Papers by Keyword: Aluminium Alloy

Abstract: Friction Stir Processing (FSP) is an advanced solid-state surface modification technique used to enhance the microstructural and mechanical behavior of metallic materials, particularly aluminum alloys. Recently, High-Entropy Alloys (HEAs) have emerged as promising reinforcement materials due to their high strength, thermal stability, and corrosion resistance. Although multiple studies have explored FSP with conventional reinforcements, the integration of HEAs into the stir zone remains limited. This study examines the influence of tool geometry, processing parameters, and reinforcement strategies in FSP while evaluating the feasibility of incorporating HEAs into aluminum matrices. The role of finite element analysis (FEA) in predicting temperature distribution, material flow, and stress evolution is also discussed. The study identifies research gaps and emphasizes the need for experimental validation of HEA-reinforced FSP systems to develop high-performance aluminum-based surface composites.

Abstract: Tungsten Inert Gas Welding (TIG) is a welding process that has low weld penetration and low heat intensity of the electric arc. This affects the low productivity of processes. To overcome this drawback, Activated Tungsten Inert Gas Welding has been developed. This study investigates Al-7 series plates using the A-TIG welding process. Different kinds of fluxes, TiO2 and Al2O3 are used with a ratio of 1:1 mixture of both these powders. This mixture was applied on Al-7075 plates to enhance weld characteristics. Activated flux has been used to improve the weld depth. The effects of various process parameters (welding current (I), welding speed(V), and gas flow rate were analysed and compared with the TIG welding method. Activated Tungsten Inert Gas (A-TIG) welding canincrease the joint penetration and weld depth width ratio compared to conventional TIG welding. The main objective of this work is to enhance weld penetration, improve mechanical properties (tensile strength and elongation), and assess metallurgical changes in Al-7075 joints using A-TIG welding with TiO₂ and Al₂O₃ mixed fluxes.

Abstract: This study investigates plantain peduncle extract as a green corrosion inhibitor for AA6063 aluminium alloy in 1M NaCl using electrochemical techniques (OCP, LSV, Tafel analysis). Extract concentrations were tested at 30–50°C. Results showed concentration-dependent inhibition, with (0.3 ml) achieving maximum efficiency: 85.48% (30°C), 88.00% (40°C), and 89.92% (50°C). Tafel data confirmed reduced corrosion rates (0.18–0.13 mm/yr vs. control: 1.24–1.29 mm/yr) and increased polarization resistance (1.71–2.34 kΩ·cm² vs. control: 0.247 kΩ·cm²). OCP/LSV curves demonstrated cathodic potential shifts and suppressed current densities, indicating mixed-type inhibition. Langmuir isotherm analysis (R² > 0.994) confirmed monolayer adsorption, with ΔG_ads values (−64.32 kJ/mol at 30°C) suggesting chemisorption dominance. Optical micrographs revealed reduced corrosion with inhibitor concentration, though isolated pitting persisted. Empirical optimization (ANOVA) identified 0.144 ml at 30.1°C as optimal for minimal corrosion rate (0.21 mm/yr).

Abstract: In this study, the Al₂O₃ round bar and Al-Si12CuNi (AC8A) round bar were joined by friction welding. AC8A is a typical piston material treated by the heat treatment T6. The parameters of the joining condition are friction time and upset pressure. SEM observed the microstructure at the interface region of joined materials. 1) Judging from these photographs, the damages to the microstructures at the interface region of joined materials by upset pressure are more significant than those caused by friction time. 2) The relationship between the joint conditions and mechanical characteristics from three points of bending test results for the joint material specimens. 3) The residual stresses around the interface were measured by the Raman spectroscopy method. There is a possibility that the friction welding conditions are correlated to the residual stresses.

Abstract: Titanium Nitride coating has attracted much interest in increasing the hardness of aluminum alloys. This study aims to investigate the effect of Ar: N gas mixture and time on increasing the hardness of aluminum alloys using DC sputtering. Preparation of TiN thin films on aluminum alloy substrates using flowing gas mixture parameters and time. First, the layer of TiN was deposited on the sample with a gas mixture of 90Ar:10N; 80Ar:20N; 70Ar:30N; and 60Ar:40N (%) for 60 minutes. Then the optimum gas mixture that produces the highest surface hardness is used in the second process with time variations of 30, 60, 90, and 120 minutes. The results showed that the highest hardness was achieved in a gas mixture of 70Ar:30N and 60 minutes. The TiN phase formed on the aluminum surface was identified by XRD, while the surface morphology was observed by SEM. Compared with untreated samples, the hardness of treated samples increased significantly.

Abstract: The present investigation focuses on the implementation of the multi-axial forging process, recognized as a severe plastic deformation (SPD) technique, with the aim of elevating the mechanical features of the widely employed Al 6061 alloy. Specifically utilized in the automotive and aviation industries, this alloy's behavior was meticulously examined through a series of quasi-static and dynamic tests. To achieve this objective, the multi-directional forging (MDF) process was implemented for up to three cycles, involving a total of nine passes, at a raised temperature of 200 °C. Subsequently, the severely deformed material underwent utilizing high strain rate loading for the Split Hopkinson Pressure Bar (SHPB) test system. After MDF, the grain size is refined down to below 11 microns with a starting grain size of 13 microns. This is reflected as increased hardness and yield strength in the quasi-static regime. For SHPB characterization, increased dynamic strength is also observed. However, although the yield strength showed about 60% increase with decent ductility, the maximum dynamic strength increased about 10% after SPD with a relatively brittle behavior.

Abstract: In high strength aluminium alloy material turning operation, high material removal and good surface are desirable output characteristics. In this investigation, experiments were conducted according to design of experiments concept with a combination of turning input parameters such as cutting speed, feed rate and depth of cut and also studied the effect of process parameters on multi outputs for machining of Al2024 aluminium alloy. Grey relation analysis was applied to know the robust process parameters. The contribution each parameter was realized with analysis of variance statistical method. The cutting speed is the most influencing parameter with contribution of 62.3% followed by depth of cut with 26.4%, and feed rate with 9.9%.

Abstract: Aluminium and its alloys are becoming more widely used in engineering due to a growing need for lightweight metals. However, owing to boundary segregation and coarse dendritic grains, typical cast aluminium alloys have low hardness and strength, limiting their use in large-scale and complex-shaped applications. Many studies have shown that reinforcing aluminium alloy with nanoparticles synthesized by various chemical and physical ways improves these shortcomings, but these approaches are both expensive and potentially dangerous. Recycling aluminium scrap is also necessary to save energy and money. Therefore, this research aimed at production of high tensile strength and hardness from scrapped aluminium reinforced with synthetic nano particle and subjected to heat treatment. The elemental composition of aluminium alloy cast from scrap was analyzed using a Light Emission Polyvac Spectrometer, and gold nanoparticles were synthesized from aloe vera leaves. In creating a Metal Matrix Nano Composite, Al alloy was reinforced with gold nanoparticles at various percentages. At 450 °C, the reinforced Metal Matrix Nano Composite was hardened. The composites' hardness, tensile strength, and microstructural analyses were determined. The composites' grain structure demonstrated a uniform distribution of reinforcing phase of Al 6063 Alloy. The microhardness and tensile strength of the composites are influenced by the % weight proportion of AuNps and the heat treatment. After 3 percent and 6 percent weight of AuNps reinforcement were used, the microhardness/tensile strength of the reinforced sample rose by 22.4 Hv/58MPa and 24.7 Hv/80MPa, respectively, but when the composites were hardened, it climbed to 41 Hv/109 MPa and 45.5 Hv/125 MPa. After 3 percent and 6 percent weight of AuNps reinforcement were used, the microhardness/tensile strength of the reinforced sample rose by 22.4 Hv/58MPa and 24.7 Hv/80MPa, respectively, but when the composites were hardened, it climbed to 41 Hv/109 MPa and 45.5 Hv/125 MPa.

Abstract: The aluminum 5754 alloy is one of the widely used engineering materials in shipping, rivet making, tread plates and automotive industries. These engineering structures envisage variable loading conditions during their service. In addition to it, it is also experiencing seismic vibrations. Hence, the engineering components made from such aluminum alloy are susceptible to fatigue fracture. In the current study, the prediction of fatigue crack growth (FCG) in 5754 aluminum alloy was made using the exponential function. The beam specimen comes up with a cross-section of 25X25 mm², a span length of 300 mm with a mechanical notch length of 2.70 mm at the centre was subjected to four-point bending (FPB) employing hydraulic INSTRON 8800 tensile testing apparatus. The periodic loading condition deformed the material up to large plastic deformation. The applied load was further down the elasticity of the material. The experimental data provided the relation between crack length (a) to the number of cycles (N) to failure. The response surface methodology (RSM) and modified exponential equation were used to predict the FCG. In RSM, when “stress intensity factor (K)” and “number of the cycle (N)" were considered independent variables, the response (a) was optimum (maximum) as compared to when “stress intensity factor range (del K)” and “fatigue crack growth rate (da/dN)” were considered independent variables. Hence, for designing the aluminum 5754 alloys as engineering structures, it was the number of cycles which provides a safe design as compared to da/dN. The modified exponential equation using an exponential function predicted the FCG for aluminum 5754 alloy in the form of a beam specimen. The anticipated results agreed with experimental data as the prediction ratio was 1.20 and the % deviation was 3.7.

Abstract: This work presents a comparative finite element analysis of a 3-wheeler novel robot chassis used for uneven terrain robot applications. The chassis was modeled using SolidWorks and further analyzed in Ansys for its total deformation, equivalent stress, equivalent elastic strain and thermal strain. Two materials were taken into consideration for comparative analysis: Aluminium alloy and Structural steel. A load (force) of 500 N was distributed on the chassis uniformly and an acceleration of 5 mm/sec² was given. Thermal conditions were added by raising the temperature from 22°C to 50°C in 1 sec. The analysis performed was majorly divided into three parts: a) Only considering force, b) Considering force as well as acceleration, c) Considering force, acceleration and thermal conditions. Total deformation in Aluminium alloy was observed 1.51 to 2.79 times that of structural steel in all the cases. Both metals exhibited almost identical equivalent stress in absence of thermal effect and structural steel exhibit 1.5 times that of Aluminium alloy at elevated temperature. Aluminium alloy possess relatively more (1.86-2.63 times) equivalent elastic strain compared to structural steel. Although, distribution of thermal strain remained constant throughout the chassis for both the materials, its magnitude was 1.91 times high in Aluminium alloy. This type of analysis helps in evaluating the current design and decide whether it will sustain the required load and acceleration under given thermal conditions