Investigation of microstructural and wear behavior of Al6061 surface composites fabricated by friction stir process using Taguchi approach

The surface composites of aluminum alloys have a higher scope of applications encountering surface interactions in the aerospace, automobile, and other industries compared to the base aluminum alloys. The friction stir process (FSP) is recently the preferred method to prepare aluminum-based surface composites due to its capability to produce improved physical properties and refined microstructure at the surface. The study examines the Al6061 alloy-based surface composite fabricated by FSP for their wear behavior and microstructure. In this study, the Al6061 alloy-based hybrid surface composites are prepared with varying weight% of copper and graphite microparticles mixture as reinforcement by FSP with two tools having unique pin profiles, i.e., threaded cylindrical and plain cylindrical. These prepared composites are investigated for the dry sliding wear test on a pin-on-disc test set-up. The experiments are designed using the L9 orthogonal array and analyzed by the Taguchi approach to obtain the influence of disc speed, load, and reinforcement weight% on wear rate. The significant parameters influencing the wear rate of the samples tested are obtained using ANOVA. Later the effects of the friction stir process and the wear tests on the microstructure of the workpieces are investigated using FE-SEM/EDS tests. It is concluded that the decrease in wear rate with the rise in reinforcement weight% (Cu + graphite) from 2% to 6%. The load has the maximum effect on the wear rate for the samples prepared by threaded cylindrical FSP tool pin profile, while reinforcement weight% affects significantly the wear rate of the samples prepared by FSP with plain cylindrical pin profile tool.

Investigation of the buckling behavior of a control arm with Si particle reinforced aluminum based metal composite material

Control arms are subjected to static and dynamic loads in car during their lifetime. Recent increases in loads in which control arms are subjected, are not complying with the low-weight design targets expected by auto makers. In this study, buckling behavior of control arms which have been produced with Si particle reinforced aluminum based metal composite material have been investigated and compared with the performance of control arms that are produced with standard aluminum alloy. The results revealed that mechanical properties of control arm housings with 10% Sip MMC material are lower than standard 6110 alloy due to different process parameters. Elasticity of modulus of control arm housings with 10% Sip MMC material are approximately 7% higher than standard aluminum alloys. Buckling results of control arms with 10% Sip MMC material are around 25% lower that control arms with standard 6110 alloy. Also, a second darker phase was found in the microstructure.

Alternative Liquid Assisted-Sintering of AL/CU Composites Using Selective Powders of AS-Cast Al-ZN Alloy

Al and its alloys constitute one of the most versatile, economical and attractive materials for a wide range of applications. The 7xxx and 2xxx series alloys are those of achieving the highest mechanical strength among aluminum alloys. In this investigation, using powder metallurgy provides the microstructural and mechanical properties characterizations of non-commercial Al6Cu5Zn alloy by using powder metallurgy. Initial powder sizes are determined and the best condition is obtained for the distribution comprised between 75-106 μm. The samples are sintered at 585 oC, 600 oC and 615 oC during 0.5, 1.5 h and 3 h. It is found that mechanical behavior similar to as-cast Al-Cu based alloys is attained (~ 125 MPa) when the samples at 615 oC during 3 h are sintered. Considering the reduction of energy consumption and metal fumes commonly produced in foundry, Al-Zn powder can be used with Al and Cu elemental powders to constitute an Al6Cu5Zn alloy.

Crystal Diffraction Techniques Were Used to Investigate the Structural Properties of Some Aluminum Alloys.

Due to the importance of these alloys in the manufacture of aircraft, coatings, radiation shields, and electronic circuits, the study’s objectives include investigating previously unstudied structural properties of some aluminum alloys, alloy A (Al-Zn-Mg-Ti) and alloy B (Al-Zn-Mg-Mn) were prepared using the casting method, and their structural properties were studied using X-ray diffraction (XRD) and scanning electron microscopy (SEM) techniques (granular size and theoretical density). The results of analyzing the X-ray diffraction data and determining the phases formed on the two alloys after matching them with the international standard cards (JCPDS) revealed that it is polycrystalline, with structures (cubic and hexagonal) on alloy A and structures (cube, hexagonal, and anorthic) on alloy B. The results revealed that the average grain size estimated by the Debye-Scherer method is less than that estimated by the Williamson-Hall method, and that the grain size of alloy A is less than that of alloy B due to the presence of titanium in alloy A’s composition, which works to reduce particle size. The theoretical density of Alloy A and B that was used in X-ray diffraction was calculated. SEM analysis of the spherical shape of the grains on the surfaces of alloys A and B revealed that the average grain size on the surface of alloy A is smaller than on the surface of alloy B, which is consistent with the results of XRD analyses.