Effects of Heat Dissipation from Friction Stir Welding to Microstructures of Semi-Solid Cast 6063 Al Alloy

In this work, temperature distribution in semi-solid cast 6063 aluminum alloy workpieces during friction stir welding (FSW) was determined by finite element analysis (FEA). The FEA results were validated by comparing them with the measurement results from thermocouples. The maximum temperature of 534.2oC was predicted at the workpiece surface contacted with the tool shoulder. The temperature profiles obtained from FEA were used to explain microstructural changes during FSW. It was observed that relatively high temperature made α-Al grains became elongated and Mg2Si intermatalics turned into a rod-like morphology with round edges.

The effect of a new route on the microstructure and property of 6063 alloy during the ECAP deformation

The microstructures and hardness of 6063 Al alloy subjected to different ECAP route (Bc and the new route) were investigated. These two routes have different rotation scheme of a sample around its long axis between two consecutive ECAP passes: Bc route, by which sample were rotated in the same direction by 90°; the new route, by which sample were rotated in the same direction by 135°. The feature microstructures of the samples subjected to the two routes were investigated by the optical microscopy (OM) and transition electron microscopy (TEM), respectively. In comparison, the pressing by the new route produces more homogeneous microstructure with the higher fraction of high angle boundaries. Furthermore, the hardness results showed that work hardening can be observed and do not depend much on the ECAP route. However, distribution of hardness in cross-sections of samples revealed that processing to total passes number of eight by the new route improves deformation uniformity.

Fabrication of carbon nanotube reinforced aluminum alloy composites by vacuum-assisted infiltration technique

Carbon nanotube (CNT) reinforced 6063 aluminum (Al) matrix composites were fabricated by vacuum-assisted infiltration of molten 6063 Al alloy into a CNT preform to enhance compressive mechanical properties. Preforms were produced with different amounts of chemically functionalized CNTs to obtain three different CNT reinforcement ratios (0.25, 0.50, and 0.75 wt.%). In addition to the investigation of properties throughout all stages of the preparation of the CNTs, CNT preforms and fabricated composites by various methods of analysis, all steps of the composite fabrication process, as well as the compressive mechanical test results of CNT/6063 Al composites are all discussed. Approximately 250% and 280% increases in the yield and ultimate compressive strength, respectively, are achieved with low-purity CNT addition. Consequently, it is confirmed from the micrographs that the mechanical enhancements of the composites are mainly interrelated with the successful bridging of CNTs in the matrix material. Meanwhile, it is observed that both the modified Halpin-Tsai model and the modified Halpin-Tsai model developed with a dispersion-based prediction model results match with experimental results. Overall results can be accepted as developmental stages of significant progress in the CNT preform reinforced metal matrix composites field.

Deformation Behavior and Microstructure Evolution of 6063 Alloy during Hot Compression

Hot compression tests of homogenized 6063 Al alloy were carried out in the temperatures range from 390°C to 510°C and strain rates from 1s-1 to 20s-1 on a Gleeble-3500 thermal simulation machine. The results showed that the flow stress decreased with increasing deformation temperature or decreasing strain rate. The dynamic softening effect was more obvious when the alloy was deformed at strain rate of 20 s-1. The Arrhenius-type constitutive equation with strain compensation can accurately describe the flow stress of 6063 aluminum alloy during hot compression. Shear bands appeared in grains interior when the alloy deformed at high strain rates, corresponding to high Zenner-Hollomon (Z) parameters. When deformed under the conditions with low Z parameters, the dynamic recrystallization started occurred.