Search Results (44)

In the present article, the effect of artificial ageing on tensile mechanical properties and resistance to corrosion of aluminium alloy 2198-T3 was investigated. The results were obtained under the framework of the Greek National project “CorLi”, which was targeted to document the mechanical behaviour of the alloy under different artificial ageing conditions, simulating the natural ageing of aircraft structures during their operation lifespan. Four (4) different ageing conditions corresponding to under-aged (UA), peak-aged (PA), and over-aged (OA) tempers based on the initial, T3 temper, were considered. In the PA condition, the conventional yield stress R_p0.2% increased by more than 50% with a simultaneous 46% decrease in tensile elongation at fracture A_f. Additionally, the effect of corrosion was found to be different for the different artificial ageing tempers of AA2198, with lower charge transfer resistance (R_CT) observed for artificially aged specimens. Nevertheless, the corrosion-induced degradation rate of R_CT was found to decrease with increasing ageing time. Full article

The study aimed to develop a superhydrophobic coating on the aluminium alloy 2024-T3 surface. The desired surface roughness and low surface energy were achieved with SiO₂ nanoparticles, synthesised via the Stöber method and modified with alkyl silane (AS) or perfluoroalkyl silane (FAS). To enhance particle adhesion to the alloy substrate, nanoparticles were incorporated into a hybrid sol–gel coating composed of tetraethyl orthosilicate, methyl methacrylate, and 3-methacryloxypropyl trimethoxysilane. The coated substrates were characterised using field emission scanning and transmission electron microscopy with energy-dispersive spectroscopy for surface topography, nanoparticle size distribution, composition, and coating thickness. The corrosion resistance of the coatings on AA2024-T3 was evaluated in a 0.1 M NaCl solution using electrochemical impedance spectroscopy. The synthesised SiO₂ nanoparticles had an average size between 25 and 35 nm. The water contact angles on coated aluminium surfaces reached 135° for SiO₂ + AS and 151° for SiO₂ + FAS. SiO₂ + FAS, indicating superhydrophobic properties, showed the most uniform surface with the most consistent size distribution of the SiO₂ nanoparticles. Incorporation of nanoparticles into the hybrid sol–gel coating further improved particle adhesion. The ~2 µm-thick coating also demonstrated efficient barrier properties, significantly enhancing corrosion resistance for over two months under the test conditions. Full article

Aluminium metal matrix composites (AMMCs) using alumina (Al₂O₃) and silicon carbide (SiC) as reinforcement elements are gaining significant interest in various applications because of their excellent properties. In this study, Al₂O₃/SiC with compositions (0.5 wt.%, 1.5 wt.%, and 2.5 wt.% for each) were used as reinforcement elements in an aluminium alloy (AA2024-T6). The samples prepared were AA2024-T6 + (0.5Al₂O₃/0.5SiC), AA2024-T6 + (1.5Al₂O₃/1.5SiC), and AA2024-T6 + (2.5Al₂O₃/2.5SiC) using a stir-casting technique. The experimental study included density calculation mechanical properties, such as tensile strength, compressive strength and hardness. The study also included a microstructure examination of the fracture surface of the tensile specimens. The results showed that incorporating Al₂O₃/SiC as reinforcement materials into aluminium AA2024-T6 significantly improved its properties. Hence, increasing the reinforcement with compositions of 2.5Al₂O₃/2.5SiC into AA2024-T6 showed a drop in density and increased mechanical properties, such as ultimate tensile strength, compressive strength and hardness, compared to the base alloy (AA2024-T6). Furthermore, the scanning electron microscopy analysis revealed the uniform distribution of the reinforcement particles resulting in strong bonding with the matrix. The findings suggest that Al₂O₃/SiC reinforced with AA2024-T6 can be used in applications where a combination of lightweight and high strength is needed. Full article

This study investigates the impact of various auxiliary cooling techniques on machinability, energy consumption, carbon emissions, and economic factors in the drilling process of AA7075T6 aluminium alloy using TiO₂ and C-reinforced composites. The study employed various cooling conditions (dry, MQL, CO₂, and hybrid MQL+CO₂), with different cutting speeds and feed rates, to evaluate their effects on drilling characteristics. The findings indicated that the combined MQL and CO₂ cooling notably enhanced the drilling process by reducing cutting forces by 32% and surface roughness by 65% compared to dry cutting. This synergy between lubrication and cooling significantly improves machinability, resulting in higher-quality machining outputs with smoother surfaces and more precise circularity. Energy analysis revealed that the MQL+CO₂ method reduces energy consumption to 64% observed under dry conditions, underscoring its efficiency through better heat dissipation and reduced friction. Furthermore, this method demonstrates a significant reduction in carbon emissions, contributing to environmental sustainability. Economically, although initial costs associated with the implementation of cooling systems are higher, they are offset by reduced tool wear and energy costs, making it a viable solution for sustainable manufacturing practices. Full article

This paper presents the results of an extensive investigation into the durability of cold spray repairs to corrosion damage in AA7075-T7351 aluminium alloy specimens where, prior to powder deposition, the surface preparation involved grit blasting. In this context, it is shown that the growth of small naturally occurring cracks in cold spray repairs to simulated corrosion damage can be accurately computed using the Hartman–Schijve crack growth equation in a fashion that is consistent with the requirements delineated in USAF Structures Bulletin EZ-SB-19-01, MIL-STD-1530D, and the US Joint Services Structural Guidelines JSSG2006. The relatively large variation in the da/dN versus ΔK curves associated with low values of da/dN highlights the fact that, before any durability assessment of a cold spray repair to an operational airframe is attempted, it is first necessary to perform a sufficient number of tests so that the worst-case small crack growth curve needed to perform the mandated airworthiness certification analysis can be determined. Full article

The joining of aluminium alloy AA6082-T6 to polyamide 6 (PA6) by friction stir spot welding (FSSW) was investigated in the current work. Although previous studies can be found on the joining of polymers and metals by FSSW, welding using aluminium plates as thin as the ones used in this work (1 mm) was not found. The influence of the plunge depth (0.1 to 0.5 mm) and the dwell time (15 and 30 s) parameters on the welding results was studied. In general, the increase of these parameters led to the improvement of the maximum load of the joints under tensile-shear testing. Additionally, the feasibility of multiple spot welding was tested and proven. Finally, although most of the welds were performed with a pinless tool, a tool with a conical pin and a concave shoulder was used for comparison. The use of this more conventional tool resulted in joints easily broken by handling. Still, the potential of the conical pin tool was demonstrated. The different conditions were evaluated based on morphology and tensile-shear testing. The weld with the best mechanical behaviour was produced with multiple spot welding, which failed for a maximum load of about 2350 N. Full article

This study presents a detailed numerical investigation into the web buckling behaviour exhibited by high-strength aluminium alloy channels, namely 7075-T6 and AA-6086, when subjected to concentrated loading. A nonlinear finite element (FE) model was established and verified using the experimental data reported by other researchers, and the material properties of 7075-T6 and AA-6086 high-strength aluminium alloy were obtained through the literature. A parametric study comprising 1024 models was performed using the validated FE models. Variables examined in this work included web slenderness ratio, internal corner radii, bearing lengths, and aluminium alloy grades. The numerical results generated by the parametric investigation were used to evaluate the applicability and reliability of the most recent design specifications given in the Australian and New Zealand Standards (AS/NZ S4600) (2018) and Australian Standards (AS/NZS 1664.1) (1997). The comparison indicated that the calculated design strength using AS/NZ S4600 was over-conservative by 41% and 43% for 7075-T6 and AA-6086 aluminium alloy, correspondingly, while the design strength computed using AS/NZS 1664.1 was marginally unconservative, compared to numerical results. Finally, using bivariate linear regression analysis, new design formulas with new coefficients for determining the web buckling behaviour of 7075-T6 and AA-6086 high-strength aluminium alloy channels were proposed. A reliability analysis was then undertaken, indicating that the proposed design equations possess the capability of accurately predicting the web buckling behaviour of these members. Full article

The aim of this paper is to analyse the mechanical properties of butt joints between S355 steel and 6061-T6 aluminium alloy, as well as their relationship to changes in the structure of the material caused by welding. The effect of the tool offset was analysed in particular. For the analysis, tensile tests were carried out using macro- and mini-specimens taken from S355/AA6061-T6 joints and base materials. In addition, the macro- and microstructure of the joints was determined, the hardness profiles in the joints were analysed, and fractographic analysis of the fractures of the specimens was carried out. Based on the results of the macro- and microstructure examinations, typical friction stir welding (FSW) joint zones were characterised. The microstructure was observed in the interface line of the materials on the root side, the negative effect of which on the quality of the joint was confirmed by digital image correlation (DIC) strain analysis during the monotonic tensile test. The highest average value of s_u = 141 MPa for the entire joint was obtained for a 0.4 mm tool offset. The highest average value of s_u = 185 MPa for the selected joint layer was obtained for a 0.3 mm tool offset. Fracturing of the joint in the selected layer for the tool offset values of 0.3 mm and 0.4 mm occurred in the weld nugget zone (WNZ) where the lowest hardness was recorded. Full article

This research focuses on the computational modelling and comparative analysis of friction stir welding (FSW) and stationary shoulder friction stir welding (SSFSW) applied to AA6061-T6 aluminium alloy. SSFSW, an FSW variant, employs a stationary shoulder and a rotating pin. This study introduces a numerical model for both processes, using the innovative Smoothed Particle Hydrodynamics (SPH) technique to capture their distinct thermo-mechanical characteristics. The aim is to unravel its mechanics and multi-physics in SSFSW and compare it with conventional FSW. The temperatures predicted by the model exhibited a close agreement between the advancing side (AS) and retreating side (RS). Plastic strain patterns show that regular FSW is different from SSFSW. In SSFSW, the strain is less, and the plastic area is comparatively slightly narrower. The distinct “ironing effect” resulting from the stationary shoulder in SSFSW reduces the heat-affected zone (HAZ). Yet, it maintains efficient plasticisation and material flow within the pin-affected zone (PAZ). This research emphasises the significant impact of temperature, strain, material flow, and thermo-mechanical characteristics on the quality of joints. Future suggestions include exploring process parameters more broadly, examining dissimilar welding techniques and hybrid approaches, and comprehensively investigating the diverse effects of SSFSW under various configurations and joint angles. Full article

Recently, new types of C-shaped members made from AA-6086 and 7075-T6 high-strength aluminium alloy have become more popular due to their high yield strength and lower cost. These members are often manufactured with pre-punched web perforations to simplify the installation of services, but this can reduce their strength. Also, such aluminium C-shaped members that contain perforated webs are vulnerable to web buckling failure, as aluminium alloy has a lower elastic modulus compared to steel. However, this influence has not been investigated for high-strength aluminium alloy sections to date. An extensive numerical investigation was undertaken to examine the effect of web perforations on the web buckling resistance of high-strength aluminium alloy C-shaped members under an end-two-flange (ETF) loading case, and this study focused on two types of aluminium alloys, namely 7075-T6 and AA-6086. To achieve this, a nonlinear finite element (FE) model was developed and validated using the test data in the literature. The material properties used in the FE models were obtained from the relevant literature. A parametric investigation was carried out, consisting of a total of 1458 models. In this investigation, a number of variables were examined, including the web hole size, web hole location, bearing length, fillet radius and aluminium alloy grades. The results showed that increasing the a/h ratio from 0.1 to 0.5 resulted in a decrease of 9.7% and 9.3% in the web buckling resistance for the 7075-T6 aluminium and AA-6086 aluminium, respectively. When the length of the bearing plates (N) varied from 100 mm to 200 mm, the web buckling resistance experienced an average increase of 61.7% for the 7075-T6 aluminium and 54.1% for the AA-6086 aluminium. Also, the web buckling resistance increased by 6.2% for the 7075-T6 aluminium alloy, while the strength increased by 4.0% for the AA-6086 aluminium alloy when the x/h ratio increased from 0.1 to 0.5. The numerical data generated from the parametric study were used to assess the accuracy and suitability of the latest design recommendations, and it was found that the design rules presented in the previous literature cannot provide reliable and safe predictions for estimating the web buckling resistance of aluminium C-shaped members that contain perforated webs under an ETF loading case. Finally, new design formulas were proposed in the form of strength reduction factors. A reliability assessment was then undertaken, and the results of this analysis indicated that the proposed design formulas can accurately predict the web buckling resistance of such members with perforated webs. Full article

Within the framework of the formability limit assessment in sheet metal forming, testing of notched tensile samples coupled with digital image correlation (DIC) has been analysed as an alternative to overcome the implications of Nakajima testing in relation to times of test preparation, cost of the equipment, presence of friction, and amount of material required for the test. Additionally, the complications of the Nakajima testing at elevated temperatures need to also be considered. In this work, specific notched sample geometries have been investigated to accurately identify the forming limits of Aluminium alloy AA6016 in T4 condition. Once the notched geometry had been defined, experimental tensile testing of the samples coupled with DIC technology allowed us to identify the formability limits of interest. Finally, a comparison at room temperature with the conventional Nakajima testing was performed experimentally. Two different methodologies for strain limit evaluation in notched samples have been investigated in the present analysis. The first one is called a position-dependent method and is based on the inverse best-fit parabola of the “bell-shaped curve”, which is used in the conventional Nakajima test. The second approach referred to a time-dependent method and is based on the strain rate evaluation at the necking zone. This strain-rate-dependent method, which works in combination with DIC measurements, was found to be more accurate to determine the necking limits than the previous one; in addition, it also provides more accurate information for the safe zone of forming. Full article

Two types of high-strength aluminium alloy (HA)—namely, AA-6086 and 7075-T6—have been developed and extensively used in recent years. These high-strength aluminium alloys offer advantages such as lower prices and higher yield strength than traditional alloys. The webs of aluminium channel members under concentrated loads are susceptible to web buckling failure, which restricts their applications. However, no research work has been reported that has evaluated the web buckling performance of high-strength aluminium alloy channel sections subjected to end-two-flange (ETF) loading, and the material characteristics of these high-strength aluminium alloys differ significantly from those of conventional aluminium alloys. This work addresses this gap by conducting a detailed numerical investigation. A parametric investigation consisting of 1024 models was performed using the finite element (FE) models previously developed for traditional aluminium alloys. A wide range of high-strength aluminium alloy sections covering varying web slenderness ratios, internal corner radii, bearing lengths, and aluminium alloy grades were considered in this investigation. It was shown that the latest design recommendations in the Australian and New Zealand Standards (AS/NZ S4600) and (AS/NZS 1664.1) were over-conservative when estimating the web buckling strength of such channel sections. Finally, new web buckling design equations for high-strength aluminium alloy channel sections were proposed through reliability analysis in this investigation. Full article

Aluminium alloy (AA2024-T4) is a material commonly used in the aerospace industry, where it forms part of the fuselage of aircraft and spacecraft thanks to its good machinability and strength/weight ratio. These characteristics allowed it to be applied in the construction of the structure of a pilot plant to produce biological extracts and nano-encapsulated bioproducts for the phytosanitary control of diseases associated with microorganisms in crops of Theobroma cacao L. (Cacao). The mechanical design of the bolted support joints for this structure implies knowing the performance under fatigue conditions of the AA2024-T4 material since the use of bolts entails the placement of circular stress concentrators in the AA2024-T4 sheet. The geometric correction constant (Y) is a dimensionless numerical scalar used to correct the stress intensity factor (SIF) at the crack tip during propagation. This factor allows the stress concentration to be modified as a function of the specimen dimensions. In this work, four compact tension specimens were modeled in AA2024-T4, and each one was modified by introducing a second circular stress concentrator varying its size between 15 mm, 20 mm, 25 mm, and 30 mm, respectively. Applying a cyclic load of 1000N, a load ratio R=-1 and a computational model with tetrahedral elements, it was determined that the highest SIF corresponds to the specimen with a 30 mm concentrator with a value close to 460 MPa.mm^0.5. Where the crack propagation had a maximum length of 53 mm. Using these simulation data, it was possible to process each one and obtain a mathematical model that calculates the geometric correction constant (Y). The calculated data using the new model was shown to have a direct relationship with the behavior obtained from the simulation. Full article

Surface metal matrix composites offer an excellent solution for applications where surface properties play a crucial role in components’ performance and durability, such as greater corrosion resistance, better wear resistance, and high formability. Solid-state processing techniques, such as friction surfacing and friction stir welding/processing, offer several advantages over conventional liquid-phase processing methods. This research investigated the feasibility of producing surface composites of aluminium-based dissimilar alloys reinforced with functional microparticles through experimental validation, determined the process parameters that resulted in a more homogeneous distribution of the particles in the surface composites, and enhanced the understanding of Upward Friction Stir Processing (UFSP) technology. The production of aluminium-based dissimilar alloys (AA 7075-T651 and AA 6082-T651) surface composites reinforced with SiC particles was studied, and it was concluded that the macrography and micrography analyses, scanning electron microscopy (SEM) analysis, microhardness measurements, and eddy currents technique reveal an extensive and homogeneous incorporation of SiC particles. In the stirred zone, a decrease of approximately 20 HV 0.5 in hardness was observed compared to the base material. This reduction is attributed to the weakening effect caused by low-temperature annealing during UFSP, which reduces the strengthening effect of the T651 heat treatment. Additionally, the presence of particles did not affect the surface composite hardness in the stirred zone. Furthermore, despite the presence of significant internal defects, SEM analyses revealed evidence of the lower alloy merging with the upper zone, indicating that the lower plate had a role beyond being merely sacrificial. Therefore, the production of bimetallic composites through UFSP may offer advantages over composites produced from a monometallic matrix. The results of the eddy currents testing and microhardness measurements support this finding and are consistent with the SEM/EDS analyses. Full article

The aluminium alloy AA 6086 attains the highest room temperature strength among Al-Mg-Si alloys. This work studies the effect of Sc and Y on the formation of dispersoids in this alloy, especially L1₂-type ones, which can increase its high-temperature strength. A comprehensive investigation was carried out using light microscopy (LM), scanning (SEM), and transmission (TEM) electron microscopy, energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), differential scanning calorimetry (DSC), and dilatometry to obtain the information regarding the mechanisms and kinetics of dispersoid formation, particularly during isothermal treatments. Sc and Y caused the formation of L1₂ dispersoids during heating to homogenization temperature and homogenization of the alloys, and during isothermal heat treatments of the as-cast alloys (T5 temper). The highest hardness of Sc and (Sc + Y) modified alloys was attained by heat-treating alloys in the as-cast state in the temperature range between 350 °C and 450 °C (via T5 temper). Full article