Alessio Gullino

Bio: Alessio Gullino is an academic researcher from Polytechnic University of Turin. The author has contributed to research in topics: Alloy & Microstructure. The author has an hindex of 4, co-authored 11 publications receiving 66 citations. Previous affiliations of Alessio Gullino include Monash University, Clayton campus.

Review of Aluminum-To-Steel Welding Technologies for Car-Body Applications

Abstract: Hybrid car bodies fabricated by joining parts made with steel and aluminum alloys are becoming increasingly common. This provides an affordable mean to decrease the car weight by using lighter or more advanced materials only where they can achieve the maximum benefit. This development is driven mainly by recent regulations on carbon dioxide emissions, and hinges on the deployment of effective joining technologies. In most cases, such technologies were not previously used in the car sector, and must be adapted to its requirements. Several dissimilar welding technologies, based on either fusion welding or solid-state welding, are reviewed here, focusing on dissimilar joining among steels and wrought aluminum alloys. These technologies are either presently being introduced in the car industry, or are used in other sectors and could be applied in the car industry in the near future.

A detailed microstructural and corrosion analysis of magnesium alloy WE43 manufactured by selective laser melting

Abstract: The production of magnesium alloy WE43 was achieved by selective laser melting (SLM). The alloy was investigated after SLM, hot isostatic pressing (HIP), and solutionising heat treatment. The microstructure and corrosion behaviour of the specimens were carefully characterised, whilst assessed and contrast relative to the conventionally cast alloy counterpart. The SLM prepared specimens possess a unique microstructure comprising fine grains growing with a strong [0001] texture along the building direction with a low fraction of process-induced and metallurgical defects, reaching < 0.1 %, after optimising the SLM parameters and the HIP treatment. Electrochemical measurements demonstrated that the SLM prepared WE43 is cathodically more active as compared with its cast counterpart. It is proposed that this behaviour is due to a high density of zirconium-rich oxide particles uniformly distributed throughout the alloy microstructure as well as the alterations in the chemical composition of the solid-solution matrix originating from the high cooling rates of SLM. It was also noted that the oxide particles are mainly sourced by powder. The present results suggest that the corrosion of SLM prepared Mg alloys could be greatly improved once the influence of powder characteristics is further understood and controlled.

Corrosion resistant and high-strength dual-phase Mg-Li-Al-Zn alloy by friction stir processing

Abstract: Abstract Magnesium is the lightest structural metal, and alloying with lithium makes it even lighter. However, multi-phase Mg-Li alloys typically undergo rapid corrosion, and their strength decreases at room temperature due to natural age-softening. Here, we engineer a rapidly degrading dual-phase Mg-Li-Al alloy to be durable via friction stir processing followed by liquid CO 2 quenching. The best performing alloy has a low electrochemical degradation rate of 0.72 mg·cm −2 · day −1 , and high specific strength of 209 kN·m·kg −1 . We attribute this electrochemical and mechanical durability to its microstructure, which consists of a refined grain size of approximately 2 µm and dense nanoprecipitates. This microstructure suppressed the formation of the detrimental AlLi phase, and an aluminium-rich protective surface layer also formed. This processing route might be useful for designing lightweight and durable engineering alloys.

Nb 2 O 5 thin film-based conductometric sensor for acetone monitoring

Abstract: Nowadays, effective detection of gases at ppm and ppb level is of crucial importance in a wide range of applications, such as industrial processes, environmental monitoring, public security and medical investigation. Several sensor types have been developed in last decades, among them the metal oxide gas sensors are the most promising for low-cost and portable applications, where good sensitivity and selectivity, together with small size are important constraints. The proposed conductometric gas sensor has been manufactured depositing a Nb 2 O 5 thin film by plasma sputtering on a commercial alumina substrate with platinum interdigitated electrodes and heater which size is 3 mm × 6 mm with a thickness of 1 mm. The Nb 2 O 5 thin film has been characterized by FE-SEM and XPS analysis. The sensor performance towards several target gases have been evaluated employing an experimental setup specifically developed for the characterization of gas sensors. The sensor exhibits good sensitivity towards acetone, a bio-marker found in human breath of diabetes patients. This makes the sensor promising in the noninvasive diagnosis of this kind of disease.

High Sensitive and Selective Minisensor for Acetone Monitoring

Abstract: This article describes a simple though extremely effective sensor for acetone monitoring in the breath. The sensor is capable of monitoring the presence of acetone at parts per million (ppm) concentrations, thus being suitable for a diabetes diagnosis. It has a dimension of $3 {\,\,\mathrm {mm}} \times 6 {\,\,\mathrm {mm}}$ and a cost of less than one dollar. The small dimensions allow one to greatly limit the power required to increase its temperature, and its high selectivity with respect to other gases present in the breath reduces the risk of false-positive responses. The sensor is based on a thin alumina substrate on which platinum strips are deposited on both faces. A thin Nb2O5 layer with a nanometric thickness provides the required sensitivity and selectivity. Sensor prototypes have been characterized by field emission scanning electron microscopy (FESEM) and X-ray photoelectron spectroscopy (XPS) and proved an inherent linear response up to a few ppm of acetone.

Recent Progress on Wear-Resistant Materials: Designs, Properties, and Applications.

Abstract: There has been tremendous interest in the development of different innovative wear-resistant materials, which can help to reduce energy losses resulted from friction and wear by ≈40% over the next 10-15 years. This paper provides a comprehensive review of the recent progress on designs, properties, and applications of wear-resistant materials, starting with an introduction of various advanced technologies for the fabrication of wear-resistant materials and anti-wear structures with their wear mechanisms. Typical strategies of surface engineering and matrix strengthening for the development of wear-resistant materials are then analyzed, focusing on the development of coatings, surface texturing, surface hardening, architecture, and the exploration of matrix compositions, microstructures, and reinforcements. Afterward, the relationship between the wear resistance of a material and its intrinsic properties including hardness, stiffness, strength, and cyclic plasticity is discussed with underlying mechanisms, such as the lattice distortion effect, bonding strength effect, grain size effect, precipitation effect, grain boundary effect, dislocation or twinning effect. A wide range of fundamental applications, specifically in aerospace components, automobile parts, wind turbines, micro-/nano-electromechanical systems, atomic force microscopes, and biomedical devices are highlighted. This review is concluded with prospects on challenges and future directions in this critical field.

Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

Abstract: Joining of aluminum alloys through friction stir welding (FSW) is effectively employed in several industries (e.g., aeronautics and aerospace) since it guarantees proper weld strength as compared to other joining technologies. Contrarily, dissimilar FSW of aluminum alloys and steels often poses important issues in the selection of welding parameters due to the difficulty to join different materials. Improper welding parameters give rise to the formation of intermetallic compounds, and internal and external defects (e.g., tunnel formation, voids, surface grooves, and flash). Intermetallic compounds are brittle precipitates of Al/Fe, which chiefly initiate crack nucleation, whereas internal and external defects mainly act as stress concentration factors. All these features significantly reduce joint strength under static and dynamic loading conditions. With reference to the literature, the influence of main welding parameters (rotational speed, welding speed, tool geometry, tilt angle, offset distance, and plunge depth) on the formation of intermetallic compounds and defects in FSW of aluminum alloys and steels is discussed here. Possible countermeasures to avoid or limit the above-mentioned issues are also summarily reported.