Magnesium and aluminum alloys continually attract interest as lightweight structural materials for transport applications. However, joining these dissimilar alloys is very challenging. The main obstacle that hinders p...Magnesium and aluminum alloys continually attract interest as lightweight structural materials for transport applications. However, joining these dissimilar alloys is very challenging. The main obstacle that hinders progress in dissimilar Mg-Al joining is the formation of brittle intermetallic compounds(IMCs). As a solid-state joining technique, FSW is an excellent candidate to attenuate the deleterious IMC effects in dissimilar Al-Mg joining due to the inherent low heat inputs involved in the process. However, the IMCs, namely Al_(3)Mg_(2) and Al_(12)Mg_(17) phases, have also been reported to form during Al-Mg dissimilar FSW;their amount and thickness depend on the heat input involved;thus,the weld parameters used. Since the heat dissipated in the material during the welding process significantly affects the amount of IMCs,the heat input during FSW should be kept as low as possible to control and reduce the amount of IMCs. This review aims to critically discuss and evaluate the studies conducted in the dissimilar Al/Mg FSW through a scientometric analysis and also with a focus on the strategies recently applied to enhance joint quality. The scientometric analysis showed that the main research directions in Mg/Al FSW are the technological weldability of aluminum and magnesium during FSW, structural morphology, and mechanical properties of dissimilar welded joints. Considering the scope of application of the aforementioned joints, the low share of articles dealing with environmental degradation and operational cracking is surprising. This might be attributed to the need for well-developed strategies for obtaining high-quality and sustainable joints for applications. Thus, the second part of this review is conventional, focusing mainly on the new strategies for obtaining high-quality Mg/Al joints. It can be concluded that in addition to the necessity to optimum welding parameters to suppress the excessive heat to limit the amount and thickness of IMC formed and improve the overall joint quality, strategies such as using Zn interlayer, electric current assisted FSW(EAFSW), ultrasonic vibration FSW(UVa FSW), are considered effective in the elimination, reduction, and fragmentation of the brittle IMCs.展开更多
Alumina-iron nanocomposite powders were prepared by a two-step process. In the first step, α-Al2O3-FeCl2 powder mixture was formed by mixing α-Al2O3 powders with FeCl2 solution followed by drying. In the second step...Alumina-iron nanocomposite powders were prepared by a two-step process. In the first step, α-Al2O3-FeCl2 powder mixture was formed by mixing α-Al2O3 powders with FeCl2 solution followed by drying. In the second step, the FeCl2 in the dry power mixture was selectively reduced to iron particles. A reduction temperature of 750℃ for 15 min in dry H2 was chosen based on the thermodynamic calculations. The concentration of iron in FeCl2 solution was calculated to be 20 vol. pct in the final composite. Two techniques were used to produce composite bulk materials. The Al2O3 nanocomposite powders were divided to two batches. The first batch of the produced mixture was hot pressed at 1400℃ and 27 MPa for 30 min in a graphite die. To study the effect of oxygen on the Al2O3/Fe interface bonding and mechanical properties of the composite, the second batch was heat treated in air at 700℃ for 20 min to partially oxidize the iron particles before hot pressing. Characterization of the composites was undertaken by conventional density measurements, X-ray diffractometry （XRD）, scanning electron microscopy （SEM）, transmission electron microscopy （TEM） and electron probe micro analysis （EPMA）. The suggested processing route （mixing, reduction and hot pressing） produces ceramic-metal nanocomposite much tougher than the pure Al2O3. The fracture strength of the produced Al2O3/Fe nanocomposite is nearly twice that of the pure Al2O3. The presence of spinel phase, FeAl204, as thick layer around the Fe particles in the Al2O3 matrix has a detrimental effect on interfacial bonding between Fe and AI203 and the fracture properties of the composite.展开更多
The incorporation of graphite particles into AA6016 aluminum alloy matrix to fabricate metal/ceramic composites is still a great challenge and various parameters should be considered. In this study, dense AA6016 alumi...The incorporation of graphite particles into AA6016 aluminum alloy matrix to fabricate metal/ceramic composites is still a great challenge and various parameters should be considered. In this study, dense AA6016 aluminum alloy/（0-20 wt%） graphite composites have successfully been fabricated by powder metallurgy process. At first, the mixed aluminum and graphite powders were cold compacted at 200 MPa and then sintered at 500 ℃ for 1 h followed by hot extrusion at 450 ℃. The influence of ceramic phases（free graphite and in-situ formed carbides） on microstructure, physical and mechanical properties of the produced composites were finally investigated. The results show that the fabricated composites have a relative density of over 98%. SEM observations indicate that the graphite has a good dispersion in the alloy matrix even at high graphite content. Hardness of all the produced composites was higher than that of aluminum alloy matrix. No cracks were observed at strain less than 23% for all hot extruded materials.Compressive strength, reduction in height, ultimate tensile stress, fracture stress, yield stress, and fracture strain of all Al/graphite composites were determined by high precision second order equations. Both compressive and ultimate tensile strengths have been correlated to microstructure constituents with focusing on the in-situ formed ceramic phases, silicon carbide（SiC） and aluminum carbide（Al4 C3）. The ductile fracture mode of the produced composites became less dominant with increasing free graphite content and in-situ formed carbides. Wear resistance of Al/graphite composites was increased with increasing graphite content. Aluminum/20 wt% graphite composite exhibited superior wear resistance over that of AA6016 aluminum alloy.展开更多
In addition to the advantage of the lightweight of magnesium alloys, magnesium composites have moderate strength and elastic modulus. The proposed application of magnesium composites as diesel truck pistons makes it n...In addition to the advantage of the lightweight of magnesium alloys, magnesium composites have moderate strength and elastic modulus. The proposed application of magnesium composites as diesel truck pistons makes it necessary to assess their wear performance. Little research data have been discussed on wear behavior of Mg alloy AE42 matrix and its composites. Thus, this paper reports wear behavior of magnesium alloy AE42(Mg–Al–Mn—RE; rare earth) and its composite AE42-C, which contains 23 vol% of randomly oriented carbon short fibers. Materials characterization, including density measurements, hardness testing, microstructures investigation, and compression testing at temperatures of 25, 150,and 300 °C, were conducted. Wear tests were performed under various loads and sliding distances. Wear mechanisms were also proposed based on the examination of worn surfaces using optical microscopy and scanning electron microscopy equipped with EDX(energy-dispersive X-ray spectrometry) analysis system. The hardness of AE42-23 vol% C composite is twice the hardness of the Mg matrix alloy AE42. Significant improvements to yield stress and compressive strength at temperatures of 25, 150, and 300 °C of the composite versus the AE42 alloy are achieved. Wear resistance of the composite is improved considerably versus that of the Mg alloy AE42 at the various sliding distances. Smearing of graphite on the worn surface produces a lubricating film that delays change from mild to severe wear of the composite, especially at high loads. EDX analysis of the worn surface shows oxidation of the matrix alloy at higher wear loads, and this mechanism decreases in the presence of carbon fibers under the same loads. Abrasive wear, oxidation, and plastic deformation are the dominant wear mechanisms for the alloy matrix AE42, whereas mainly abrasive wear is the wear mechanism of AE42-23 vol% C composite under the proposed testing conditions.展开更多
基金sponsored by the Prince Sattam bin Abdulaziz University via project number 2023/RV/018。
文摘Magnesium and aluminum alloys continually attract interest as lightweight structural materials for transport applications. However, joining these dissimilar alloys is very challenging. The main obstacle that hinders progress in dissimilar Mg-Al joining is the formation of brittle intermetallic compounds(IMCs). As a solid-state joining technique, FSW is an excellent candidate to attenuate the deleterious IMC effects in dissimilar Al-Mg joining due to the inherent low heat inputs involved in the process. However, the IMCs, namely Al_(3)Mg_(2) and Al_(12)Mg_(17) phases, have also been reported to form during Al-Mg dissimilar FSW;their amount and thickness depend on the heat input involved;thus,the weld parameters used. Since the heat dissipated in the material during the welding process significantly affects the amount of IMCs,the heat input during FSW should be kept as low as possible to control and reduce the amount of IMCs. This review aims to critically discuss and evaluate the studies conducted in the dissimilar Al/Mg FSW through a scientometric analysis and also with a focus on the strategies recently applied to enhance joint quality. The scientometric analysis showed that the main research directions in Mg/Al FSW are the technological weldability of aluminum and magnesium during FSW, structural morphology, and mechanical properties of dissimilar welded joints. Considering the scope of application of the aforementioned joints, the low share of articles dealing with environmental degradation and operational cracking is surprising. This might be attributed to the need for well-developed strategies for obtaining high-quality and sustainable joints for applications. Thus, the second part of this review is conventional, focusing mainly on the new strategies for obtaining high-quality Mg/Al joints. It can be concluded that in addition to the necessity to optimum welding parameters to suppress the excessive heat to limit the amount and thickness of IMC formed and improve the overall joint quality, strategies such as using Zn interlayer, electric current assisted FSW(EAFSW), ultrasonic vibration FSW(UVa FSW), are considered effective in the elimination, reduction, and fragmentation of the brittle IMCs.
文摘Alumina-iron nanocomposite powders were prepared by a two-step process. In the first step, α-Al2O3-FeCl2 powder mixture was formed by mixing α-Al2O3 powders with FeCl2 solution followed by drying. In the second step, the FeCl2 in the dry power mixture was selectively reduced to iron particles. A reduction temperature of 750℃ for 15 min in dry H2 was chosen based on the thermodynamic calculations. The concentration of iron in FeCl2 solution was calculated to be 20 vol. pct in the final composite. Two techniques were used to produce composite bulk materials. The Al2O3 nanocomposite powders were divided to two batches. The first batch of the produced mixture was hot pressed at 1400℃ and 27 MPa for 30 min in a graphite die. To study the effect of oxygen on the Al2O3/Fe interface bonding and mechanical properties of the composite, the second batch was heat treated in air at 700℃ for 20 min to partially oxidize the iron particles before hot pressing. Characterization of the composites was undertaken by conventional density measurements, X-ray diffractometry （XRD）, scanning electron microscopy （SEM）, transmission electron microscopy （TEM） and electron probe micro analysis （EPMA）. The suggested processing route （mixing, reduction and hot pressing） produces ceramic-metal nanocomposite much tougher than the pure Al2O3. The fracture strength of the produced Al2O3/Fe nanocomposite is nearly twice that of the pure Al2O3. The presence of spinel phase, FeAl204, as thick layer around the Fe particles in the Al2O3 matrix has a detrimental effect on interfacial bonding between Fe and AI203 and the fracture properties of the composite.
文摘The incorporation of graphite particles into AA6016 aluminum alloy matrix to fabricate metal/ceramic composites is still a great challenge and various parameters should be considered. In this study, dense AA6016 aluminum alloy/（0-20 wt%） graphite composites have successfully been fabricated by powder metallurgy process. At first, the mixed aluminum and graphite powders were cold compacted at 200 MPa and then sintered at 500 ℃ for 1 h followed by hot extrusion at 450 ℃. The influence of ceramic phases（free graphite and in-situ formed carbides） on microstructure, physical and mechanical properties of the produced composites were finally investigated. The results show that the fabricated composites have a relative density of over 98%. SEM observations indicate that the graphite has a good dispersion in the alloy matrix even at high graphite content. Hardness of all the produced composites was higher than that of aluminum alloy matrix. No cracks were observed at strain less than 23% for all hot extruded materials.Compressive strength, reduction in height, ultimate tensile stress, fracture stress, yield stress, and fracture strain of all Al/graphite composites were determined by high precision second order equations. Both compressive and ultimate tensile strengths have been correlated to microstructure constituents with focusing on the in-situ formed ceramic phases, silicon carbide（SiC） and aluminum carbide（Al4 C3）. The ductile fracture mode of the produced composites became less dominant with increasing free graphite content and in-situ formed carbides. Wear resistance of Al/graphite composites was increased with increasing graphite content. Aluminum/20 wt% graphite composite exhibited superior wear resistance over that of AA6016 aluminum alloy.
文摘In addition to the advantage of the lightweight of magnesium alloys, magnesium composites have moderate strength and elastic modulus. The proposed application of magnesium composites as diesel truck pistons makes it necessary to assess their wear performance. Little research data have been discussed on wear behavior of Mg alloy AE42 matrix and its composites. Thus, this paper reports wear behavior of magnesium alloy AE42(Mg–Al–Mn—RE; rare earth) and its composite AE42-C, which contains 23 vol% of randomly oriented carbon short fibers. Materials characterization, including density measurements, hardness testing, microstructures investigation, and compression testing at temperatures of 25, 150,and 300 °C, were conducted. Wear tests were performed under various loads and sliding distances. Wear mechanisms were also proposed based on the examination of worn surfaces using optical microscopy and scanning electron microscopy equipped with EDX(energy-dispersive X-ray spectrometry) analysis system. The hardness of AE42-23 vol% C composite is twice the hardness of the Mg matrix alloy AE42. Significant improvements to yield stress and compressive strength at temperatures of 25, 150, and 300 °C of the composite versus the AE42 alloy are achieved. Wear resistance of the composite is improved considerably versus that of the Mg alloy AE42 at the various sliding distances. Smearing of graphite on the worn surface produces a lubricating film that delays change from mild to severe wear of the composite, especially at high loads. EDX analysis of the worn surface shows oxidation of the matrix alloy at higher wear loads, and this mechanism decreases in the presence of carbon fibers under the same loads. Abrasive wear, oxidation, and plastic deformation are the dominant wear mechanisms for the alloy matrix AE42, whereas mainly abrasive wear is the wear mechanism of AE42-23 vol% C composite under the proposed testing conditions.
