Aluminum Alloy Research Articles

Research on the microstructure, mechanical and fatigue performance of 7075/6061 dissimilar aluminum alloy fusion welding joint treated by nanoparticle and post-weld heat treatment

The microstructure and mechanical properties of 7075/6061 high-strength dissimilar aluminum alloy fusion welds, after TiC nanoparticle-assisted welding and heat treatment, were discussed, and their fatigue performance was analyzed. The results indicate that the significant increase in hardness at the weld zone with T6 treatment compared to T5 is due to the solution treatment providing supersaturated solid solution for subsequent aging precipitation. T5 treatment causes the precipitation in the heat affected zones, thereby increasing the hardness of these regions. The joints exhibit excellent yield strength and tensile strength after heat treatment, with the elongation performance being optimal in T6 state. The fatigue performance of dissimilar aluminum alloy joints treated with nanoparticle and heat treatment is superior to the joints with single riveting. Porosity defects and microcracks generated during welding are prone to stress concentration, with interconnected pores and easily propagating cracks forming fatigue sources for pores and cracks. The crack propagation behavior is influenced by the pinning effect of TiC nanoparticles at the grain boundaries, and the second phase particles hinder crack propagation along the grain boundaries, forcing cracks to extend towards the 6061 side or the HAZ of the lower strength 6061 matrix. It demonstrates that the method of combining nanoparticle-assisted melt inert-gas welding and T6 heat treatment improves the fatigue life of 7075/6061 dissimilar aluminum alloy joints.

Effects of conventional interweaving and secondary deposition on the microstructure and properties of Ti6Al4V/AA2024 alloy component fabricated by laser-directed energy deposition

The connection of dissimilar materials has always been a great challenge, especially titanium alloy and aluminum alloy, which have broad application prospects in the aerospace industry. In this work, the Ti6Al4V/AA2024 alloy component was prepared by laser-directed energy deposition (L-DED) technology based on a conventional interweaving structure, and the microstructure of four typical position interfaces was analyzed. Aiming at the problem of poor forming quality of titanium alloy in the second interweaving layer caused by high laser reflectivity of aluminum alloy, a secondary deposition process was proposed. The microstructure and mechanical properties of Ti6Al4V/AA2024 alloy component fabricated by two different processes were characterized and tested. The problems of discontinuity and penetrating cracks at the Ti6Al4V layer in the second interweaving layer are effectively tackled by secondary deposition. As a result, the mechanical property of the deposited structure can be effectively improved, of which the average compressive shear strength is 8% higher than that of the conventional interweaving Ti6Al4V/AA2024 alloy component. The stress at the Ti6Al4V/AA2024 interface presents a zig-zag distribution because of the interweaving structure, which avoids the generation of continuous stress bands and effectively inhibits the interface crack propagation.

Strain Hardening of 1565ch, AMg6, 01570, and 1580 Aluminum Alloys in the Process of Cold Rolling of Plates

Strain Hardening of 1565ch, AMg6, 01570, and 1580 Aluminum Alloys in the Process of Cold Rolling of Plates

Alloying of Industrial Aluminum Alloys with Scandium

Alloying of Industrial Aluminum Alloys with Scandium

An integrated hybrid wire-arc directed energy deposition, friction stir processing, and milling system for multi-track, multi-layer part manufacturing

Wire-based Directed Energy Deposition (DED) is a widely-used manufacturing method due to its high productivity and large part fabrication capability. Meanwhile, Friction Stir Processing (FSP) is a solid-state joining process that can modify microstructure and weld lightweight alloys. Additionally, wire-based DED printed parts need machining process to achieve the desired dimensional accuracy. To take advantage of all these three processes, this work proposes an integrated hybrid system by combining the wire-arc DED, FSP, and milling processes into a standalone system which can fabricate superior materials in a multi-track, multi-layer manner for the first time. The integrated system can improve dimensional accuracy and productivity by processing the workpiece without the need to move it between different systems. It is demonstrated that a 150 × 40 × 21 mm3 block of aluminum alloy AA5183 can be fabricated using the hybrid wire-DED/FSP/milling process from wire feedstock. Material characterization shows that the hybrid process is able to refine the grain size by two orders of magnitude to sub-micron scale, while eliminating all the pores and microcracks produced by the DED process. These enhancements result in significantly improved mechanical properties including Young's modulus (15 %), yield strength (161 %), ultimate strength (33 %), and hardness (55 %) without compromising ductility.

Tailoring the coefficient of thermal expansion in a functionally graded material: Al alloyed with Ti-6Al-4V using additive manufacturing

Functionally graded materials enable the spatial tailoring of properties through controlling compositions and phases that appear as a function of position within a component. The present study investigates the ability to reduce the coefficient of thermal expansion (CTE) of an aluminum alloy, Al 2219, through additions of Ti-6Al-4V. Thermodynamic simulations were used for phase predictions, and homogenization methods were used for CTE predictions of the bulk CTE of samples spanning compositions between 100 wt% Al 2219 and 70 wt% Al 2219 (balance Ti-6Al-4V) in 10 wt% increments. The samples were fabricated using directed energy deposition (DED) additive manufacturing (AM). Al2Cu and fcc phases were experimentally identified in all samples, and aluminides were shown to form in the samples containing Ti-6Al-4V. Thermomechanical analysis was used to measure the CTE of the samples, which agreed with the predicted CTE values from homogenization methods. The present study demonstrates the ability to tailor the CTEs of samples through compositional modification, thermodynamic calculations, and homogenization methods for property predictions.

Numerical Analysis of the Influence of the Rolling Speed on the Cold Rolling under Specific Thermal Condition of the AA 5052-O Aluminum Alloy

In this study, the behavior of the rolling process of the AA 5052 aluminum alloy plate has been investigated using numerical data. An FEM technique was utilized in order to make a prediction regarding the impact that the rolling speed has on the cold rolling of the AA 5052-O aluminum alloy. In order to carry out the simulation procedure, the static structure tool was considered. The geometry of the situation. The total deformation, stresses, including von and normal stresses, and energy have all been the subject of investigation for the simulation that is now being performed. In both the axial and radial directions, the deformation has been investigated using numerical methods. It is possible to get a maximum result of 550 and 140 mm, respectively. at a speed of 200 revolutions per minute, the energy reached 8 kilojoules. It has been established that both normal and von mises stresses have been established. A total of 3.6 and 1.9 MPa are the numerical results that the stress has produced.

Investigation of age-hardening behaviour of Al alloys via feature screening-assisted machine learning

Age hardening stands as a crucial strengthening process for aluminium (Al) alloys. However, determining the optimal ageing conditions has traditionally relied on resource-intensive trial-and-error methods. To streamline the design of Al alloys, this study introduces a novel feature screening-assisted machine learning (ML) approach to explore age-hardening behaviour across varying compositions and heat treatment parameters, focusing on yield tensile strength (YTS), ultimate tensile strength (UTS), and elongation (EL). A comprehensive pool of features, incorporating alloy composition and fundamental elemental properties, was generated to provide metallurgical insights for ML predictions. Subsequently, feature screening methodologies, including correlation analysis, feature elimination, and multi-objective genetic algorithm (MOGA), were employed to identify key features from the vast feature pool, balancing model complexity and prediction accuracy. Employing support vector regression models trained on these optimized feature sets, we demonstrate enhanced prediction accuracy for strength properties while maintaining model simplicity for EL, with minimal impact on accuracy. In addition, experimental results further validate the method's ability to reproduce ageing curves across all three mechanical properties for both commercialized and newly designed Al alloys.

Effects of Stainless Steel Woven Wire Mesh Reinforcement on the Load-Bearing Capacity of Adhesively Bonded Aluminium Alloy Single-Lap Joints

Effects of Stainless Steel Woven Wire Mesh Reinforcement on the Load-Bearing Capacity of Adhesively Bonded Aluminium Alloy Single-Lap Joints

Investigation of an L-Shaped Cross-Sectioned AA6061 Aluminum Alloy Ring via Extrusion and Self-Bending Integral Processing Technology

Investigation of an L-Shaped Cross-Sectioned AA6061 Aluminum Alloy Ring via Extrusion and Self-Bending Integral Processing Technology

The effects of different strengthening treatments on wear performance of ZL109 aluminum alloy at high temperature

Enhancing strength or hardness is a widely employed strategy to improve wear resistance of ZL109 aluminum alloy at elevated temperatures. This study aimed to investigate the effects of various strengthening treatments on the wear performance of ZL109 aluminum alloy. Three strengthening methods, namely structural refinement, strain hardening, and precipitation strengthening, were employed to achieve a similar hardness level. Subsequently, the wear tests were conducted using a reciprocating ball-on-disk tribometer under different temperature conditions. The results showed that all the strengthening samples exhibited a similar wear rate (approximately 7.0 × 10−4 mm3/N·m) at room temperature. However, at 250 °C, the precipitation strengthening sample performed best with a wear rate of 1.32 × 10−3 mm3/N·m, followed by the strain hardening and structural refinement samples (approximately 1.7 × 10−3 mm3/N·m). This superior performance was attributed to the precipitation phase, which could effectively maintain material strength through dislocation pinning. By contrast, dynamic recovery and recrystallization behavior weakened the effectiveness of strain hardening, while crystal growth diminished the efficacy of structural refinement. In addition, the wear mechanisms transitioned from abrasion to adhesion and slight oxidative wear as the temperature increased.

Synergetic effect of hybrid surface treatment on the mechanical properties of adhesively bonded AA2024-T3 joints

ABSTRACT Improving the surface properties of AA2024-T3 aluminium alloys is crucial for achieving durable and sustainable joints. For this purpose, AA2024-T3 alloys were first sandblasted at 4, 5 and 6 bar pressures using aluminium oxide and glass sphere abrasives. Then, the sandblasted samples were subjected to the chemical surface treatment resulting in a hybrid surface process. The surface properties of sandblasted and hybrid surface-treated AA2024-T3 alloys were characterised by 3D image analysis, contact angle and roughness measurement. Additionally, single-lap joints were fabricated using adhesives with low and high viscosity. The effect of changes in the viscosity of adhesives and the surface properties of the AA2024-T3 on the mechanical properties of the joints has been analysed in detail. It was found that both sandblasting and hybrid surface treatments applied to AA2024-T3 alloys caused significant improvement in the mechanical properties of the joints. AA2024-T3 alloys, which were chemically surface treated after being sandblasted with glass spheres at 6 bar pressure, were joined using low and high viscosity adhesives, and the failure load of these joints increased by approximately 110% and 68%, respectively, compared to untreated samples. In the case of aluminium oxide usage, the increase rates were determined to be 93% and 43%.

Correction to: Effects of Aging Processes on the Dynamic Mechanical Response of 7B52 Laminated Aluminum Alloy

Correction to: Effects of Aging Processes on the Dynamic Mechanical Response of 7B52 Laminated Aluminum Alloy

Analysis of fatigue fracture mechanism of laser spiral welding of dissimilar metals of 6082 high strength aluminum alloy and DP980 high strength dual phase steel

This paper investigates the relationship between weld quality, influencing factors, microstructure and mechanical properties of laser spiral dissimilarity welding of 6082 high-strength aluminum alloy and DP980 high-strength dual-phase steel, focusing on the fatigue properties and fracture mechanism of 6082-DP980 dissimilar metal welded joints. The research shows that intermetallic compound layers (IMCs) dominate the fatigue crack initiation stage and part of the crack extension stage, two fatigue crack initiation modes are obtained, one is the main crack initiation mode along the FeAl and FeAl2 interlayer, and the other is the secondary crack initiation mode along the Fe3Al and FeAl interlayer. In the crack propagation stage, due to the diffusion of Fe and Al elements generated by IMCs during the welding process, solid solution strengthening, intergranular strengthening and grain boundary strengthening, in the fatigue crack propagation stage formed a hardened zone, hindering the main crack to continue to expand along the IMCs, the main crack shifted to the expansion of the 6082 base material, thus extending the fatigue life.

Study on the mechanism of improvement of mechanical properties of Al–Mg–Si aluminum alloys by Cu and Ce

First, the stability and tensile properties of the Al/Mg2Si interface doped with alloying elements in the Al–Mg–Si system of aluminum alloys are calculated from first principles. Then, the two experimental alloys with different components were heat treated and the properties were characterized. Calculations show that when the interface is doped with Cu, the tensile stress that the interface can withstand increases to 3.13 GPa; when the interface is doped with Cu and Ce, the tensile strain that the interface can withstand increases to 20% and the tensile stress that the interface can withstand increases to 4.17 GPa; when the interface is doped with Cu and Sc, the tensile strain that the interface can withstand increases to more than 25% and the tensile stress that the interface can withstand increases to 5.08 GPa or more. Characterization of the organization and properties of the experimental alloys showed that Ce not only increased the peak solid solution temperature of the alloys, but also increased the tensile and yield strengths of the alloys in the extruded state by 16% and 13.74%, respectively. During hot extrusion, Ce was able to promote the precipitation of precipitated phases. During aging, the addition of Ce promoted the aging precipitation of the alloy, which not only increased the number of precipitated phases in the alloy, but also refined the precipitated phases and enhanced the aging strengthening effect of the alloy. This study provides technical guidance for the development of new aluminum alloy materials with high strength and low cost.

Effects of hard anodizing on mechanical and electrochemical characteristics of aluminum alloys under tribocorrosion condition

In this research, the effects of hard anodizing on the mechanical and electrochemical characteristics of aluminum alloys under tribocorrosion conditions was investigated. Compared with dry conditions, friction coefficient of aluminum alloys under tribocorrosion conditions increased, whereas that of hard anodized specimens decreased. This was attributed to corrosive ions in the solution corroding the transfer film of the counter-body and tribofilm of the hard anodized specimen. In potentiodynamic polarization experiments under tribocorrosion conditions, the aluminum alloys exhibited high current density with applied load. However, at potentials above –0.05 V, current density decreased and was reversed. This is believed to be due to the corrosive ions preferentially reacting with the generated wear debris, thereby reducing the oxidation reaction with wear track. However, the current density of the hard anodized specimens increased with load and potential. In addition, the increasing rate in the wear width and depth was significant under tribocorrosion conditions (Width: 42.65 %, Depth: 32.63 %). This is due to the cavitation and fluid impact generated during friction/wear accelerating the cracking and damage of the hard anodizing film with the brittleness and porousity. However, the tribocorrosion resistance of the hard anodized aluminum alloy was improved by more than 97 %.

Innovation in sustainable composite research: Investigating graphene-reinforced MMCs for liquid hydrogen storage tanks in aerospace and space exploration

The demand for lightweight materials in space exploration applications has seen a significant rise. This study presents a novel approach by integrating graphene with Aluminium alloy (AA) 2900 powder, synthesized through High energy ball milling technique. The resulting powder was used to reinforce Aluminium alloy 2195, creating metal matrix composites (MMCs) via squeeze casting. The findings demonstrate that incorporating 0.5 wt % 2D graphene nanoplatelets (2D-Grnp) in AA 2195 achieved density match, enabling homogeneous dispersion, addressing composite casting challenges. Consequently, the AA 2900 alloy embedded with 2D-Grnp facilitated the homogeneous dispersion of reinforcements during the squeeze casting process, yielding MMCs Ideal for potential use in lightweight liquid hydrogen fuel tank structures for launch vehicles. Following T8 heat treatment, the final casted composite plate exhibited significant enhancements in ultimate tensile strength, with a 4.5% increase over monolithic Al 2195-T8, exhibiting nominal reduction in elongation behavior and higher hardness. Additionally, scanning and transmission electron microscopy (SEM, TEM), Small Angle Neutron Scattering (SANS) and Electron Backscatter Diffraction (EBSD) revealed the squeeze casting technique's effectiveness by exhibiting enhanced bonding among homogeneously reinforced 2D-Grnp, T1/θ’ precipitates, and AA 2195.

Gap tolerance and molten pool destabilization mechanism in oscillating laser-arc hybrid welding of aluminum alloys

Oscillating laser-arc hybrid welding (O-LAHW) offers significant advantages in enhancing efficiency and mechanical properties. However, in actual production, gap fluctuations can cause instability, limiting its application in large-scale structure manufacturing. In this study, we explored the impact of gap fluctuation on the destabilization of the molten pool in aluminum alloy O-LAHW and identified the maximum gap tolerance for various conditions. High-speed photography revealed that the oscillating molten pool undergoes a transitional state of periodic collapse before complete instability, a behavior distinct from that of a non-oscillating molten pool. We also analyzed the variations in weld geometry prior to destabilization and developed a global force model of the molten pool to identify key geometrical parameters and related driving forces contributing to destabilization. The results show that maintaining a surface tension ratio of over 55 % at the root of the molten pool is crucial for its stability. Additionally, the effects of oscillatory behavior and gap variations on the laser-substrate interaction were explored, revealing the physical mechanisms behind the changes in key geometrical parameters of the melt pool cross-section. The centrifugal effect generated by high-frequency oscillation is identified as a crucial mechanism for extending the duration of periodic collapse compared to non-oscillating molten pools. By discussing the interactions between energy absorption, molten pool shape, and molten pool forces, the study reveals the evolution process of weld destabilization and explains the differences in gap tolerance between oscillating and non-oscillating laser-arc hybrid welding, providing a reference for improving weld stability.

Influences of Zr and V Addition on the Crystal Chemistry of θ-Al13Fe4 and the Grain Refinement of α-Al in an Al-4Fe Alloy Based on Experiment and First-Principle Calculations

Fe-containing intermetallic compounds (IMCs) are among the most detrimental second phases in aluminum alloys. One particularly harmful type is θ-Al13Fe4, which exhibits a needle- or plate-like morphology, leading to greater degradation of mechanical properties compared to other Fe-IMCs with more compact structures, such as α-Al15(Fe,Mn)3Si2. The addition of alloying elements is a crucial strategy for modifying the microstructure during the solidification process of aluminum alloys. This study investigates the effects of adding vanadium (V) and zirconium (Zr) on the morphology and crystal chemistry of θ-Al13Fe4 in an Al-4Fe alloy, employing a combination of experimental observations, first-principle calculations, and thermodynamic analysis. Our findings indicate that zirconium significantly refines both the primary θ-Al13Fe4 particles and the α-Al grains. Additionally, a small amount of vanadium can be incorporated into one of the Wyckoff 4i Al sites in θ-Al13Fe4, rather than occupying any Fe sites, under casting conditions, in addition to the formation of binary Al-V phases.

Alternative Solution for Towing Systems Used in the Automotive Industry

This paper aims, in the context of the need to reduce the weight and price of vehicles, to present theoretical and experimental results regarding towing systems made of alternative materials (fibrous composite materials and aluminum alloys). The study of the main element of the whole system, namely towbar research, was stressed, presenting comparative results. The FEM will be used to obtain the stress and strain field in the towball and the towing system. The experimental tests validate the theoretical results obtained. This paper studies five towing systems made by different materials and finally presents a series of practical recommendations, useful in the industry, regarding the improvement of the analyzed models.