Search Results (91)

This article explores how alloy composition, hardness, and machining parameters can affect the cutting forces encountered in aluminum–lithium (Al-Li)-based alloys. By analyzing Cu and Cu with Sc additions to Al-Li alloys and exposing them to various heat treatments to modify their hardness, this research was designed to evaluate milling performance under various feed rates, cutting speeds, and cooling conditions. The findings indicate that increased hardness leads to higher cutting forces, with Al-Li-Cu-Sc exhibiting the greatest resistance due to scandium’s grain-refining effect and the formation of stable precipitates. Statistical analyses identify the feed rate as the main parameter controlling cutting force, along with hardness and cooling conditions. Notably, wet machining consistently reduces cutting forces, especially in Al-Li-Cu-Sc alloys, enhancing machinability when using high cutting speeds. This work underscores the significance of selecting optimal machining parameters tailored to specific alloy compositions. These findings contribute to improved process efficiency, reduced tool wear, and enhanced productivity. Given the attractive characteristics of these alloys, i.e., their low weight and high strength, the insights from this study are particularly beneficial for aerospace applications where machining performance directly impacts component quality, cost, and overall operational efficiency. Full article

This study evaluates the wear and corrosion resistance of the Cu-50Ni-5Al alloy reinforced with CeO₂ nanoparticles for potential use as anodes in molten carbonate fuel cells (MCFCs). Cu–50Ni–5Al alloys were synthesized, with and without the incorporation of 1% CeO₂ nanoparticles, by the mechanical alloying method and spark plasma sintering (SPS). The samples were evaluated using a single scratch test with a cone-spherical diamond indenter under progressive normal loading conditions. A non-contact 3D surface profiler characterized the scratched surfaces to support the analysis. Progressive loading tests indicated a reduction of up to 50% in COF with 1% NPs, with specific values drop-ping from 0.48 in the unreinforced alloy to 0.25 in the CeO₂-doped composite at 15 N of applied load. Furthermore, the introduction of CeO₂ decreased scratch depths by 25%, indicating enhanced wear resistance. The electrochemical behavior of the samples was evaluated by electrochemical impedance spectroscopy (EIS) in a molten carbonate medium under a H₂/N₂ atmosphere at 550 °C for 120 h. Subsequently, the corrosion products were characterized using X-ray diffraction (XRD), scanning electron microscopy coupled with energy dispersive spectroscopy (SEM-EDS), and X-ray photoelectron spectroscopy (XPS). The results demonstrated that the CeO₂-reinforced alloy exhibits superior electro-chemical stability in molten carbonate environments (Li₂CO₃-K₂CO₃) under an H₂/N₂ atmosphere at 550 °C for 120 h. A marked reduction in polarization resistance and a pronounced re-passivation effect were observed, suggesting enhanced anodic protection. This effect is attributed to the formation of aluminum and copper oxides in both compositions, together with the appearance of NiO as the predominant phase in the materials reinforced with nanoparticles in a hydrogen-reducing atmosphere. The addition of CeO₂ nanoparticles significantly improves wear resistance and corrosion performance. Recognizing this effect is vital for creating strategies to enhance the material’s durability in challenging environments like MCFC. Full article

Due to their excellent specific strength and lightweight characteristics, Al-Cu-Li alloys are widely used in aerospace applications. The newly developed three-stage creep aging (CA) process ensures both the formability and high performance of the Al alloy. However, research at the atomic scale investigating the relationship between the microstructure and performance of ternary alloys under intricate heat treatment conditions remains scarce. This study investigates the microstructural evolution of Al-Cu-Li alloys during multi-stage low-high-low temperature CA experiments, combined with molecular dynamics (MD) simulations based on the neuroevolutionary machine learning potential (NEP) function. The simulation results indicate that the segregation state of lithium atoms at low temperatures is unstable and cannot persist at elevated temperatures. As the aging temperature in the second stage increases, the segregation of lithium atoms gradually diminishes. However, the low-temperature aging in the third stage facilitates continued atomic segregation, although the recovery is somewhat limited. Additionally, it was observed that high-temperature aging in the second stage reduces the material’s performance, while the low-temperature aging in the third stage contributes to the recovery of its properties. The experimental results indicate that the degree of precipitation phase enrichment decreases with the increase in temperature during the second stage but slightly increases with the low-temperature aging in the third stage. The excellent agreement between the experimental and simulation results validates the reliability of the MD simulations, providing a valuable reference for the performance enhancement and microstructural optimization of Al-Cu-Li alloys. Full article

In this work, the effects of the Cu/Li ratio on the mechanical properties and corrosion behavior of Sc-containing Al-Cu-Li alloys were systematically investigated by utilizing age-hardening behavior, tensile property, corrosion behavior, and electrochemical behavior, complemented by microstructural characterization through EBSD and TEM. The results show that the peak aging strength of the alloys remained relatively consistent but slightly decreased with the decrease in Cu/Li ratio, and the yield strengths were 585 MPa, 578 MPa, and 573 MPa, respectively. The changes in the Cu/Li ratio caused different matching patterns of precipitates in the peak aging alloys. The cumulative precipitation strengthening by T₁, θ′, δ′, and S′ phases are equal within the alloys with different Cu/Li ratios. However, the strength contribution of the T₁ phase decreases from 81% to 66% with the decrease in the Cu/Li ratio. Concurrently, the precipitates of LAGBs gradually increase in number and are continuously distributed, and the precipitates of HAGBs become larger in size with lower Cu content as the Cu/Li ratio decreases, all of which leads to a weakening of the intergranular corrosion (IGC) resistance within the low Cu/Li ratio alloy. Full article

The influence of Cu content (3.10, 3.50, and 3.80 wt.%) on the precipitation behavior and mechanical properties of Al-Cu-Li alloys under two aging conditions (direct aging at 175 °C vs. 3.5% pre-stretching followed by aging at 155 °C) was systematically investigated. The alloys were characterized using hardness testing, tensile property evaluation, and transmission electron microscopy (TEM) to correlate microstructural evolution with performance. The results revealed that increased Cu content accelerated early-stage hardening kinetics and elevated peak hardness and strength. Aging at 175 °C/36 h produced T₁ phase-dominated microstructures with θ′ phases. With the increase of Cu content, the enhancement effect on the precipitation of T₁ and θ′ phases becomes more pronounced, gradually overshadowing the initial promotion effect on precipitate growth. Pre-deformation prior to 155 °C/36 h aging induced significant T₁ phase refinement and proliferation, with increasing Cu content continuously reducing T₁ phase sizes while moderately enlarging θ′ precipitates. Precipitation-strengthening analysis revealed a transition in T₁ strengthening from bypass to shearing dominance under 155 °C/36 h aging after pre-deformation, enhanced by Cu-promoted T₁ refinement, which collectively drove superior strength in high-Cu alloys. These findings provide valuable insights for the composition design and mechanical property optimization of Al-Cu-Li alloys. Full article

Al-Mg-Li alloy is an ideal lightweight structural material for aerospace applications due to its low density, high specific strength, and excellent low-temperature performance. This study examines the mechanical properties and microstructural evolution of Al-Mg-Li alloy subjected to cryogenic and room temperature cold rolling, which induces large plastic deformation. Compared with room temperature rolling, cryogenic rolling significantly reduces surface cavity formation, thereby enhancing the alloy’s rolling surface quality. After cryogenic rolling by 80% and subsequent natural aging, the yield strength of artificially aged Al-Mg-Li alloy reaches 560 MPa, delivering a 60% increase compared to the traditional T6 state with a slight reduction in elongation from 6.5% to 4.6%. The specific strength achieves 2.23 × 10⁵ N·m/kg, outperforming conventional Al-Cu-Li and 7xxx-series Al alloys. The depth of intergranular corrosion decreases from 100 µm to 10 µm, demonstrating excellent corrosion resistance enabled by the new method. Transmission electron microscopy reveals that finely distributed δ′ (Al₃Li) is the primary strengthening phase, with high-density dislocations further enhancing strength. However, coarsening of δ′ (from ~2.9 nm to >6 nm) induced by ensuing artificial aging results in coplanar slip and reduced elongation. Lowering the post-aging temperature inhibits δ′ coarsening, thereby improving both strength and elongation. Our results provide valuable insights into optimizing the properties of Al-Mg-Li alloys for advanced lightweight applications. Full article

This study investigates the effect of TiC particles regarding the properties of aluminium–lithium alloys under high-temperature conditions, focusing on the reinforcing effect of TiC and TiB₂ particles in the aluminium matrix and the effect on the coarsening process of T₁ precipitates. Aluminium–lithium alloys are widely used in aerospace applications, especially as skin materials for fast vehicles, due to their excellent high specific strength and corrosion resistance. However, conventional aluminium alloys are inadequate in meeting the elevated temperature service requirements associated with supersonic flight. Consequently, there is a significant scientific imperative to investigate the heat resistance of novel aluminium–lithium alloys. The inclusion of TiC and TiB₂ nanoparticles has been demonstrated to enhance the mechanical properties of the alloys, particularly at high temperatures of 200 °C. These particles have been shown to enhance the strength and toughness of the alloy through mechanisms such as grain refinement and increased dislocation density. Concurrently, this study determined that the coarsening phenomenon of T₁ precipitates occurs at elevated temperatures. The inclusion of TiC particles, however, has been shown to inhibit the coarsening process, delay the coarsening of the T₁ phase, and enhance the mechanical properties of the material. This outcome is of considerable significance for the composition design of aluminium–lithium alloys and their performance optimisation in high-temperature applications. Full article

Al-Li alloys are widely used in aerospace applications due to their high strength, high fracture toughness, and strong resistance to stress corrosion. However, the lack of interatomic potentials has hindered systematic investigations of the relationship between structures and properties. To address this issue, we apply a neural network-based neuroevolutionary machine learning potential (NEP) and use evolutionary strategies to train it for large-scale molecular dynamics (MD) simulations. The results obtained from this potential function are compared with those from Density Functional Theory (DFT) calculations, with training errors of 2.1 meV/atom for energy, 47.4 meV/Å for force, and 14.8 meV/atom for virial, demonstrating high training accuracy. Using this potential, we simulate cluster formation and the high-temperature stability of the T1 phase, with results consistent with previous experimental findings, confirming the accurate predictive capability of this potential. This approach provides a simple and efficient method for predicting atomic motion, offering a promising tool for the thermal treatment of Al-Li alloys. Full article

For this article, hot compression tests were carried out on homogenized 2050 Al-Cu-Li alloys under different deformation temperatures and strain rates, and an Arrhenius-type constitutive model with strain compensation was established to accurately describe the alloy flow behavior. Furthermore, thermal processing maps were created and the deformation mechanisms in different working regions were revealed by microstructural characterization. The results showed that most of the deformed grains orientated toward <101>//CD (CD: compression direction) during the hot compression process, and, together with some dynamic recovery (DRV), dynamic recrystallization (DRX) occurred. The appearance of large-scale DRX grains at low temperatures rather than in high-temperature conditions is related to the particle-stimulated nucleation mechanism, due to the dynamic precipitation that occurs during the deformation process. The hot-working diagrams with a true strain of 0.8 indicated that the high strain-rate regions C (300 °C–400 °C, 0.1–1 s⁻¹) and D (440 °C–500 °C, 0.1–1 s⁻¹) are unfavorable for the processing of 2050 Al-Li alloys, owing to the flow instability caused by local deformation banding, microcracks, and micro-voids. The optimum processing region was considered to be 430 °C–500 °C and 0.1 s⁻¹–0.001 s⁻¹, with a dissipation efficiency of more than 30%, dominated by DRV and DRX; the DRX mechanisms are DDRX and CDRX. Full article

With the development of society, there is an increasingly urgent demand for light-weight, high-strength, and high-temperature-resistant structural materials. High-entropy alloys (HEAs) owe much of their unusual properties to the selection among three phases: solid solution (SS), intermetallic compound (IM), and mixed SS and IM (SS and IM). Therefore, accurate phase prediction is crucial for guiding the selection of element combinations to form HEAs with desired properties. Light high-entropy alloys (LHEAs), as a significant branch of HEAs, exhibit excellent performance in terms of specific strength. In this study, we employ a machine learning (ML) method to realize the design of light-weight high-entropy alloys based on solid solutions. We determined the Gradient Boosting Classifier model as the best machine learning model through a two-step feature and model selection, in which its accuracy and F1_Score achieve 0.9166 and 0.8923. According to the predicted results, we obtained Al₂₈Li₃₅Mg₁₅Zn₁₀Cu₁₂ LHEAs, which are mainly composed of 90% solid solution. This alloy accords with the prediction results of machine learning. But it is made up of a two-phase solid solution. In order to obtain a light-weight high-entropy alloy dominated by a single solid solution, we designed Al₂₄Li₁₅Mg₂₆Zn₉Cu₂₆ LHEAs on the basis of machine learning prediction results accompanied by expert experience. Its main structure includes a single-phase solid solution. Our work provides an alternative approach to the computational design of HEAs and provides a direction for future exploration of light-weight high-entropy alloys. Full article

In the present work, the effect of Zn on the aging precipitates and mechanical properties of Al-Cu-Li alloys was investigated by Vickers hardness, tensile tests, transmission electron microscopy (TEM) and differential scanning calorimetry (DSC). The results indicated that the addition of Zn reduced the activation energy of the T₁ phase and makes it easier to precipitate. The activation energy of the T₁ phase, which was 107.02 ± 1.8 KJ/mol, 94.33 ± 1.7 KJ/mol, 90.33 ± 1.7 KJ/mol and 90.28 ± 1.6 KJ/mol for 0Zn, 0.4Zn, 0.8Zn and 1.2Zn alloy, respectively. The area number density of the T₁ precipitate ranged from 97.0 ± 4.4 pcs/μm² to 118.2 ± 2.8 pcs/μm² as the Zn content increased from 0 to 1.2 wt.%. Consequently, the addition of Zn promoted the precipitation of the T₁ phase. Therefore, the peak hardness and tensile strength of the alloy also increased with the increase in the Zn content, and the hardness of the alloy with Zn content of 1.2 wt.% increased by 16.5 ± 1.4 HV; meanwhile, the ultimate tensile strength increased by 46.5 ± 2.5 MPa. Therefore, the area number density of precipitates increased and improved the strength of the Zn-containing alloy. Full article

In this study, concurrent enhancements in both strength and ductility of the Al-2Li-2Cu-0.5Mg-0.2Zr cast alloy (hereafter referred to as Al-Li) were achieved through an optimized forming process comprising ultrasonic treatment followed by squeeze casting, coupled with the incorporation of Sc. Initially, the variations in the microstructure and mechanical properties of the Sc-free Al-Li cast alloy (i.e., alloy A) during various forming processes were investigated. The results revealed that the grain size in the UT+SC (ultrasonic treatment + squeeze casting) alloy was reduced by 76.3% and 57.7%, respectively, compared to those of the GC (gravity casting) or SC alloys. Additionally, significant improvements were observed in its compositional segregation and porosity reduction. After UT+SC, the ultimate tensile strength (UTS), yield strength (YS), and elongation reached 235 MPa, 135 MPa, and 15%, respectively, which were 113.6%, 28.6%, and 1150% higher than those of the GC alloy. Subsequently, the Al-Li cast alloy containing 0.2 wt.% Sc (referred to as alloy B) exhibited even finer grains under the UT+SC process, resulting in simultaneous enhancements in its UTS, YS, and elongation. Interestingly, the product of ultimate tensile strength and elongation (i.e., UTS × EL) for both alloys reached 36 GPa•% and 42 GPa•%, respectively, which is much higher than that of other Al-Li cast alloys reported in the available literature. Full article

The Laser Beam Welding (LBW) of aluminum alloys has attracted significant interest from industrial sectors, including the shipbuilding, automotive and aeronautics industries, as it expects to contribute to significant cost reduction associated with the production of high-quality welds. To comprehend the behavior of welded structures in regard to their damage tolerance, the application of fracture mechanics serves as the instrumental tool. However, the methods employed overlook the changes in the microstructure within the Heat-Affected Zone (HAZ), which leads to the degradation of the mechanical properties of the material. The purpose of this study is to simulate microhardness evolution in the HAZ of AA2198-T351 LBW. The material represents the latest generation of Al-Cu-Li alloys, which exhibit improved mechanical properties, enhanced damage tolerance behavior, lower density and better corrosion and fatigue crack growth resistance than conventional Al-Cu alloys. In this work, the microhardness profile of LBW AA2198 was measured, and subsequently, through isothermal heat treatments on samples, the microhardness values of the HAZ were replicated. The conditions of the heat treatments (T, t) were selected in line with the thermal cycles that each area of the HAZ experienced during welding. ThermoCalc and DICTRA were employed in order to identify the strengthening precipitates and their evolution (dissolution and coarsening) during the weld thermal cycle. The microstructure of the heat-treated samples was studied employing LOM and TEM, and the strengthening precipitates and their characteristics (volume fraction and size) were defined and correlated to the calculations and the experimental conditions employed during welding. The main conclusion of this study is that it is feasible to imitate the microstructure evolution within the HAZ through the implementation of isothermal heat treatments. This implies that it is possible to fabricate samples for fatigue crack growth tests, enabling the experimental examination of the damage tolerance behavior in welded structures. Full article

Research on the development of new lightweight Al–Li alloys using a selective laser melting process has great potential for industrial applications. This paper reports on the development of novel aluminum–lithium alloys using selective laser melting technology. Al–Cu–Li–Mg–Ag–Sc–Zr pre-alloyed powders with lithium contents of 1 wt.%, 2 wt.% and 3 wt.%, respectively, were prepared by inert gas atomization. After SLM process optimization, the microstructure and mechanical properties of the as-printed specimens were investigated. The densifications of the three newly developed alloys were 99.51%, 98.96% and 92.01%, respectively. They all had good formability, with the lithium loss rate at about 15%. The as-printed alloy with 1% Li content presented good comprehensive properties, with a yield strength of 413 ± 16 MPa, an ultimate tensile strength of 461 ± 12 MPa, and an elongation of 14 ± 1%. The three alloys exhibited a layered molten pool stacking morphology and had a typical heterostructure. The columnar crystals and equiaxed fine grains were alternately arranged, and most of the precipitated phases were enriched at the grain boundaries. The change in Li content mainly affected the precipitation of the Cu-containing phase. When the Li content was 1 wt.%, the following occured: θ phase, T₁ phase and T_B phase. When Li increased to 2 wt.%, T₁ and T₂ phases precipitated together. When Li reaches 3 wt.%, δ’ phase precipitated with T₂ phase. This study provides useful guidance for the future SLM forming of new crack-free and high-strength Al–Li alloys. Full article

A homogenization of billets from Al-Cu-Li-Mg-Sc-Zr alloys should be accomplished at high annealing temperatures exceeding 500 °C. This type of aluminum alloy is susceptible to the depletion of surface layers from Li. Therefore, choosing a suitable homogenization temperature and duration is a crucial step in assuring a homogeneous distribution of alloying elements and optimal exploitation of the potential of the alloy. In situ heating in an electron microscope was performed on a twin-roll-cast Al-Cu-Li-Mg-Sc-Zr alloy to understand the peculiarities of the homogenization process. Four types of primary phase particles rich in Cu, Li, Mg, and Fe were identified in the as-cast material. They appear as coarse particles at the boundaries of eutectic cells. Their partial dissolution occurs at temperatures above 450 °C. They are almost fully dissolved at 550 °C, except for complex phases containing Fe and Cu. Small dimensions of eutectic cells in the range of 10 µm assure a homogeneous distribution of the main alloying elements within the matrix after 20 min of annealing at 530 °C. Direct comparison with the same material prepared by mold casting indicates that such short annealing times result in the dissolution of the main primary phase particles but do not assure a homogeneous distribution of the alloying elements in the whole volume of the specimen. Full article