Search Results (32)

In this study, we examine the evolution of dislocation substructures influenced by the fatigue behavior of SSM 6063 aluminum alloy processed through friction stir welding (FSW). The findings indicate that dislocation substructures have a significant impact on fatigue life. Cyclic loading induced recrystallization in the stir zone (SZ), the advancing-side thermomechanically affected zone (AS-TMAZ), and the retreating-side thermomechanically affected zone (RS-TMAZ). The transformation of the α-primary aluminum matrix phase into an S/S’ structure and the precipitation of Al₅FeSi intermetallic compounds into the T-phase were observed. Furthermore, the precipitation of Si and Mg, the primary alloying elements, was observed in the Guinier–Preston (GP) zone within the SZ. Transmission electron microscopy (TEM) analysis revealed small rod-like particles in the T-phase, measuring approximately 10–20 nm in width and 20–30 nm in length in the SZ. In the AS-TMAZ, these rod-like structures ranged from 10 to 120 nm in width and 20 to 180 nm in length, whereas in the RS-TMAZ, they varied between 10 and 70 nm in width and from 20 to 110 nm in length. The dislocation substructures influenced the stress amplitude, which was 42.46 MPa in the base metal (BM) and 33.12 MPa in the FSW-processed SSM 6063 aluminum alloy after undergoing more than 2 × 10⁶ loading cycles. The endurance limit was 42.50 MPa for BM and 32.40 MPa for FSW. Fractographic analysis of the FSW samples revealed distinct laminar crack zones and shear fracture surface zones, differing from those of other regions. Both brittle and ductile fracture characteristics were identified. Full article

Stress-oriented precipitation and the resulting mechanical anisotropy have been widely studied over the decades. However, the local anisotropy of precipitates with specific orientations has been less thoroughly investigated. This study models the interaction between an edge dislocation source and {100} variants of Guinier–Preston (GP) zones in Al-Cu alloys using the parametric dislocation dynamics (PDD) method. Concentric geometrically necessary dislocation (GND) loops were employed to construct a line integral model for thin platelets. The simulations, conducted with our self-developed code based on Green’s function method and Eshelby inclusion theory revealed distinct strengthening behavior along the strong and weak directions for 60° GP zones, demonstrating anisotropic strengthening from the perspective of elastic interactions. Furthermore, the optimal inclined arrangement of the GP zone array was determined through elastic energy calculations, and these results were corroborated by TEM observations. Full article

This study examines the impact of high-pressure torsion (HPT) processing at various temperatures on the precipitation behavior of Cu-Cr alloys. The introduction of defects through HPT is observed to promote the precipitation of Cr atoms. Unlike the traditional large-scale precipitation that typically occurs around 400 °C, HPT can induce the precipitation of solute atoms even at room temperature. Furthermore, the temperature at which HPT is performed significantly influences the behavior of the precipitated phase during subsequent aging, ultimately affecting the alloy’s overall properties. At elevated temperatures (ETs) and room temperature (RT), Cr atoms tend to aggregate, forming Guinier–Preston (GP) zones or precipitates, which coarsen into incoherent precipitates after annealing. In contrast, when HPT is conducted at liquid nitrogen temperature (LNT), Cr atoms are retained in their original positions, leading to the formation of uniformly distributed, high-density small precipitates post-annealing. This phenomenon results in superior properties for HPT-LNT-treated samples, evidenced by a microhardness of 191.8 ± 3.2 HV and an electrical conductivity of 84.6 ± 1.8% IACS. Full article

In this study, the compositional design of high-formability, high-bake-hardening Al–Mg–Zn-Cu-based aluminum alloys was carried out, and process conditions were established to secure mechanical properties under harsh conditions for Al–Mg–Zn-Cu-based alloys. Using JMatPro13.0 for precipitation phase simulation, the optimal pre-aging temperature and time of the design composition were selected. Through the introduction of pre-aging, it was confirmed that no over-aging phenomena occurred, even after bake-hardening, and it was confirmed that it could have mechanical properties similar to those of test specimens subjected to traditional heat treatment. Through DSC (Differential Scanning Calorimetry) and TEM (Transmission Electron Microscope) analyses, it was found that pre-aging provided sufficient thermal stability to the GP (Guinier–Preston) zone and facilitated transformation to the η’-phase. In addition, it was confirmed that, even under bake-hardening conditions, coarsening of the precipitation phase was prevented and number density was increased, thereby contributing to improvements in the mechanical properties. The designed alloy plate was evaluated as having excellent anisotropy properties through n-value and $\overline{\mathrm{r}}$-value calculations, and it was confirmed that a similar level of formability was secured through FLC (Forming Limit Curve) comparison with commercial plates. Full article

In magnesium–rare earth–transition metal (Mg-RE-TM) alloys, the γ” phase (with a hexagonal structure with the space group P$\overline{6}$2m) is a critical strengthening phase that can significantly improve their mechanical properties. However, compared to other phases in Mg-RE-TM alloys, research on the γ” phase is less documented, and an understanding of the γ” phase is not well established. As a result, different models of the structure of the γ” phase have been proposed. In this review, we summarize these structural models and find that the γ” phase is different from the Guinier–Preston (G.P.) zone, as revealed via Cs-corrected high-angle annular dark field-scanning transmission electron microscopy (HAADF-STEM) and density functional theory (DFT) calculations. In addition, we briefly summarize the stability of the γ” phase and its effect on the mechanical properties of Mg-RE-TM alloys. Full article

The research aim was to optimize post-weld heat-treatment (PWHT) modes for a laser-welded joint of the Al–Cu–Li alloy and improve their respective strength properties. As a result, the ultimate tensile strength, yield point, and elongation of the joint were enhanced up to 95%, 94%, and 38%, respectively, of those inherent in the base metal. Before and after PWHT, both microstructures and phase compositions have been examined by optical and scanning electron microscopy, as well as synchrotron X-ray diffractometry. In the as-welded metal, the α-Al and T₁(Al₂CuLi) phases were found, along with the θ′(Al₂Cu) and S′(Al₂CuMg) phases localized at the grain boundaries, significantly reducing the mechanical properties of the joint. Upon quenching, the agglomerates dissolved at the grain boundaries, the solid solution was homogenized, and both Guinier–Preston zones and precipitates of the intermediate metastable θ″ phase were formed. After subsequent optimal artificial aging, the (predominant) hardening θ′ and (partial) T₁(Al₂CuLi) phases were observed in the weld metal, which contributed to the improvement of the strength properties of the joint. Full article

Nanostructured Guinier–Preston (GP) zones are critical for the strength of Al-Mg-Si(-Cu) aluminum alloys. However, there are controversial reports about the structure and growth mechanism of GP zones. In this study, we construct several atomic configurations of GP zones according to the previous research. Then first-principles calculations based on density functional theory were used to investigate the relatively stable atomic structure and GP-zones growth mechanism. The results show that on the (100) plane, GP zones consist of {MgSi} atomic layers without Al atoms, and the size tends to grow up to 2 nm. Along the (100) growth direction, even numbers of {MgSi} atomic layers are more energetically favorable and there exist Al atomic layers to relieve the lattice strain. {MgSi}₂Al₄ is the most energetically favorable GP-zones configuration, and the substitution sequence of Cu atoms in {MgSi}₂Al₄ during the aging process is Al → Si → Mg. The growth of GP zones is accompanied by the increase in Mg and Si solute atoms and the decrease in Al atoms. Point defects, such as Cu atoms and vacancies, exhibit different occupation tendencies in GP zones: Cu atoms tend to segregate in the Al layer near the GP zones, while vacancies tend to be captured by the GP zones. Full article

The effect of final thermomechanical treatment (FTMT) on the mechanical properties and microstructure of a T-Mg₃₂(Al Zn)₄₉ phase precipitation hardened Al-5.8Mg-4.5Zn-0.5Cu alloy was studied. The as-cold rolled aluminum alloy samples were subjected sequentially to solid solution treatment, pre-deformation, and two-stage aging treatment. Vickers hardness was measured during the aging process under various parameters. Tensile tests were conducted on the representative samples based on the hardness results. Microstructural characteristics were analyzed via transmission electron microscopy and high-resolution transmission electron microscopy. The conventional T6 process was also carried out for comparison. The hardness and tensile strength are increased evidently by the FTMT process for the Al-Mg-Zn-Cu alloy, while the ductility is adversely affected to a small extent. The precipitation at the T6 state consists of a coherent Guinier–Preston zone and T″ phase in the form of intragranular, fine, and spherical particles, while a semi-coherent T′ phase appears after the FTMT process as a new constituent. The distribution of dislocation tangles and isolated dislocations is another feature of FTMT samples. Enhanced precipitation hardening and dislocation strengthening account for the improved mechanical performance of FTMT samples. Full article

In this work, the effect of ultrasonic vibration during solidification on the aging kinetics of an AlSi7Mg alloy is investigated. With the ultrasonic equipment coupled to the mold walls, melt treatment was performed by two approaches: (i) fully above liquidus (>635 °C); and (ii) in the full range between liquidus and solidus (630 °C→ 550 °C). Cast samples were then subjected to T6 heat treatment for different aging times. It is shown that indirect ultrasound treatment increases the cooling rate while active. The eutectic Si was refined and further modified when ultrasound treatment was performed in the semisolid state. Due to the significant release of solute during the decomposition of π-Al8FeMg3Si6 into fine β-Al5FeSi, this has a significant impact in the solution stage. Ultrasound treatment fully above liquidus decreased the underaging time to 50% and peak aging time to 25% without compromising strength. The results suggest aging kinetics are correlated with a higher vacancy density and solute enrichment which favors Guinier–Preston (GP) zone formation. These findings show a promising route to tailor the aging kinetics in these alloys by selectively modifying phases and cooling rates. Full article

The creep ageing process can have a significant influence on the mechanical properties of aluminum alloys. In the present work, microstructural analysis and mechanical testing were implemented to characterize the age hardening effect and microstructure evolution, and to investigate how the stress applied under creep ageing conditions can affect a material’s microstructure. The curves depicting yield strength in relation to creep ageing time suggested that the stress applied in creep ageing can result in a reduction of the strength of aluminum alloy 7050; the yield strength decreases with increasing applied stress. Microstructural analysis by transmission electron microscopy (TEM) revealed that by applying stress, the growth and coarsening rate of the Guinier-Preston (GP) zones and η′ precipitates can be sped up. Even after pure/creep ageing for 8 h, there are still some GP zones in the aluminum matrix, demonstrating that the GP zones’ nucleation is a continuous process. Full article

The main objective of this contribution was to determine the impact of magnesium (Mg) concentration and solidification rate (about 800 °C/s) on the mechanical properties of commercial A380.1 die-cast alloy. Respective amounts of 0.10%, 0.30%, and 0.50% Mg were used to establish their influence on the main tensile properties, namely, the ultimate limit, the elastic limit, and the percentage of elongation to fracture. The study also focused on the effect of magnesium on the fatigue behavior of A380.1 alloy where the role of surface defects and internal defects (porosity, oxide films, and inclusions) on the alloy fatigue life was also determined. The tensile properties were analyzed in order to optimize the heat treatments of T6 (under-aging) and T7 (over-aging). Consequently, the influence of several parameters was evaluated using tensile testing and optical and scanning electron micrography. Fatigue strength was investigated by performing rotational bending tests. The results show that the alloy tensile strength parameters improve with up to 0.3% Mg. Further addition of Mg, i.e., 0.5%, does not produce any significant improvement with respect to either traction or fatigue. It is observed that the tensile properties fluctuate according to the Guinier–Preston zones which occur during heat treatment, while the fatigue properties decrease as the Mg content increases. In contrast to a mechanical fatigue failure mechanism, in the present study, cracks were initiated at the sample’s outer surface and then propagated toward the center. Full article

A novel Al-Cu-Zr alloy is designed in this paper, which provides a method for further improving the strength of Al-Cu alloys. In this paper, the addition of the micro-alloying element Zr in Al-Cu alloy was studied. The effect of aging treatment on the mechanical properties and precipitation behavior of the alloy was studied. With the addition of Zr, Al₃Zr phases were formed in the alloy, which acts as obstacles to dislocation motion. In addition, Al₃Zr phases can be used as the nucleation site of θ′ phases to promote precipitation. All this can improve the strength of Al-Cu alloys. After one-step aging, corresponding to the highest hardness, the largest amount of θ′ phases were observed in the alloy matrix. By contrast, after two-step aging, the θ′ phases were finer, and a large amount of Guinier–Preston (GP) zones formed during the pre-aging step, which were transformed into denser and finer θ′ phases in the secondary aging step. After the same solution treatment (540 °C/12 h), undergoing 120 °C/4 h + 175 °C/10 h two-step aging, the ultimate tensile strength, yield strength, and elongation of the Al-Cu-Zr alloy were 398.7 MPa, 313.3 MPa, and 7.9%, respectively. Full article

The A356 alloy has been widely used in automotive components, such as wheels and brake disks, because it is an excellent lightweight material with high corrosion resistance and good mechanical properties. Recently, to reduce the weight of brake disks, the Fe-A356 hybrid brake disk has been suggested. Because brake disk quality is directly related to driving safety, the T4/T6 heat treatment of centrifugally cast A356 alloys were performed to enhance the mechanical properties and reduce micro-segregation. The solid-solution heat treatment followed by annealing caused the formation of Mg-rich intermetallic compounds on the grain boundaries of the Al matrix, decreasing the average hardness of the alloys by 13 HV. In contrast, the solid solution followed by water quenching (T4) reduced the area fractions of the intermetallic compounds and increased the average hardness by 11 HV. The T6 heat-treated A356 alloys, which were influenced by the formation of the Guinier–Preston zone exhibited a relatively higher average hardness, by 18 HV, compared to T4 heat-treated A356 alloys. Full article

The influence of pre-stretch on the mechanical properties of 2219 Al alloys sheets were systematically investigated, with the aim of examining the age-strengthening in parts draw-formed from as-quenched sheets. The precipitation was characterized based on differential scanning calorimetry (DSC) analysis and transmission electron microscope (TEM) observation of specimens of as-quenched and quenched-stretched condition to address the influence of pre-stretching. A tensile test was performed to evaluate the effect on mechanical properties. The introduction of pre-stretching endues increased yield strength (YS) and thus can be helpful to exert the potential of the alloy. Peak YS of 387.5 and 376.8 MPa are obtained when specimens pre-stretched for 10% are aged at 150 and 170 °C, respectively, much higher than that obtained in the non-stretched specimens (319.2 MPa). The precipitation of Guinier-Preston zone (G.P. zones) and the transition to θ″ shifts to a lower temperature when pre-stretched is performed. The high density of dislocations developed during the stretching contributes to the acceleration in precipitation. Quench-stretched specimens present a much quicker age-hardening response at the beginning stage, which endue higher peaked yield strength. The yield strength, however, decrease much more quickly due to the recovery that occurs during the aging processes. The study suggested the feasibility of aging draw-formed components of 2219 Al alloy to obtain high strength. Full article

The effect of different precipitate microstructures obtained by different heat treatments on fatigue behavior of 7020 aluminum alloy was investigated. The fine Guinier Preston I (GPI) zones in the under-aged alloy can be repeatedly sheared by dislocations produced in cyclic loading, making the fatigue crack initiate difficultly and fatigue crack path propagate tortuously. Fatigue strength and fatigue crack propagation resistance of the alloy with shearable precipitates are much higher than those of the alloy with unshearable precipitates. The peak-aged alloy with continuous grain boundary precipitate (GBP) and narrow precipitate free zone (PFZ) is prone to initiate fatigue cracks and reduce fatigue strength. With the growth of unshearable precipitates, the fatigue strength of the alloy firstly increases and then decreases. Precipitates with moderate size in the over-aged alloy improve the roughness-induced crack closure (RICC) effect. Soft matrix with appropriate width between the precipitates can promote the slip reversibility and relax the crack tip stress. The fatigue strength of the moderately over-aged alloy reaches to 122.1 MPa at 10⁷ cycles of loading, and the fatigue crack growth rate (FCGR) is 35.6% slower than that of the peak-aged alloy at ΔK of 10 MPa·m^1/2. Full article