Influence of Al2O3 particles on the microstructure and mechanical properties of copper surface composites fabricated by friction stir processing

The influence of three factors, such as volume percentage of reinforcement particles (i.e. Al₂O₃), tool tilt angle and concave angle of shoulder, on the mechanical properties of Cu–Al₂O₃ surface composites fabricated via friction stir processing was studied. Taguchi method was used to optimize these factors for maximizing the mechanical properties of surface composites. The fabricated surface composites were examined by optical microscope for dispersion of reinforcement particles. It was found that Al₂O₃ particles are uniformly dispersed in the stir zone. The tensile properties of the surface composites increased with the increase in the volume percentage of the Al₂O₃ reinforcement particles. This is due to the addition of the reinforcement particles which increases the temperature of recrystallization by pinning the grain boundaries of the copper matrix and blocking the movement of the dislocations. The observed mechanical properties are correlated with microstructure and fracture features.     

Influence of yttrium on microstructure and properties of Ni–Al alloy coatings prepared by laser cladding

Ni–Al alloy coatings with different Y additions are prepared on 45^# medium steel by laser cladding. The influence of Y contents on the microstructure and properties of Ni–Al alloy coatings is investigated using X-ray diffraction, scanning electron microscopy, electron probe microanalyzer, Vickers hardness tester, friction wear testing machine, and thermal analyzer. The results show that the cladding layers are mainly composed of NiAl dendrites, and the dendrites are gradually refined with the increase in Y additions. The purification effect of Y can effectively prevent Al₂O₃ oxide from forming. However, when the atomic percent of Y addition exceeds 1.5%, the extra Y addition will react with O to form Y₂O₃ oxide, even to form Al₅Y₃O₁₂ oxide, depending on the amount of Y added. The Y addition in a range of 1.5–3.5 at.% reduces the hardness and anti-attrition of cladding layer, but improves obviously its wear and oxidation resistances.     

Experimental and numerical investigations of interface properties of Ti6Al4V/CP-Ti/Copper composite plate prepared by explosive welding

Explosive welding technique is widely used in many industries. This technique is useful to weld different kinds of metal alloys that are not easily welded by any other welding methods. Interlayer plays an important role to improve the welding quality and control energy loss during the collision process. In this paper, the Ti6Al4V plate was welded with a copper plate in the presence of a commercially pure titanium interlayer. Microstructure details of welded composite plate were observed through optical and scanning electron microscope. Interlayer-base plate interface morphology showed a wavy structure with solid melted regions inside the vortices. Moreover, the energy dispersive spectroscopy analysis in the interlayer-base interface reveals that there are some identified regions of different kinds of chemical equilibrium phases of Cu–Ti, i.e. CuTi, Cu₂Ti, CuTi₂, Cu₄Ti, etc. To study the mechanical properties of composite plates, mechanical tests were conducted, including the tensile test, bending test, shear test and Vickers hardness test. Numerical simulation of explosive welding process was performed with coupled Smooth Particle Hydrodynamic method, Euler and Arbitrary Lagrangian-Eulerian method. The multi-physics process of explosive welding, including detonation, jetting and interface morphology, was observed with simulation. Moreover, simulated plastic strain, temperature and pressure profiles were analysed to understand the welding conditions. Simulated results show that the interlayer base plate interface was created due to the high plastic deformation and localized melting of the parent plates. At the collision point, both alloys behave like fluids, resulting in the formation of a wavy morphology with vortices, which is in good agreement with the experimental results.     

Dissimilar friction stir spot welding of AA2024-T3/AA7075-T6 aluminum alloys under different welding parameters and media

This paper studies the friction stir spot welding of AA2024-T3/AA7075-T6 Al alloys in the ambient and underwater environments by clarifying the nugget features,microstructure,fracture and mechanical properties of the joints.The results show that the water-cooling medium exhibits a significant heat absorption capacity in the AA2024-T3/AA7075-T6 welded joint.Nugget features such as stir zone width,circular imprints,average grain sizes,and angular inter-material hooking are reduced by the water-cooling effect in the joints.Narrower whitish(intercalated structures)bands are formed in the under-water joints while Mg2Si and Al2CuMg precipitates are formed in the ambient and the underwater welded joints respectively.An increase in tool rotational speed(600-1400 rpm)and plunge depth(0.1-0.5 mm)increases the tensile-shear force of the welded AA2024-T3/AA7075-T6 joints in both the ambient and underwater environments.The maximum tensile-shear forces of 5900 N and 6700 N were obtained in the ambient and the underwater welds respectively.     

Influence of magnetically constricted arc traverse speed (MCATS) on tensile properties and microstructural characteristics of welded Inconel 718 alloy sheets

The magnetically constricted arc technique was implemented to mitigate the heat input related metal-lurgical problems in Gas Tungsten Arc Welding (GTAW) of Inconel 718 alloy particularly Nb segregation and subsequent laves phase evolution in fusion zone. This paper reports the direct effect of magnetically constricted arc traverse speed (MCATS) on bead profile, tensile properties and microstructural evolution of Inconel 718 alloy sheets joined by Gas Tungsten Constricted Arc Welding (GTCAW) process. The mechanism amenable for the microstructural modification and corresponding influence on the tensile properties of joints is investigated both in qualitative and quantitative manner related to the mechanics of arc constriction and pulsing. It is correlated to the solidification conditions during welding. The relationship between MCATS and Arc Constriction Current (ACC) was derived. Its interaction effect on the magnetic arc constriction and joint performance was analysed. Results showed that the joints fabricated using CATS of 70 mm/min exhibited superior tensile properties (98.39% of base metal strength with 31.50% elongation). It is attributed to the grain refinement in fusion zone microstructure leading to the evolution of finer, discrete laves phase in interdendritic areas.     

Microstructural characterization of silicon carbide reinforced dissimilar grade aluminium explosive clads

Aluminium composites are inevitable in ship building, commercial and defence aircrafts construction due to their light weight, high strength to weight ratio, admirable properties and cost affordability. In this study, the microstructural characteristics of explosive cladded dissimilar grade aluminium (Al 1100-A1 5052) clad composites reinforced with silicon carbide (SiC) particles is presented. Microstructure taken at the interface by optical and scanning electron microscopes (SEM) revealed the formation of a silicon carbide layer between the dissimilar grade aluminium sheets. Though reaction layers were witnessed at few locations along the interface, the diffusion of atoms between the participant metals is not visible as confirmed by energy dispersive spectroscopy, elemental mapping, line analysis and X-ray diffraction (XRD). The variation in microhardness at various regions of the silicon carbide reinforced dissimilar aluminium explosive clad is reported. The increase in tensile strength of the SiC laced clad is also presented.     

Multifunctional A356 alloy/ PKSAnp composites: Microstructure and mechanical properties

Mechanical properties and microstructure of multifunctional composites produced with palm kernel shell ash nanoparticle (PKSAnp)-A356 alloy composites was studied. The composites were produced using Double layer feeding stir casting method (DLF-SCM) by adding 1 wt%‒4 wt.% PKSAnp. The microstructure, density, electrical and mechanical properties were determined. The results shows that there was a uniform distribution of the PKSAnp in A356 alloy. The mismatch at the interface between the PKSAnp and A356 alloy was 4.26%. Improvement of 30.47%, 41.91%, 49.52%, 40.90% and 65.09% were obtained for hardness values, tensile, yield strength, %elongation and impact energy at 4 wt% PKASnp. The work has established that the developed composites can be used for multifunctional applications where combination of toughness and strength is vital.     

Effect of silicon carbide and wire-mesh reinforcements in dissimilar grade aluminium explosive clad composites

Aluminium composites are inevitable in the manufacture of aircraft structural elements owing to less weight, superior corrosion resistance and higher specific properties. These composites reduce the weight of the aircraft, improve the fuel efficiency and enhance the maintenance duration. This study proposes the development of dissimilar grade aluminium (aluminium 1100-aluminium 5052) composites with different reinforcement’s viz., stainless steel wire-mesh, silicon carbide (SiC) powders and SiC powder interspersed wire-mesh, by explosive cladding technique. Wire-mesh enhances the friction and restricts the movement of flyer plate to craft a defect free clad, while SiC particles form a band on the interface. Highest strength is obtained when SiC powder interspersed wire mesh is employed as reinforcement. The dissimilar aluminium explosive clad with SiC particle reinforcement results in lower strength, which is higher than that of the weaker parent alloy and that of the conventional dissimilar aluminium explosive clads without any reinforcement.     

Effect of microstructure on short pulse duration shock initiation of TATB and initial response mechanism

Micro-TATB particles with different sizes and 3D nanoporous TATB architectures with different specific surface areas were prepared through recrystallization to study short pulse duration shock initiation properties by electric gun technology. For micro-TATB, the initiation threshold significantly decreases with TATB average size ranging from 79.7 μm to 0.5 μm. For 3D nanoporous TATB architecture, the initiation threshold decreases and then increases with specific surface areas increased from 9.6 m²/g to 36.2 m²/g. The lowest initiation thresholds are obtained for the micro-TATB with average sizes of 1.3 μm and 0.5 μm, and 3D nanoporous TATB architecture with specific surface area of 22.4 m²/g. The shock initiation thresholds of micro-TATB and 3D nanoporous TATB architectures show significantly decreases with the porosity increased. The decomposition reaction and thermal conductivity properties were further investigated to understand the initial response mechanism. High porosity provides more collapse sites to generate high temperature for formation of hot spots. The low thermal conductivity and decomposition temperature could enhance the formation and ignition of the hot spots, and initial decomposition reaction of TATB. The effect of the decomposition temperature is higher than that of the thermal conductivity on the shock initiation properties. The enhanced decomposition reaction could promote energy release and transfer process from the ignition to the combustion. This work offers a new insight to understand the effects of microstructure on the shock initiation properties and the initial response mechanism of TATB.