Search Results (41)

There is limited research on dissimilar joints of RE-containing Mg alloys and Al alloys, and the diffusion of elements is fundamental for the properties of Mg/Al interfaces. In this study, samples were manufactured by magnetic pulse welding (MPW) with plates of the AA1060 aluminum alloy and the as-cast Mg–4.80Gd–1.92Zn (in wt.%) alloy, and the effects of heat treatments at 200 °C and 250 °C, from 1 h to 4 h, on the diffusion of the Mg/Al interface were investigated. The results indicated that diffusion of the Mg and Al elements occurs at 250 °C for no less than 2 h, since Gd and Zn are mainly concentrated in precipitates in the Mg–4.80Gd–1.92Zn alloy. When the heat treatment time at 250 °C is increased from 2 h to 4 h, the width of the Mg/Al interface increases from ~15 μm to ~20 μm. At positions near precipitates in the Mg alloy, the diffusion of Al atoms into the Mg lattice can be hindered by the precipitates, leading to an abnormal decrease in the width of the interface, which is also related to the difficulties of the Mg element diffusing into the Al matrix. Full article

The characteristics of aluminum alloys make them the most extensively used material in the aerospace sector. Aluminum, in a natural way, when interacting with oxygen, forms a protective layer of aluminum oxide, Al₂O₃, that enhances its properties, for example, resistance to corrosion and fatigue. This work aims to optimize the anodizing process by identifying the optimum values and combination of factors that allow the formation of an alumina layer with a thickness of 12 µm and the maximum Vickers microhardness. The parameters to be evaluated will include time, current density, and sulfuric acid concentration, which were considered variables at two levels: 15 and 20 min, 2.5 and 3.5 A/dm², and 180 and 350 g/L, respectively. We used the response surface methodology (RSM) with a composite central design (CCD). The results of the optimization MSR reveal that to obtain the optimum Type III hard anodizing on AA6063 aluminum alloy with a target thickness of 11.85 µm and a Vickers microhardness of 297.14, a combination consisting of 15 min, 2.55 A/dm², and 333.15 g/L of H₂SO₄ is required. Full article

Al-Zn-Mg-Cu alloys are widely used as heat-treatable ultra-high-strength materials in aerospace structural applications. While conventional single-stage aging enables high strength, advanced performance demands call for precise microstructural control via multi-stage aging. In this study, we employ a combination of scanning transmission electron microscopy (STEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) to investigate the microstructural evolution and its correlation with mechanical properties of AA7150 aluminum alloy subjected to two-step aging treatments, following a 6 h pre-aging at 120 °C. Through atomic-scale STEM imaging along the [110]_Al zone axis, we systematically characterize the precipitation behavior of GPII zones, η′ phases, and equilibrium η phases both within the grains and at grain boundaries under varying secondary aging (SA) conditions. Our results reveal that increasing the SA temperature from 140 °C to 180 °C leads to coarsening and reduced number density of intragranular precipitates, while promoting the continuous and coarse precipitation of η phases along grain boundaries, accompanied by a widening of the precipitation-free zone (PFZ). Notably, SA at 160 °C induces the formation of fine, uniformly dispersed nanoscale η′ precipitates in the alloy, as confirmed by XRD phase analysis. Aging at this temperature markedly enhances the mechanical properties, achieving an ultimate tensile strength (UTS) of 613 MPa and a yield strength (YS) of 598 MPa, while presenting an exceptionally broad peak-aging plateau. Owing to this feature, a moderate extension of the SA duration does not reduce strength and can further improve ductility, increasing the elongation (EL) to 14.26%. These results demonstrate a novel two-step heat-treatment strategy that simultaneously achieves ultra-high strength and excellent ductility, highlighting the critical role of advanced electron microscopy in elucidating phase-transformation pathways that inform microstructure-guided alloy design and processing. Full article

The Portevin-Le Chatelier (PLC) effect has been studied for many decades, yet the influence of testing modes has received limited attention. In the past 20 years, it has become increasingly recognized that the stiffness of the testing machine can significantly affect the occurrence of jerky flow, particularly the serrations observed during tensile tests. This study addresses this issue by conducting tests on the Al-Mg alloy AA5083H111, which contains a substantial amount of diffusible magnesium in solid solution and exhibits dynamic strain aging, resulting in a pronounced PLC effect. Both electromechanical and servohydraulic testing machines were used in the tests; these machines differ in stiffness and control technology for applied strain rates. The study also explored different control modes, including stroke control for both machines and true strain control for the servohydraulic machine. The findings indicate that machine stiffness has a moderate effect on material behavior, and no single machine or testing mode can precisely control the strain rate in the sample during the PLC effect. However, it was noted that true strain rate control using a servohydraulic machine comes closest to accurately reflecting the material’s behavior during jerky flow. Full article

Friction surfacing (FS) is increasingly recognized as an advanced technique for coating similar and dissimilar materials, enabling superior joint quality through plastic deformation and grain refinement. This study investigates the deposition of AA6082-T651 alloy on a medium-carbon steel EN14B substrate using FS, with process parameters optimized, and the effect of axial load, rotational speed, and traverse speed on coating integrity. The optimal sample was subjected to heat treatment (HT) at 550 °C for 24, 36, and 48 h to further enhance mechanical properties. Comprehensive microstructural and mechanical analyses were performed on both heat-treated and non-heat-treated samples using optical microscopy (OM), field emission scanning electron microscopy (FESEM) with energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), microhardness testing, and micro-tensile techniques. The optimized sample was processed with a 6 kN axial load, a rotational speed of 2700 rpm, and a traverse speed of 400 mm/min, and demonstrated superior bond quality and enhanced mechanical properties. The highest interfacial hardness values, 138 HV0.1 were achieved for the sample annealed for 48 h, under an axial load of 6 kN. Annealing for 48 h significantly improved atomic bonding at the aluminum–steel interface, confirmed by the formation of Fe₃Al intermetallic compounds detected via FESEM-EDS and XRD. These compounds were the primary reason for the enhancement in the mechanical properties of the FS deposit. Furthermore, the interrelationship between process and thermal parameters revealed that a peak temperature of 422 °C, heat input of 1.1 kJ/mm, and an axial load of 6 kN are critical for achieving optimal mechanical interlocking and superior coating quality. The findings highlight that optimized FS parameters and post-heat treatment are critical in achieving high-quality, durable coatings, with improved interfacial bonding and hardness, making the process suitable for structural applications. Full article

This study investigates the influence of nano-sized reinforcements on aluminum matrix composites’ mechanical and tribological properties. Microstructural analysis revealed that introducing nanoparticles led to grain refinement, reducing the grain size from 129.7 μm to 41.3 μm with 2 wt.% TiO₂ addition. Furthermore, ultrasonic-assisted squeeze casting of AA6061 composites reinforced with TiO₂ and Al₂O₃ resulted in a 52% decrease in grain size, demonstrating nano-reinforcements’ effectiveness in refining the matrix structure. Despite these advantages, the high surface energy of nanoparticles causes agglomeration, which can undermine composite performance. However, ultrasonic-assisted stir casting reduced agglomeration by approximately 80% compared to conventional stir casting, and cold isostatic pressing improved dispersion uniformity by 27%. The incorporation of nano-reinforcements such as SiC, Al₂O₃, and TiC significantly enhanced the material properties, with hardness increasing by ~30% and ultimate tensile strength improving by ~80% compared to pure Al. The hardness of nano-reinforced composites substantially rose from 83 HV (pure Al) to 117 HV with 1.0 vol.% CNT reinforcement. Additionally, TiC-reinforced AA7075 composites improved hardness from 94.41 HB to 277.55 HB after 10 h of milling, indicating a nearly threefold increase. The wear resistance of Al-Si alloys was notably improved, with wear rates reduced by up to 52%, while the coefficient of friction decreased by 20–40% with the incorporation of graphene and CNT reinforcements. These findings highlight the potential of nano-reinforcements in significantly improving the mechanical and tribological performance of n-AMCs, making them suitable for high-performance applications in aerospace, automotive, and structural industries. Full article

In this study, the behavior of sodium silicate (Na₂SiO₃), manganese sulfate monohydrate (MnSO₄·H₂O), and ammonium metavanadate (NH₄VO₃) as corrosion inhibitors for AA6061 aluminum alloy (Al) was investigated. The polarization resistance (R_p) of the Al substrate immersed in 0.1 M NaCl solution was found to be 13 kΩ·cm². In comparison, the R_p of the Al substrate immersed in 0.1 M NaCl in the presence of Na₂SiO₃, Na₂SiO₃/MnSO₄·H₂O, and Na₂SiO₃/NH₄VO₃ inhibitors was found to be 100, 133, and 679 kΩ·cm², respectively. The best inhibition result was obtained when the mixture of the inhibitors was used with R_p of 722 kΩ·cm². The maximum percentage of the corroded area calculated from the scanning electron microscopy (SEM) images was found to be 5.7% for Al substrate immersed in 0.1 M NaCl, which decreased to 0.06% when the mixture of the inhibitors was used. The synergetic effects between the three inhibitors were studied, and the results illustrated that the combination of Na₂SiO₃, MnSO₄·H₂O, and NH₄VO₃ provided the best corrosion inhibition properties for Al in aqueous NaCl environments. Full article

The paper presents a new approach towards forming Ce-based nanostructures using deep eutectic solvents (DESs) as new green solvents and large-scale media for the chemical and electrochemical synthesis of advanced functional surfaces and nanomaterials. Some experimental results regarding the cathodic electrodeposition of cerium-based conversion coatings onto AA7075 aluminum alloys involving different DES-based formulations are discussed. Electrolytes containing Ce(NO₃)₃·6H₂O dissolved in choline chloride-glycerine and choline chloride-urea (1:2 molar ratio) eutectic mixtures with additions of H₂O₂ have been proposed and investigated. The influence of the operating parameters, including the applied current density, process duration and temperature on the quality of the formed Ce-containing conversion layers was studied. Adherent and uniform Ce-based conversion layers containing 0.3–5 wt.%. Ce have been obtained onto Al alloy substrates. Higher values of the applied current density and longer process durations led to higher Ce content when a choline chloride-urea eutectic mixture was used. Several accelerated corrosion tests were performed to evaluate the corrosion performance, respectively: (i) continuous immersion in 0.5 M NaCl for 720 h with intermediary visual examinations, recording of (ii) potentiodynamic polarization curves and of (iii) impedance spectra at open circuit potential in 0.5 M NaCl, as well as (iv) salt mist test for 240 h. The influence of an additional post-treatment step consisting in the electrochemical deposition of a hydrophobic Ce-based layer involving ethanolic solutions of stearic acid and cerium nitrate is also considered. Different corrosion performances are discussed, taking into account the used DES-based systems and electrodeposition parameters. Full article

The Plasma Electrolytic Oxidation (PEO) process was investigated to enhance the adhesion of AA2024-O aluminum alloy with a polyetherimide (PEI) matrix composite, using oxy-fuel welding (OFW). A Central Composite Design (CCD) statistical model was used to optimize three independent parameters in PEO: immersion time (s), duty cycle (%), and electrolyte concentration (Na₂B₄O₇·10H₂O), aiming to achieve a maximum value of shear strength of the hybrid joint (in MPa). The hybrid joint without PEO treatment presented a resistance of 2.2 MPa while the best condition presented a resistance of 9.5 MPa, resulting in a value 4× higher than the untreated material, due to the characteristics of the coating, which presented a more hydrophilic surface, allowing better mechanical interlocking with the polymer matrix and resulting in mixed-mode failure (adhesive, cohesive, and light fiber). In addition to improving adhesion, the PEO treatment provided better corrosion resistance to the alloy, forming an inert aluminum oxide (Al₂O₃) coating, with an improvement of approximately 99.84% compared to the untreated alloy. The statistical design covers about 77.15% of the total variability of the PEO + welding process, with independent factors influencing around 48.4% of the variability. Full article

The presented study investigates the effects of weight percentages of boron carbide reinforcement on the wear properties of aluminum alloy composites. Composites were fabricated via ball milling and the hot extrusion process. During the fabrication of composites, B₄C content was varied (0, 5, and 10 wt.%), as well as milling time (0, 10, and 20 h). Microstructural observations with SEM microscopy showed that with an increase in milling time, the distribution of B₄C particles is more homogeneous without agglomerates, and that an increase in wt.% of B₄C results in a more uniform distribution with distinct grain boundaries. Taguchi and ANOVA analyses are applied in order to investigate how parameters like particle content of B₄C, normal load, and milling time affect the wear properties of AA2024-based composites. The ANOVA results showed that the most influential parameters on wear loss and coefficient of friction were the content of B₄C with 51.35% and the normal load with 45.54%, respectively. An artificial neural network was applied for the prediction of wear loss and the coefficient of friction. Two separate networks were developed, both having an architecture of 3-10-1 and a tansig activation function. By comparing the predicted values with the experimental data, it was demonstrated that the well-trained feed-forward-back propagation ANN model is a powerful tool for predicting the wear behavior of Al2024-B₄C composites. The developed models can be used for predicting the properties of Al2024-B₄C composite powders produced with different reinforcement ratios and milling times. Full article

The yield behavior of aluminum alloy 5754-H111 under different stress conditions for three kinds of plastic work is studied using an anisotropic Drucker model. It is found that when the plastic work is 30 MPa, the anisotropic Drucker model has the most accurate prediction. Comparing the Hill48 and Yld91 models with the Drucker model, the results show that both the anisotropic Drucker and Yld91 models can accurately predict the yield behavior of the alloy. Cylinder drawing finite element analysis is performed under the AFR, but it is not possible to accurately predict the position and height of earing appearance. The anisotropic Drucker model is used to predict the earing behavior under the non-AFR, which can accurately predict the earing phenomenon. Numerical simulation is conducted using three different combinations of yield functions: the anisotropic yield function and the anisotropic plastic potential function (AYAPP), the anisotropic yield function and the isotropic plastic potential function (AYIPP), and the isotropic yield function and the anisotropic plastic potential function (IYAPP). It is concluded that the influence of the plastic potential function on predicting earing behavior is more critical than that of the yield function. Full article

The casting structure of the AA6063 alloy contains intermetallic particles of β-Al₅FeSi, which can result in the fragility of the cast pieces. However, with heat treatment, the β phase transforms from a needle or plate form into an intermetallic phase known as α, which resembles Chinese-script in its morphology. To analyze the effect of the ratio of Fe/Mn with different ratios of 0.5, 0.75, and 1, a heat treatment process is used with intermittent interruptions. The alloy is subjected to a temperature of 575 °C for 12 h to determine the microstructural evolution of the β-Al₆FeMn and α-Al₁₅(FeMn)₃Si₂ phases. This study used scanning electron microscopy to conduct point analyses and elemental mappings of the intermetallics found in the casting and heat treatment samples. Additionally, X-ray diffraction was employed to determine the stoichiometry of the present phases. The results indicated that the cast structure contains β-Al₆FeMn and α-Al₁₅(FeMn)₃Si₂ phases and that the β-Al₆FeMn phase transforms into the α-Al₁₅(FeMn)₃Si₂ phase upon completion of the heat treatment process. By using specific Fe/Mn ratios, the formation of the needle-shaped Al₅FeSi phase in the casting structure of the alloy can be inhibited, leading to the precipitation of phases such as β-Al₆FeMn and α-Al₁₅(FeMn)₃Si₂ instead. Full article

Magnesium Potassium Phosphate Cements (MKPCs) are considered a good alternative for the immobilization of aluminium radioactive waste. MKPC composition and moisture curing conditions are relevant issues to be evaluated. The corrosion of pure aluminium (A1050) and AlMg alloys (AA5754) with 3.5% of Mg is studied in MKPC systems prepared with different MgO/KH₂PO₄ (M/P) molar ratios (1, 2, and 3M) and moisture curing conditions (100% Relative Humidity (RH) and isolated in plastic containers (endogenous curing)). The Al corrosion potential (E_corr) and corrosion kinetic (i_corr and V_corr) are evaluated over 90 days. Additionally, the pore ion evolution, the matrix electrical resistance, the pore structure, and compressive strength are analysed. The corrosion process of Al alloy is affected by the pH and ion content in the pore solution. The pore pH increases from near neutral for the 1M M/P ratio to 9 and 10 for the 2 and 3M M/P ratio, increasing in the same way the corrosion of pure Al (AA1050) and AlMg alloys (AA5754). The effect of Mg content in the alloy (AA5754) becomes more relevant with the increase in the M/P ratio. The presence of phosphate ions in the pore solution inhibits the corrosion process in both Al alloys. The MKPC physicochemical stability improved with the increase in the M/P ratio, higher mechanical strength, and more refined pore structure. Full article

Due to the rising need for energy saving, high-performing automotive heat exchangers, demand has significantly grown in recent years. As a result, effective fin-tube heat exchangers are becoming more popular. These tubes are typically made by rolling flat strips of AA3003 aluminum alloys that have either one or both sides coated with AA4xxx alloys. The AA3003 type of alloy is typically used as the core, which is then covered in either AA4045 or AA4343, which melts during the brazing process to adhere the fins to the tubes. To maintain the optimal size and distribution of manganese (Mn)-containing precipitates, preheating parameters are carefully controlled. Then, longer soaking times or higher soaking temperatures result in larger precipitates, which cause the final product to exhibit poor mechanical properties. Therefore, it is crucial to optimize the different manufacturing steps, such as homogenization, soaking time, and brazing in order to achieve a high quality product. Studies on the impact of homogenization temperature and time on the microstructure of AA3xxx aluminum alloys have been conducted. However, there has been little research on the impact of soaking (reheating) time on AA3003 cladded alloys. Hence, the effects of isothermal soaking time on the microstructure and mechanical properties of AA3003 cladded with AA4045 alloy were investigated in this work. Optical microscopy (OM) and scanning electron microscopy (SEM) were used to characterize the microstructure and identify intermetallic phases. The final microstructure in terms of grain structure at various homogenization times was characterized by electron backscattered diffraction (EBSD). After the hot-rolling and cold-rolling of the as-received material, large particles of intermetallic (mainly in the form of Chinese script morphology consisting of Fe-Mn-Si) were broken into smaller particles with an increased Fe, Mn, and Si content, indicating the formation of an α-Al(Fe,Mn)Si phase. The α-Al(Mn,Fe)Si was found to be a dominant dispersoid precipitate in the modified AA3003 core. Coarsening of the Al(Mn,Fe)Si dispersoids at 505 °C was only observed at a 45 h homogenization time. The hardness trend with homogenization time was found to be similar to that after homogenization, cold working, and annealing, with exception of an increase in hardness in the latter possibly due to strain hardening (from cold-rolling). Full article

This paper investigated the Mg-rich phase precipitation behavior and the corrosion performance throughout the thickness direction within the stirred zone (SZ) of friction stir welded (FSW) AA5083 alloy after 175 °C/100 h sensitization. For the as-welded SZ, the recrystallized grain size gradually decreased from the top surface (5.5 μm) to the bottom (3.7 μm). The top and bottom of the SZ maintained relatively high levels of deformed grains and accumulated strain induced by either shoulder pressing or pin stirring. After 175 °C/100 h sensitization, 100 nm thick β′-Al₃Mg₂ precipitates were present along the grain boundaries (GBs) in the SZ. The bottom of the SZ exhibited more continuous precipitates along GBs due to the fine grain size and the large fraction of high-angle grain boundaries (0.724%). Although the as-welded SZ exhibited excellent corrosion resistance, it became extremely vulnerable to intergranular cracking (IGC) and stress corrosion cracking (SCC) after sensitization. The large SCC susceptibility indices of the SZ samples ranged from 66.9% to 73.1%. These findings suggest that sensitization can strongly deteriorate the corrosion resistance of the Al-Mg FSW joint, which is of critical importance for the safety and reliability of marine applications. Full article