Papers by Author: M.Y. Ahmad

Abstract: In this paper, a study on the electrochemical behaviour and electrical properties of Al-Zn and Al-Zn-Sn alloys in tropical seawater using open circuit potential (OCP) measurement and electrochemical impedance spectroscopy (EIS) are reported. The results from both the OCP and EIS tests show that surface activation was observed in the Al-Zn alloy with the addition of 1.34 wt.% Sn which can be manifested by the shift of OCP values towards more electronegative direction. The EIS spectra of Al-Zn alloy exhibits a semicircle loop, while the EIS spectra for the Al-Zn-Sn alloy exhibits a semicircle with a semicircle inductive loop. The change in EIS spectra for Al-Zn-Sn alloy is correlated to the increase of surface activation resulting in a less stable passive layer. Equivalent circuits models were proposed to fit the impedance spectra and the corresponding electrical parameters with optimum values were deduced. The modulus impedance in the low frequency region or polarization resistance, R_pol obtained for the Al-Zn-Sn alloy, R_pol = 2.76 kΩ cm²) is slightly decreased compared to the corresponding value of the Al-Zn alloy, R_pol = 3.97 kΩ cm²), indicating a considerable reduction in the protective capability of the oxide layer on the Al-Zn-Sn alloy. It appears that the heterogeneous oxide film and pores formed on the Al-Zn-Sn alloy play a key role in reducing total resistance to the flow of electron at the alloy-electrolyte interface.

Abstract: This paper presents an investigation on microstructure and mechanical properties of welded AA 6061-T6 plate using filler metal ER 4043 in the Gas Metal Arc Welding (GMAW) process. Double pass welding technique on both sides of 5 mm thick plate or more is required to provide sufficient weld pool in the joint. The weld metal of the first welding pass exhibits finer microstructure than the second welding pass. The size of Mg₂Si precipitations in the heat-affected zone (HAZ) region is larger than in the base metal due to the welding process that reheats the alloy from the T6 condition above the eutectic temperature. Rapid cooling of the first pass and moderate cooling rate for the second pass during weld metal solidification eventually resulted in significantly change the shape and size in the microstructure that had affected the hardness and mechanical properties. Comparisons made to the base metal on the hardness test results found that the hardness of first pass weld metal dropped by 15%, and by 37.5% for the second weld metal, while the hardness at the boundaries of the first and second weld metals dropped by 32.5%. The ultimate tensile strength and strain of the weld joint with ER 4043 also decreased by 48% and 94% respectively. Based on the findings of the study, it is concluded that even though the double sided welding technique is able to overcome shallow weld penetration to avoid stress concentration that leads to the fatigue failure, the metallurgical changes eventually contributes to degradation of mechanical properties.

Abstract: The purpose of this study is to evaluate the effect of filler metals in the gas metal arc welding (GMAW) process on the Aluminium alloy of AA 6061-T6 welded joints. 6 mm thickness plate with single V butt configuration was used and welded using two different fillers ER 4043 and ER 5356 and controlled welding parameters. The relationship between hardness and microstructure of the welded parts were studied and compared and the results showed that the post weld mechanical property has decreased especially for the filler ER 5356. The hardness at the heat affected zone (HAZ) of ER 5356 also has reduced almost 85% compared to the hardness of AA 6061 base metal. The microstructure of ER 4043 welding material shows the shape of columnar grains and dendrite structure. Microstructure morphology of ER 5356 welding material shows dendrites and intermetallic particles (Mg2Si) have partially dissolved and scattered in the welding material.

Abstract: Electrochemical behaviour of cast Al-Zn alloys in natural chloride solution were investigated by potentiodynamic measurements and electrochemical impedance spectroscopy (EIS). Results from open circuit potential (OCP) measurement against immersion time showed a stable free corrosion process was achieved after 15 kiloseconds and alloys with more Sn contents had shifted OCP value towards more negative direction. Potentiodynamic polarisation curves showed that the corrosion potential (Ecorr) of aluminium alloys with Sn addition were much active compared to alloy without Sn. The anodic curves were characterized by no sign of passive current due active dissolution on the surface of the Al-Zn-Sn alloy. SEM images show that the presence of Sn in Al-Zn alloys produces better and uniform dissolution morphology. EIS results confirm that the presence of Sn is beneficial in improving anodic dissolution of Al-Zn alloys by reducing resistance to polarization (Rp). The presence of 0.1%wt. Sn in Al-Zn alloy has been found to be useful in activating electrochemical reaction at alloy-solution interface based on inductive loop in EIS diagram.