratio, it can be seen that the application is convenient and easy for the lightweight and optimal design of automobile parts.

Effect of Coated Composite Micro–Texture Tool on Cutting Shape and Cutting Force during Aluminum Alloy Cutting

Aluminum alloy materials are very difficult to break in the processing process; chip accumulation leads to poor processing stability. In this paper, a coated composite micro–textured tool is presented. The influence of coated composite micro–textured tool on chip shape and cutting force under the same cutting parameters is studied. Firstly, the combination of cutting force and cutting temperature is optimized based on cutting test. Secondly, combined with the finite element simulation technology, three kinds of composite micro–texture tools are tested to determine the same cutting parameters, tools and workpiece materials, and optimize the composite micro–texture combination from the angle of chip shape, cutting temperature and cutting force. Finally, on the basis of optimizing the microstructure combination, the optimization of the cutting performance of aluminum alloy by coating material is studied. It was found that the chip was more easily broken in the composite microstructure when two tools were used. The cutting force decreased by 25% and the cutting temperature decreased by 9.09% compared with the non–micro–texture tools. The cutting temperature and cutting force decreased by 3% and 4.99% compared with those of uncoated composite microstructure.

Study on the Reinforcement Effect of Different Graphene-Aluminum Matrix Composites Prepared by High-Energy Ball Milling

In order to explore the best graphene raw materials for the preparation of graphene-aluminum matrix composites by high-energy ball milling. The graphene-aluminum matrix composites were prepared by high-energy ball milling and vacuum hot pressing sintering, and the mechanical properties of the composites were tested. The enhancement effect of reduced graphene oxide (R-GNPs), multilayer graphene (M-GNPs), and graphene oxide (GO) was analyzed by SEM, TEM, XRD, XPS, and FT-IR spectroscopy. The results show that the enhancement effect of graphene oxide is more significant, the tensile strength can reach 329.256 MPa, and the hardness is 136.3 ± 5 HV. GO forms a sandwich-type composite structure in the 2024 aluminum alloy matrix under the action of high-energy ball milling, and the formed composite structure avoids the agglomeration of graphene during the composite process. During the sintering process, GO undergoes thermal reduction to form reduced graphene oxide, which improves the mechanical properties of the composite.

Experimental Fatigue Studies of Additively Manufactured Fiber Reinforced Thermoplastic

Additive manufacturing (AM) is a field of study that is gaining importance due to quick manufacturing techniques while providing viable flexibility in design modifications. In comparison with conventional manufacturing methods, AM uses easier processes to manufacture intricate components. AM products maintain consistency as it is constructed by robust universal AM machines. In the present study, a continuous carbon fiber thermoplastics (CFRTP) as a replacement to aluminum alloy (Al6061-T6) material is used for additively manufacturing bicycle crank components. The results from the tensile test and fatigue behavior of the component indicate a strong dependence of percentage concentration of the reinforcement in the CFRTP. A finite element analysis is performed to ascertain the stress distribution for a static load condition as mimicked in the real world situations. To explore the brittle fracture nature of the CFRTP specimen, a SEM image depicting the microstructural nature is provided. It is imperative to note that the comparative studies indicate the light weight CFRTP crank specimen stands out to be a viable replacement to the Al 6061-T6 material.