Square and circular tubes were tested experimentally and numerically in quasi-static three-point bending. A finite element model with failure criterion was developed that correlated well with the experimental results and provided accurate simulation of top surface failure of the tubes. The model was used to conduct a parametric study of the effects of common cross-section shapes, with or without rib reinforcements, on dynamic bending performance. Results showed the reinforced shapes had higher specific energy absorption (SEA). The highest SEA was obtained for a square tube with internal parabolic shaped rib, but this was the only shape that suffered catastrophic failure.

Parametric study of the cross-section shape of aluminium tubes in dynamic three-point bending

The final builds with multiple layers for a non-age-hardenable aluminum alloy were successfully fabricated under different rotation speeds using friction extrusion additive manufacturing, a force-controlled friction-based additive manufacturing process that allows the free design of the deposition path. The single layer thickness increased from 1.7 mm to 3.0 mm when the rotation speed was reduced from 800 r/min to 400 r/min for a given layer thickness of 4 mm. The grain size at the interface was refined to 3.8–5.0 μm at 800 r/min because less recrystallization occurred, resulting in a higher geometrically necessary dislocations density. The grains formed at the interface at 800 r/min were mainly determined by recrystallization textures Cube, Cube RD , and Cube ND and deformation texture S. However, a stronger coupling effect between heat and plastic deformation at 600 r/min leads to the dominance of shear textures B / B ¯ and RtCu and deformation textures S. The final deposits superior to the wrought Al alloy 5083-H112 in terms of tensile properties were obtained at 600 r/min due to the largest contribution of grain refinement strengthening. Grain refinement increases strength at the interface and interlayer by 113.1 MPa and 92.1 MPa, respectively. The tensile strength, yield strength, and elongation at break in the Z direction reach 290.2 MPa, 163.3 MPa, and 12.6%, respectively. Due to the existence of kissing bonding at 800 rpm, the value of the elongation at break in the Z direction is only 19% of the value in the X direction. • Rotation speed detrmines layer thickness of additively manufactured Al 5083. • Shear textures governed the interface without defects at lower rotation speed. • A strength prediction model was developed for additively manufactured Al 5083. • Al 5083 with wrought like properties obtained under higher deposition rate. 

Effect of rotation speed on microstructure and mechanical anisotropy of Al-5083 alloy builds fabricated by friction extrusion additive manufacturing

Enhancing tensile properties of MIG welded AA6061 joints: Effect of pulse mode and post-weld heat treatment

Insufficient performance, especially at high temperatures, limits the extensive application of cast Al–Cu alloys. This study proposes a novel method of direct reaction synthesis (DRS) for the simultaneous synthesis and dispersion of hybrid-sized in situ TiC–TiB2 particles in the melt to prepare a trace-particle-reinforced high-performance cast Al–Cu5.5–Mn0.45–Ti0.3–V0.3–Cr0.2–Zr0.14–B0.04 alloy. The particulate-reinforced alloy achieved strength–ductility synergetic enhancement at room and high temperatures. In comparison to the Al–Cu matrix alloy, the yield strength of 0.7 wt% (TiC–TiB2)/Al–Cu alloy at 298 K (529 MPa), 493 K (214 MPa), and 533 K (183 MPa) had an increase of 28%, 18% and 35%, meanwhile their elongation increased by 4%, 50% and 62%, respectively. The yield strength enhancement primarily benefited from the thermal mismatch between the particles and matrix, and Orowan strengthening. The strength–ductility performance improvement is due to the optimization of the microstructure: significantly refined α-Al grains with smaller and more dispersed θʹ precipitates. Further, the improvement mechanism of the microstructure is due to the action of the nanoparticles on the heterogeneous nucleation stimulation and dendrite growth inhibition of α-Al during the solidification process. Meanwhile, the segregation of the Cu atoms was inhibited by the particles. The precipitation was significantly promoted because of more uniformly distributed Cu atoms, and more defects induced by particles improved diffusion of the Cu atoms the number and density of the precipitation sites. The results of this study provide an economical and accessible synthesis strategy for industrial manufacturing. 

Novel method to achieve synergetic strength–ductility improvement of Al–Cu alloy by in situ TiC–TiB2 particles via direct reaction synthesis

Influence of rotation speed on interfacial bonding mechanism and mechanical performance of aluminum 6061 fabricated by multilayer friction-based additive manufacturing

Microstructural heterogeneity and bonding strength of planar interface formed in additive manufacturing of Al−Mg−Si alloy based on friction and extrusion

Microstructure heterogeneity and mechanical properties of Mg-Gd-Y-Zr alloy fabricated by force-controlled additive friction stir deposition

In order to investigate the microstructure evolution, texture features, and strengthening mechanisms at different positions in the welding nugget zone (WNZ) of thick-plate joints in depth, stationary shoulder friction stir welding (SSFSW) tests were conducted on a 12-mm thick 2195-T8 Al–Li alloy with rotating speeds of 300–500 rpm. At 300 rpm, the results demonstrate that WNZ is mostly made up of equiaxed grains orientated in <111> and <101>//TD, with a homogeneous grain size distribution along the plate thickness. In contrast, at 500 rpm, the crystal orientations convert to <001> and <101>//TD, and the grain size at the bottom of WNZ reaches only 39.3% of that at the top. At 300 rpm, WNZ is predominantly composed of shear textures and remains a large number of needle-like precipitates T1 and θ′, both of which contribute to the improvement in mechanical properties. The weld zone exhibits higher microhardness and tensile strength along the plate thickness at a lower rotating speed, retaining a high level within 8 mm from the weld surface but gradually decreasing from 8 to 12 mm as the rotating speed increases. In addition, the strengthening mechanism of the whole WNZ is dominated by precipitation strengthening at 300 rpm, which is replaced by dislocation strengthening at 400 rpm. As the rotating speed increases to 500 rpm, grain refinement strengthening takes over as the dominant strengthening mechanism in the WNZ. 

Texture features and strengthening mechanisms in welding nugget zone of SSFSWed thick-plate Al–Li alloy joint

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