Mechanical Property Improvement in Dissimilar Friction Stir Welded Al5083/Al6061 Joints: Effects of Post-Weld Heat Treatment and Abnormal Grain Growth

The 5083 and 6061(T6) aluminum (Al) alloys are widely used in transportation industries and the development of structural designs because of their high toughness and high corrosion resistance. Friction stir welding (FSW) was performed to produce the dissimilar welded joint of Al5083-Al 6061(T6) under different welding parameters. However, softening behavior occurred in the friction stir welded (FSWed) samples because of grain coarsening or the dissolution of precipitation-hardening phases in the welding zone. Consequently, this research intended to investigate the effect of the post-weld heat treatment (PWHT) method on the mechanical property improvement of the dissimilar FSWed Al5083-Al6061(T6) and governing abnormal grain growth (AGG) through different welding parameters. The results showed PWHT enhanced the mechanical properties of dissimilar joints of Al5083-Al6061(T6). AGG was obtained in the microstructure of PWHTed joints, but appropriate PWHT could recover the dissolved precipitation-hardening particle in the heat-affected zone of the as-welded joint. Further, the tensile strength of the dissimilar joint increased from 181 MPa in the as-welded joint to 270 MPa in the PWHTed joint, showing 93% welding efficacy.     

New Graphene Composites for Power Engineering

Intensive research is underway worldwide to develop new conductive materials for applications in the power industry. Such tests aim to increase the electrical conductivity of materials for conductors and cables, thus increasing the current carrying capacity of the line and reducing the loss of electricity transmission. The scientific discovery of recent years, graphene, one of the allotropic types of carbon with very high electrical and thermal conductivity and mechanical strength, creates great opportunities for designing and producing new materials with above-standard operational properties. This project concentrates on developing technology for manufacturing aluminum-graphene and copper-graphene composites intended to be used to produce a new generation of power engineering conductors. In particular, we present the results of the research on the mechanical synthesis of aluminum-graphene and copper -graphene composites, as well as the results of the electric, mechanical, and structural properties of rods obtained after the extrusion process and wires after the drawing process.     

Self-Pierce Riveting of Three Thin Sheets of Aluminum Alloy A5052 and 980 MPa Steel

Self-pierce riveting of three thin sheets of 980 MPa steel and 5052 aluminum alloy was performed to investigate the effect of sheet configuration on the deforming behaviors of the sheets and the rivet and joint strength. When the lower sheet was aluminum alloy, the joining range was relatively wide, i.e., the interlock hooking the rivet leg tended to be large. In the sheet configuration in which the upper and lower sheets were A5052 and the middle sheet was 980 MPa steel, the rivet leg spread out moderately and the joint without defects was obtained. In the lower 980 MPa steel sheet, fracture tended to occur due to the low ductility of the lower sheet, and the joining range was narrow with the small interlock although the three sheets were joined by an appropriate die shape. In joint strength of joined three sheets, fracture occurred in the lower-strength aluminum alloy sheet if interlocks of about 300 μm and 150 μm could be formed in the lower aluminum alloy sheet and 980 MPa steel sheet, respectively.     

Tribological Behavior of Aluminum Hybrid Nanocomposites Reinforced with Alumina and Graphene Oxide

Due to rapid technological advancements, the demand for lightweight materials with improved tribo-mechanical properties is continuously growing. The development of composite materials is one of the routes taken by researchers to meet these target properties. Aluminum (Al) is one of the most suitable materials used for developing composites for a wide range of applications because of its light weight, high conductivity, and high specific strength. In this study, aluminum hybrid nanocomposites with alumina (10 Vol% Al₂O₃) and varying loadings of graphene oxide (0.25, 0.5 and 1 wt% GO) were fabricated using the spark plasma sintering technique. The tribological properties of the developed hybrid composites were evaluated by conducting ball-on-disk wear tests at a normal load of 3N, with a sliding speed of 0.1 m/s, and for a sliding distance of 100 m. A 440C hardened stainless steel ball with a diameter of 6.3 mm and a hardness of 62 RC was used as a counterface. Scanning electron microscopy (SEM), elemental X-ray dispersive analysis (EDS), and optical profilometry were used to ascertain the involved wear mechanisms. The results revealed that Al-10 Vol%Vol% Al₂O₃-0.25 wt% GO hybrid nanocomposite showed an increase of 48% in the hardness, a reduction of 55% in the specific wear rate, and a reduction of 5% in COF compared with pure aluminum.     

Bioconjugation Strategy for Ceramic Membranes Decorated with Candida Antarctica Lipase B—Impact of Immobilization Process on Material Features

A strategy for the bioconjugation of the enzyme Candida antarctica lipase B onto titania ceramic membranes with varied pore sizes (15, 50, 150, and 300 kDa) was successfully performed. The relationship between the membrane morphology, i.e.,the pore size of the ceramic support, and bioconjugation performance was considered. Owing to the dimension of the enzyme (~33 kDa), the morphology of the ceramics allowed (50, 150, and 300 kDa) or did not allow (15 kDa) the entrance of the enzyme molecules into the porous structure. Such a strategy made it possible to better understand the changes in the material (morphology) and physicochemical features (wettability, adhesiveness, and surface charge) of the samples, which were systematically examined. The silane functionalization and enzyme immobilization were accomplished via the covalent route. The samples were characterized after each stage of the modification, which was very informative from the material point of view. As a consequence of the modification, significant changes in the contact angle, roughness, adhesion, and zeta potential were observed. For instance, for the 50 kDa membrane, the contact angle increased from 29.1 ± 1.5° for the pristine sample to 72.3 ± 1.5° after silane attachment; subsequently, it was reduced to 57.2 ± 1.5° after the enzyme immobilization. Finally, the contact angle of the bioconjugated membrane used in the enzymatic process rose to 92.9 ± 1.5°. By roughness (S_q) controlling, the following amendments were noticed: for the pristine 50 kDa membrane, S_q = 1.87 ± 0.21 µm; after silanization, S_q = 2.33 ± 0.30 µm; after enzyme immobilization, S_q = 2.74 ± 0.26 µm; and eventually, after the enzymatic process, S_q = 2.37 ± 0.27 µm. The adhesion work of the 50 kDa samples was equal to 136.41 ± 2.20 mN m⁻¹ (pristine membrane), 94.93 ± 2.00 mN m⁻¹ (with silane), 112.24 ± 1.90 mN m⁻¹ (with silane and enzyme), and finally, 69.12 ± 1.40 mN m⁻¹ (after the enzymatic process). The materials and physicochemical features changed substantially, particularly after the application of the membrane in the enzymatic process. Moreover, the impact of ceramic material morphology on the zeta potential value is here presented for the first time. With an increase in the ceramic support cut-off, the amount of immobilized lipase rose, but the specific productivity was higher for membranes possessing smaller pores, owing to the higher grafting density. For the enzymatic process, two modes of accomplishment were selected, i.e., stirred-tank and cross-flow. The latter method was characterized by a much higher effectiveness, with a resulting productivity equal to 99.7 and 60.3 µmol h⁻¹ for the 300 and 15 kD membranes, respectively.     

Comparative Study on Electrical Conductivity of CeO2-Doped AlN Ceramics Sintered by Hot-Pressing and Spark Plasma Sintering

Aluminum nitride (AlN) ceramics were prepared by both Hot-pressing (HP) and Spark-Plasma-Sintering (SPS) using cerium oxide as the sintering aid. The characterization of AlN raw powder denoted the presence of an amorphous layer that led to the formation of aluminum oxide. During the sintering process, CeO₂ introduced as a sintering aid was reduced into Ce₂O₃. The latter reacted with aluminum oxide to form a transient liquid phase that promotes sintering by both HP and SPS. A reactional path leading to the formation of secondary phases, such as CeAlO₃ and CeAl₁₁O₁₈, has been proposed according to the pseudo-binary Al₂O₃ – Ce₂O₃. Ceramics obtained from HP and SPS are presented as similar, except for the secondary-phase distribution. The influences of secondary phase composition and distribution on electrical conductivity were evaluated by leakage current measurements. The mechanism of DC conduction and the global conductivity of ceramics were discussed according to the sintering process and the number of secondary phases.     

Revealing the Pb Whisker Growth Mechanism from Al-Alloy Surface and Morphological Dependency on Material Stress and Growth Environment

Spontaneous metallic Pb whisker formation from Pb and Bi containing Al-alloy’s surfaces is a newly discovered phenomenon. The whiskers display unique formations, growth and morphology, which give the opportunity to be applied for specialized sensor and electronics applications. Within this work, the impact of environmental conditions (gas composition and moisture) is investigated and correlated with the modification of whisker evolution and growth dynamics. Furthermore, the residual stress state of the aluminum matrix using deep cryogenic treatment is modified and used to further increase whisker nucleation and growth by up to three- and seven-fold, respectively, supported by quantitative results. The results of this paper indicate the possibility to manipulate the whisker not only in terms of their kinetics but also their morphology (optimal conditions are 20% O₂ and 35% humidity). Such features allow the tailoring of the whisker structure and surface to volume ratio, which can be optimized for different applications. Finally, this research provides new insight into the growth dynamics of the whiskers through in situ and ex situ measurements, providing further evidence of the complex nucleation and growth mechanisms that dictate the spontaneous growth of Pb whiskers from Al-alloy 6026 surfaces with growth velocities up to 1.15 µm/s.     

Research on Microstructure and Properties of AlSi10Mg Fabricated by Selective Laser Melting

In order to obtain high-performance aluminum alloy parts fabricated by selective laser melting, this paper investigates the relationship between the process parameters and microstructure properties of AlSi10Mg. The appropriate process parameters are obtained: the layer thickness is 0.03 mm, the laser power is 370 W, the scanning speed is 1454 mm/s, and the hatch spacing is 0.16 mm. With these process parameters, the ultimate tensile strength of the as-printed status is 500.7 ± 0.8 MPa, the yield strength is 311.5 ± 5.9 MPa, the elongation is 7.7 ± 0.5%, and the relative density is 99.94%. After annealing treatment at 275 °C for 2 h, the ultimate tensile strength is 310.8 ± 1.3 MPa, the yield strength is 198.0 ± 2.0 MPa, and the elongation is 13.7 ± 0.6%. The mechanical properties are mainly due to the high relative density, supersaturate solid solution, and fine dispersed Si. The supersaturate solid solution and nano-sized Si formed by the high cooling rate of SLM. After annealing treatment, the Si have been granulated and grown significantly. The ultimate tensile strength and yield strength are reduced, and the elongation is significantly improved.     

Experimental and Molecular Dynamics Simulation Study on Sol–Gel Conversion Process of Aluminum Carboxylate System

Due to the lack of relevant in situ characterization techniques, the investigation of aluminum sol–gel progress is lacking. In this study, combined with molecular dynamics simulation and conventional experimental methods, the microstructures, rheological properties, and gelation process of the carboxylic aluminum sol system were studied. The experimental results showed that, with the increase in solid content, the microstructure of the colloid developed from a loose and porous framework to a homogeneous and compact structure. The viscosity of aluminum sol decreased significantly with the increase in temperature, and a temperature above 318 k was more conducive to improving the fluidity. The simulation results show that the increase in free volume and the connectivity of pores in colloidal framework structure were the key factors to improve fluidity. In addition, free water molecules had a higher migration rate, which could assist the rotation and rearrangement of macromolecular chains and also played an essential role in improving fluidity. The Molecular dynamics simulation (MD) results were consistent with experimental results and broaden the scope of experimental research, providing necessary theoretical guidance for enhancing the spinning properties of aluminum sol.     

Laser Powder-Bed Fusion of Ceramic Particulate Reinforced Aluminum Alloys: A Review

Aluminum (Al) and its alloys are the second most used materials spanning industrial applications in automotive, aircraft and aerospace industries. To comply with the industrial demand for high-performance aluminum alloys with superb mechanical properties, one promising approach is reinforcement with ceramic particulates. Laser powder-bed fusion (LPBF) of Al alloy powders provides vast freedom in design and allows fabrication of aluminum matrix composites with significant grain refinement and textureless microstructure. This review paper evaluates the trends in in situ and ex situ reinforcement of aluminum alloys by ceramic particulates, while analyzing their effect on the material properties and process parameters. The current research efforts are mainly directed toward additives for grain refinement to improve the mechanical performance of the printed parts. Reinforcing additives has been demonstrated as a promising perspective for the industrialization of Al-based composites produced via laser powder-bed fusion technique. In this review, attention is mainly paid to borides (TiB₂, LaB₆, CaB₆), carbides (TiC, SiC), nitrides (TiN, Si₃N₄, BN, AlN), hybrid additives and their effect on the densification, grain refinement and mechanical behavior of the LPBF-produced composites.