Aluminum Components Research Articles

Effect of grain boundary precipitation on corrosion behaviour of nonisothermally aged Al-Zn-Mg-Cu alloys

The corrosion properties of five nonisothermally aged (NIA) Al-Zn-Mg-Cu alloys with different heating rates are studied and compared with those of the T6-treated alloys by electrochemical experiments and weight loss test. The results show that reducing the heating rate results in an increase in the corrosion resistance of the alloy. The aging treatment at a heating rate of 10℃/h results in an alloy with an excellent corrosion resistance and a low corrosion current density. Additionally, the hardness of the alloy is similar to that of the alloy treated with T6. Coarse precipitates are obtained by 10℃/h aging treatment, with the grain boundaries (GBs) transferring to intermittent phases with narrow precipitation-free zones (PFZs). Therefore, this approach effectively prevents anodic dissolution and improves the corrosion resistance of the alloy. These findings suggest that NIA can enhance the mechanical properties and corrosion resistance of an alloy. Additionally, the 10°C/h aging process reduces the processing time by approximately 50%, compared to that of the T6 treatment, offering a cost-effective alternative. These results provide valuable insights into the processing of large aluminium components.

Smart piezoelectric composite: impact of piezoelectric ceramic microparticles embedded in heat-treated 7075-T651 aluminium alloy

AbstractSignificant advances have been made in material synthesis in the last two decades, with a focus on polymers, ceramics, metals, and smart materials. Piezoelectric-based smart materials generate an electric voltage in response to loads, enabling distributed monitoring in critical structural parts. Friction stir processing (FSP) is a versatile approach that can enhance material performance in various engineering fields. The primary objective of the current research is to examine the sensorial properties of heat-treated AA7075-T651 aluminium plates that have been included with Lead Zirconate Titanate (PZT) and Barium Titanate (BT) particles via FSP. This study includes a comparative analysis of sensitivities with AA5083-H111 self-sensing material, metallographic and physicochemical characterization, and an assessment of the mechanical properties impacted by the incorporation of piezoelectric particles. The sensitivity of AA7075-PZT was found to be significantly higher than that of AA7075-BT. AA7075-PZT achieved a maximum sensitivity of 15.27 × 10−4 μV/MPa while AA7075-BT had a sensitivity of only 7.28 × 10−4 μV/MPa, which is 52% lower. Microhardness and uniaxial tensile tests demonstrated that the presence of particles has an influence on both mechanical strength and electrical conductivity of aluminium components, as opposed to those that do not have particles. The complete investigation intends to give significant insights into the performance and prospective uses of these innovative smart materials, therefore advancing materials science and engineering. Graphical abstract

Connecting environmental systems analysis to manufacturing technology: A catalogue of the world's steel and aluminium components

In pursuit of greenhouse gas emissions reductions, the environmental systems community has developed material flow analyses to describe the transformation of resources into goods, while the manufacturing technology community has developed innovations that can affect the production of individual components. However, these two communities have remained disconnected, because neither is able to relate their insights to their point of common interest: the global production of components. For the first time, this paper connects global analyses of the use of steel and aluminium to the production of components, classified by the metal forming processes which shape them. The results demonstrate the proportions of steel and aluminium used in ten distinct component groups, at global level, and for the major product groups which drive demand for these two metals. This helps both to prioritise requirements for innovation in design and manufacturing and to evaluate of the emissions potential of such innovations.

Structural features of bimetallic composites of the Me-Al type (Cu, Ni, Nb), obtained by ball milling of powder mixtures and consolidation by torsion under pressure

A comparative study of the features of the microstructure of bimetallic composites of the Me-Al (Cu, Ni, Nb) type, obtained by ball milling of powder mixtures and consolidation by torsion under pressure in Bridgman anvils, was carried out. In all systems studied in this work, the formation of a nanoband structural state is observed, the elements of which are elongated predominantly along the direction parallel to the anvil plane. It has been established that in local areas characterized by the absence of the aluminum component, an SMC state without a nanolaminate structure is formed. An analysis of the features of structure formation was carried out taking into account the comparison of the characteristics of powder systems components (melting point, shear modulus and stacking-fault energy). It was shown that low shear modulus of aluminum, compared to other components, in combination with a higher homologous temperature, provides it high accommodative ability. It has been suggested that under conditions of torsion under pressure, the aluminum component, being a kind of solid lubricant, ensures slipping and flattening of stronger layers of the second component, which contributes to the formation of a nanolaminate structure in the metal‑aluminum systems under consideration.

Establishment of ductile fracture locus of 2219 aluminum alloy at cryogenic temperature

Abstract Cryogenic forming has been used to manufacture intricate curved surface aluminum components. The special geometry and mold constraints cause the stress state to continuously evolve. Coupling with the cryogenic temperature makes the deformation process more complicated. Especially for the final fracture, which greatly determines the forming quality of the components. Thus, the cryogenic fracture behavior of three typical stress states was obtained by conducting tensile experiments. Fracture strains and stress paths were obtained using a hybrid numerical-experimental method. Finally, the cryogenic fracture locus was obtained based on the MMC ductile fracture criterion. The results indicate that the AA2219-O exhibits superior ductile fracture properties at cryogenic temperature. The fracture strain of AA2219-O was increased by 52.6% at the uniaxial tensile stress state, and by up to 80.0% at under plane strain stress state. This research has a guiding significance for cryogenic forming.

Prediction of Damage Behavior of Casting Aluminum Components Considering Inhomogeneous Properties

The purpose of the work is to quantify and predict the influence of inhomogeneity of local properties on the overall behavior of the selected casting aluminum wheel and knuckle in different loading cases. Smooth and notched tensile specimens and torsion specimens are extracted from different positions in the wheel and knuckle and tested. The dependences of the flow stress, the fracture strain, and the S-N curve on position for specimen extraction are evaluated. Metallographic investigations are performed to reveal the relations between microstructure/microdefects and the mentioned properties. A damage model based on a triaxiality-dependent fracture strain is calibrated and used to simulate the specimens and component tests. The simulations of static wheel tests and knuckle fatigue tests are performed with position-dependent material parameters. The prediction of the component tests is compared with the experimental results.

Welding electrical connections between battery sheet metal materials and additively manufactured (AM) aluminum components: The effect of surface roughness

The integration of additive manufacturing's design versatility with a push for electrification can lead to unique innovations. In this context, when discussing welded joints, their quality and reliability play a significant role. The restricting factor for the use of laser powder bed fusion of metal (PBF-LB/M) additive manufactured (AM) parts is often their surface quality in the as-built state. In addition, the surface quality changes when part plane orientation changes. In this study, AlSi10Mg aluminum test samples were additive manufactured in seven different build angles. The AM samples were glass bead blasted after manufacturing, and the surface roughness of the joint surface area was optically measured. After the measurement, the AM samples were welded to nickel-plated copper and aluminum sheet metals. A continuous wave single-mode fiber laser with scanner optics was used to carry out the welding experiments in lap joint configuration. The structural and mechanical properties of the welds were evaluated by the macroscopic images of weld cross sections and tensile testing of the samples. The electric resistivity of the samples was also tested. Based on the measurement results of the samples, the impact of surface quality was discussed. The results indicated that there was no clear effect of building angle on the final weld quality. The worst surface quality in the joint area was on the test pieces in which the joint surface was facing down toward the build plate.

Design of bimetallic interpenetrating biomimetic structures and additive-casting synergetic manufacturing

Inspired by biological materials like shell nacre, biphase interpenetrating materials with alternating soft and hard phases significantly enhance mechanical properties. However, their application in metallic materials is still unexplored. This study investigates the microstructure and fracture patterns of steel/aluminum interpenetrating composites with a Diamond TPMS structure, fabricated via vacuum infiltration casting. We found that steel and aluminum form a biomimetic "brick-and-mortar" structure under the Diamond framework, significantly enhancing the composites' ductility and strength. The interfacial bonding layer, composed of Fe2Al5, Al8Fe2Si, and Al4.5FeSi, shows a hardness far exceeding the adjacent base materials. This hardness increases unevenly with distance from the interface. Tensile tests reveal that structurally periodic interpenetrating materials outperform both trapezoidal interpenetrating and planar materials. Upon fracturing, cracks initially form at the interfacial bonding layer and gradually spread into the interpenetrating region. Subsequently, under tensile and shear stress from mechanical interlocking, brittle fractures develop between aluminum components. The crack then extends into the steel framework, causing ductile fractures and complete failure of the composite.

Optimizing Construction Spoil Reactivity for Cementitious Applications: Effects of Thermal Treatment and Alkaline Activation

Construction spoil (CS), a prevalent type of construction and demolition waste, is characterized by high production volumes and substantial stockpiles. It contaminates water, soil, and air, and it can also trigger natural disasters such as landslides and debris flows. With the advent of alkali activation technology, utilizing CS as a precursor for alkali-activated materials (AAMs) or supplementary cementitious materials (SCMs) presents a novel approach for managing this waste. Currently, the low reactivity of CS remains a significant constraint to its high-value-added resource utilization in the field of construction materials. Researchers have attempted various methods to enhance its reactivity, including grinding, calcination, and the addition of fluxing agents. However, there is no consensus on the optimal calcination temperature and alkali concentration, which significantly limits the large-scale application of CS. This study investigates the effects of the calcination temperature and alkali concentration on the mechanical properties of CS–cement mortar specimens and the ion dissolution performance of CS in alkali solutions. Mortar strength tests and ICP ion dissolution tests are conducted to quantitatively assess the reactivity of CS. The results indicate that, compared to uncalcined CS, the ion dissolution performance of calcined CS is significantly enhanced. The dissolution amounts of active aluminum, silicon, and calcium are increased by up to 420.06%, 195.81%, and 256.00%, respectively. The optimal calcination temperature for CS is determined to be 750 °C, and the most suitable alkali concentration is found to be 6 M. Furthermore, since the Al O bond is weaker and more easily broken than the Si O bond, the dissolution amount and release rate of active aluminum components in calcined CS are substantially higher than those of active silicon components. This finding indicates significant limitations in using CS solely as a precursor, emphasizing that an adequate supply of silicon and calcium sources is essential when preparing CS-dominated AAMs.

Jet on demand—A pneumatically driven molten metal jetting method for printing crack-free aluminum components

Additive manufacturing (AM) of many traditional aluminum alloys is difficult due to hot cracking during cooling, which motivates investigating alternative AM methods that can mitigate this challenge. Here we demonstrate a new pneumatically driven molten metal jetting (MMJ) AM technique which uses a longer pressure pulse width to produce a jet of liquid metal that reaches the heated build plate. The “jet on demand” technique is utilized to build Al-6061 parts on heated build plates. Due to the large thermal mass contained in each jet, excellent adhesion is observed between droplets and layers while still maintaining dimensional control to produce parts with high relative densities (>98%). While as-printed parts exhibit different microstructure and hardness than traditional Al-6061, both microstructure and hardness are restored to traditionally processed values through a traditional T6 heat treatment. Microhardness values of 104 HV were obtained for printed Al-6061, which compares well to wrought properties. We observe that high build plate temperatures allow for lower solidification rates and eliminate hot cracking. These results point to a method for additively manufacturing traditional aluminum or other alloys that cannot currently be additively manufactured due to hot cracking.

A molecular dynamics study of the effect of initial pressure on the mechanical resilience of aluminum polycrystalline

Polycrystalline materials are essential in engineering due to their ability to withstand various forces, heat, and environmental conditions. The arrangement of atoms within these crystals significantly affects their mechanical properties. This study used molecular dynamics simulations to explore how initial pressure affects the mechanical resilience of aluminum polycrystals. Aluminum composite materials, known for their strength, flexibility, and environmental sustainability, are the focus of this investigation. We particularly investigated stress-strain reactions at 1, 2, and 3 bar initial pressures. Reduced free volume causes atomic migration to be hampered as pressure increases, therefore affecting mean square displacement and diffusion coefficient. The results show that ultimate strength and Young's modulus of the polycrystalline samples were 30 and 6.64 GPa at 1 bar pressure. Moreover, the results demonstrated a notable decrease in mechanical performance by increasing pressure; the ultimate strength and Young's modulus of the polycrystalline samples diminished to 5.66 GPa and 22.43 GPa, respectively, at 3 bar. Furthermore, the heat flux increased by rising initial pressure in the Al-polycrystalline sample due to the compression of material that reduced atomic distances. This improved atomic arrangement facilitated more efficient heat transfer. These insights are essential for engineering applications, as they establish a foundation for the production of aluminum components that maintain structural integrity in the face of extreme conditions.

Development of a Capacitive Pressure Sensor Based on Nanoporous Anodic Aluminium Oxide

Capacitive pressure sensors make pressure sensing technology more accessible to a wider range of applications and industries, including consumer electronics, automotive, healthcare etc. However, developing a capacitive pressure sensor with brilliant performance using a lowcost technique remains a difficulty. In this work, the development of a capacitive pressure sensor based on nanoporous AAO fabricated by a two-step anodization approach which offers a promising solution for precise pressure measurement is fabricated by a two-step anodization approach. A parallel plate capacitive sensor was fabricated by placing two AAO deposited sheets are placed face to face, with the non-anodized aluminum component at the base functioning as the top and bottom electrodes. A variation in the capacitance value of the as fabricated sensor was observed over an applied pressure range (100 Pa-100 kPa). This change in capacitance can be attributed to the decrease in the distance between the two plates and the non-homogenous distribution of contact stress and strain due to the presence of nanoporous AAO structure. In this pressure range the sensor showed high sensitivity, short response time and excellent repeatability which indicates a promising future of the fabricated sensor in consumer electronics, intelligent robotics etc.

Separation of Used Coolants From High-Pressure Aluminium Alloys Die-Casting Via Turbidimetric Method

Abstract The growth of the automotive industry and increased efforts to reduce the environmental impact of transportation require the use of more and more aluminium components in the production of new cars. The process of high-pressure die casting of aluminium makes it possible to meet the goals, but it requires the use of coolants based on oil and wax emulsions that are difficult to dispose of. A method for demulsification of real wastewater samples from the high pressure die casting process was developed and evaluated. The optimal parameters for conducting the separation process were determined, and the changes occurring in the emulsion being separated were analysed.

Modelling and Characterisation of Orthotropic Damage in Aluminium Alloy 2024.

The aim of the work presented in this paper was development of a thermodynamically consistent constitutive model for orthotopic metals and determination of its parameters based on standard characterisation methods used in the aerospace industry. The model was derived with additive decomposition of the strain tensor and consisted of an elastic part, derived from Helmholtz free energy, Hill's thermodynamic potential, which controls evolution of plastic deformation, and damage orthotopic potential, which controls evolution of damage in material. Damage effects were incorporated using the continuum damage mechanics approach, with the effective stress and energy equivalence principle. Material characterisation and derivation of model parameters was conducted with standard specimens with a uniform cross-section, although a number of tests with non-uniform cross-sections were also conducted here. The tests were designed to assess the extent of damage in material over a range of plastic deformation values, where displacement was measured locally using digital image correlation. The new model was implemented as a user material subroutine in Abaqus and verified and validated against the experimental results for aerospace-grade aluminium alloy 2024-T3. Verification was conducted in a series of single element tests, designed to separately validate elasticity, plasticity and damage-related parts of the model. Validation at this stage of the development was based on comparison of the numerical results with experimental data obtained in the quasistatic characterisation tests, which illustrated the ability of the modelling approach to predict experimentally observed behaviour. A validated user material subroutine allows for efficient simulation-led design improvements of aluminium components, such as stiffened panels and the other thin-wall structures used in the aerospace industry.

Efficient formability in Radial-Shear Rolling of A2024 aluminum alloy with screw rollers

The Radial-Shear Rolling (RSR) process, commonly utilizing traditional conical rollers, encounters challenges in achieving optimal deformation in high-strength aluminum alloy A2024, vital for aerospace applications due to its exceptional strength-to-weight ratio. This study explores the potential of screw rollers to enhance RSR efficiency for A2024 aluminum, aiming to evaluate their impact on microstructure, mechanical properties, and key deformation parameters (force, temperature) compared to conical rollers. Employing a combined approach of finite element simulations and experiments with force analysis, the study assesses the effects of screw rollers in a two-pass RSR process. The findings reveal significant advantages with screw rollers, achieving a 15 % increase in equivalent strain compared to conical rollers, indicating enhanced material formability. Consistent temperature distribution across roller types ensures stable processing conditions. Screw rollers also demonstrate a 9 % reduction in force required during the second rolling pass, potentially reducing equipment load demands and enabling higher compression per pass for improved process efficiency. Additionally, a more uniform microhardness distribution suggests consistent mechanical properties with screw rollers compared to conical ones. These results highlight the potential of screw rollers to optimize RSR of A2024 aluminum, offering improved plastic deformation efficiency, temperature control, and potentially lower equipment loads. This advancement holds promise for a more efficient and cost-effective RSR process in producing high-quality A2024 aluminum components for aerospace and other demanding applications.

Dynamics of Portevin-Le Chatelier (PLC) bands and fracture behavior of W-tempered 7075 aluminum alloys with different cooling methods

The relationship between Portevin-Le Chatelier (PLC) band propagation, plastic deformation, and failure mechanisms in solution heat-treated 7075-T6 aluminum alloys cooled by water quenching (7075-WQ) or air cooling (7075-AC) is compared using 5052-H32 alloy as a reference. Miniature tension tests, strain rate jump (SRJ) tests, and digital image correlation reveal that 7075-WQ shows diffused band configurations, 7075-AC exhibits localized patterns, and 5052-H32 has relatively stationary bands. These PLC band dynamics, related to geometry and band densities, are supported by fractography and microstructure analyses. The 7075-WQ and 7075-AC alloys exhibit mixed ductile and quasi-brittle fractures, while 5052-H32 shows ductile fractures with cup-and-cone surfaces. The findings provide new insights into the PLC bands and their formation mechanisms in W-tempered 7075 aluminum alloy concerning different cooling methods, supporting the development of thermal-mechanical processing routes for aluminum components with controllable plastic instability.

Co-Extraction of Aluminum and Silicon and Kinetics Analysis in Carbochlorination Process of Low-Grade Bauxite.

Addressing the issue that the Bayer process is not suitable for low-grade bauxite, carbochlorination was proposed to recover aluminum and silicon from low-grade bauxite. This study focused on the behavior of aluminum and silicon during the carbochlorination process of low-grade bauxite. The impact of various process parameters on the chlorination efficiency was investigated, and the chlorination mechanism and kinetics of aluminum and silicon chlorination in bauxite were analyzed and discussed. Under optimal experimental conditions, the chlorination efficiency of Al2O3 and SiO2 reached 94.93% and 86.32%, respectively. The carbochlorination of aluminum and silicon in bauxite adhered to a shrinking, unreacted core model governed by gas diffusion within the product layer. This process can be bifurcated into two stages. Additionally, calculations were conducted to determine the apparent activation energy and reaction order of the chlorination processes involving Al2O3 and SiO2. Examining the chlorination mechanism revealed that the bauxite carbochlorination encompasses transformations among various minerals. Notably, the aluminum component prefers to participate in the carbothermal chlorination reaction over silicon.

Process Selection on the Basis of Time Cost and Quality for Development Components of Aluminium Bracket

Development of various new processes has reduced the development of tooling while Designing of Aluminium Component before going to mass production by Dies. The selection of the Process to manufacture Proto quality of Aluminium is not significant. In present research is an attempt to prove that Die Casting Die in soft condition die is also recommended process for commissioning quantity of aluminium component because for prototyping one or two quantity are sufficient. Proto DCD process is also Compared with Time, Cost & quality parameters on this basis process can be selected only for maximum one thousand quantity requirement

Synergistic Leaching of Titanium, Aluminum, and Magnesium Components during Dilute Acid Pressure Treatment of High-Titanium Blast Furnace Slag.

This study focuses on an improved leaching process through the combination of pressurized conditions and direct filtration of acid leaching slurry, which is conductive to improving the filterability of acid leaching systems and the extraction rates of Ti, Al, and Mg components. The effects of sulfuric acid concentration, reaction temperature, particle size of materials, acid-slag ratio, and reaction time on the leaching efficiency were systematically investigated. The results showed that pressurization significantly enhances the filtration efficiency of the reaction slurry. Under the same filtration time, the filtration efficiency increased from 46% under ordinary pressure to 78% under pressurized conditions. Moreover, under the optimal reaction conditions, the extraction rates of Ti, Al, and Mg components were more than 88.21%, 97.8%, and 96.31%, respectively. Additionally, XRD and FTIR showed that titanium oxide sulfate hydrate crystals were produced in the acid-leached residues when the reaction temperature exceeded 190 °C, thereby reducing the extraction rate of Ti component. And the XRD pattern shows that when the reaction temperature is maintained at 190 °C and the reaction time is extended to 150 min, titanium oxide sulfate hydrate crystals will be formed to reduce the extraction rate of the Ti component. In summary, this study not only provides important theoretical support for the resource utilization of high-titanium blast furnace slag but also offers a feasible solution for efficient extraction and convenient filtration, thus holding significant academic and practical implications.

Optimization of automated anodizing plant efficiency and process prediction using Random Forest based Levy flight method

The anodizing process is mainly carried out by industrialists to protect aluminium components from corrosion and strengthen their physical and chemical behavior. The goal of this study is to minimize the total cycle time of aluminum anodizing by optimizing pre-treatment procedures and forecasting the anodization process time. The experiments were carried out at the GOLDEN ANODIZER premises, a local aluminum anodizing industry in Coimbatore, India. The relationship between various anodizing pre-treatment parameters such as Nitric bath pH, Caustic pH, alkaline pH, Mean time duration was optimized to reduce time without affecting output qualities like Surface finish (µm), Film thickness (µm), and correction (%). Also, the anodizing pre-treatment process parameters were predicted using a hybrid machine learning method called the Random Forest Levy Flight Algorithm (RF-LFA). The proposed RF-LFA shows 2–3 times better prediction performance than existing RF and deep neural networks.