Showing papers in "Journal of Materials Engineering and Performance in 2010"

A Review of FSW Research on Dissimilar Metal and Alloy Systems

Abstract: This review summarizes friction-stir welding (FSW) research over a period of a decade and a half, involving 18 different same materials FSW reference systems, and the FSW of 25 different, dissimilar materials systems. These are summarized in tables. The FSW of dissimilar materials systems is distinguished from same materials systems FSW by the formation of complex, intercalated vortex, and related flow patterns. These intercalated, lamellar-like patterns represent solid-state flow by dynamic recrystallization (DRX) which facilitates unrecrystallized, block flow in the DRX regime. A detailed characterization of representative systems involving optical and transmission electron microscopy is also presented. Residual microindentation hardness or other hardness measured across the weld face provides comparative performance signatures for the same material FSW systems in contrast to the dissimilar FSW systems. Hardness fluctuations or complex spikes occurring in the dissimilar systems are skewed from the weld centerline and are shifted when the tool rotation direction changes or the advancing side is reversed.

316L Stainless Steel with Gradient Porosity Fabricated by Selective Laser Melting

Abstract: To fabricate 316L stainless steel part with a pore gradient structure, the method using selective laser melting (SLM) technique is exploited. Scan tracks feature, densification, and tensile property of SLM-produced samples prepared via different scan speeds were investigated. The results show that the porosity is strongly influenced by scan speed. On this basis, a gradient changed scan speed was applied in every SLM layer for the purpose of producing a gradient porosity metal. The results indicate that the structure exhibits a gradually increased porosity and a reduced molten pool size along the gradient direction of scan speed variation. The forming mechanisms for the gradient porosity were also addressed.

Aluminum-Copper-Lithium Alloy 2050 Developed for Medium to Thick Plate

Abstract: This article discusses Al-Cu-Li 2050 alloy developed, qualified, and produced by Alcan Aerospace as plates. AA2050 alloy offers a low density high corrosion resistant alternative to incumbent medium to thick plate alloys like 7050-T7451, and to thin plate alloys like 2024 or higher damage tolerant versions. The fundamentals behind the choice of the Al-Cu-Li chemistry are highlighted, as well as the property balance generated in a wide range of thickness from 12 to 127 mm (0.5 to 5 in.). Manufacturing behavior of the alloy when machining or friction stir welding is also discussed in detail. Finally, it is shown that the appropriate recycling investments and logistics permit the use of 2050 alloy at an acceptable level of extra cost per kilo saved, when weight benefits are taken into account.

Effects of Ultrasonic Nanocrystal Surface Modification (UNSM) on Residual Stress State and Fatigue Strength of AISI 304

Abstract: The effects of a new mechanical surface treatment method, called ultrasonic nanocrystal surface modification (UNSM), on near-surface microstructures and residual stress states as well as on the fatigue behavior of an austenitic steel AISI 304 are investigated and discussed. The results are compared with consequences of other mechanical surface treatment methods such as deep rolling or shot peening.

Modeling of AA5083 Material-Microstructure Evolution During Butt Friction-Stir Welding

Abstract: A concise yet a fairly comprehensive overview of the friction stir welding (FSW) process is provided. This is followed by a computational investigation in which FSW behavior of a prototypical solution-strengthened and strain-hardened aluminum alloy, AA5083-H131, is modeled using a fully coupled thermo-mechanical finite-element procedure developed in our prior study. Particular attention is given to proper modeling of the welding work-piece material behavior during the FSW process. Specifically, competition and interactions between plastic-deformation and dynamic-recrystallization processes are considered to properly account for the material-microstructure evolution in the weld nugget zone. The results showed that with proper modeling of the material behavior under high-temperature/severe-plastic-deformation conditions, significantly improved agreement can be attained between the computed and measured post-FSW residual-stress and material-strength distribution results.

An Investigation into Microstructures and Mechanical Properties of AA7075-T6 during Friction Stir Welding at Relatively High Rotational Speeds

Abstract: In this study, microstructural changes and mechanical properties during friction stir welding of AA7075-T6 have been investigated. Friction stir welding at relatively high rotational speeds ranging from 1000 to 1400 rpm and longitudinal speeds in the range of 40 to 80 mm/min have been performed and then microstructures and mechanical properties of the weldments have been studied. The results show that the rotational and longitudinal speeds have a significant effect on the microstructures as well as the mechanical behavior of the welded material while a fine grain structure is produced at higher ratio of rotational speed to longitudinal speed. On the other hand, for a given longitudinal speed, it is revealed that there is an optimum rotational speed which gives the highest tensile strength and elongation for the stirred zone.

Multidisciplinary Design Optimization for Glass-Fiber Epoxy-Matrix Composite 5 MW Horizontal-Axis Wind-Turbine Blades

Abstract: A multi-disciplinary design-optimization procedure has been introduced and used for the development of cost-effective glass-fiber reinforced epoxy-matrix composite 5 MW horizontal-axis wind-turbine (HAWT) blades The turbine-blade cost-effectiveness has been defined using the cost of energy (CoE), ie, a ratio of the three-blade HAWT rotor development/fabrication cost and the associated annual energy production To assess the annual energy production as a function of the blade design and operating conditions, an aerodynamics-based computational analysis had to be employed As far as the turbine blade cost is concerned, it is assessed for a given aerodynamic design by separately computing the blade mass and the associated blade-mass/size-dependent production cost For each aerodynamic design analyzed, a structural finite element-based and a post-processing life-cycle assessment analyses were employed in order to determine a minimal blade mass which ensures that the functional requirements pertaining to the quasi-static strength of the blade, fatigue-controlled blade durability and blade stiffness are satisfied To determine the turbine-blade production cost (for the currently prevailing fabrication process, the wet lay-up) available data regarding the industry manufacturing experience were combined with the attendant blade mass, surface area, and the duration of the assumed production run The work clearly revealed the challenges associated with simultaneously satisfying the strength, durability and stiffness requirements while maintaining a high level of wind-energy capture efficiency and a lower production cost

Influence of Surface Roughness on Corrosion and Tribological Behavior of CP-Ti After Thermal Oxidation Treatment

Abstract: In this study, tribological and corrosion behavior of commercially pure titanium (CP-Ti) with different surface roughness values after thermal oxidation was investigated. The CP-Ti specimens were prepared with three different roughness values from silicon carbide paper, Ra = 0.1, 0.3, and 0.6 μm, and the thermal oxidization process was conducted at a temperature of 850 °C for 8 h in an O2 atmosphere. Structural, mechanical, corrosion, and tribological properties of untreated and thermally oxidized CP-Ti with different surface roughness values were investigated through x-ray diffraction, scanning electron microscopy, microhardness, potensiostat, and pin-on-disk techniques. The corrosion and tribological behavior of CP-Ti improved as an oxide layer was formed by thermal oxidation. It was observed that the surface roughness had an effect on these characteristics. It was established that the decreased roughness improves the tribological and corrosion properties.

Kinetic Analysis of the Austenite Grain Growth in GCr15 Steel

Abstract: The growth behavior of austenite grains in GCr15 steel was investigated through the isothermal annealing tests of the steel under different heating temperatures and holding times. The tests were performed on a Gleeble-3800 thermo-mechanical simulation machine. Austenitizing temperatures 1223, 1323, 1373, and 1423 K were chosen, and holding time varied from 0 to 480 s. Experimental results suggest that austenite grains grow gradually with the increase of heating temperature, and holding time has an important effect on the growth of austenite grains. The time exponent for the growth is bigger at higher temperature, and the growth rate decreases with increasing time. On the basis of previous models and experimental results, a mathematical model that can describe the growth behavior of austenite grains in the tested steel under different heating temperatures and holding times was obtained using regression analysis. The predicted grain sizes by the model are in good agreement with measured ones.

Investigations on the Effects of the Tool Material, Geometry, and Tilt Angle on Friction Stir Welding of Pure Titanium

Abstract: Friction stir welding (FSW) parameters, such as tool material, tool geometry, tilt angle, tool rotational speed, welding speed, and axial force play a major role in the weld quality of titanium alloys. Because of excessive erosion, tool material and geometry play the main roles in FSW of titanium alloys. Therefore, in the present work for the first time, tool material and geometry, tool tilt angle, cooling system and shielding gas effects on macrostructure, microstructure, and mechanical properties of pure titanium weld joint were investigated. Result of this research shows that Ti can be joined by the FSW, using a tool with a shoulder made of tungsten (W) and simple pin made of tungsten carbide (WC). The best conditions for welding were use of compressed air as a cooling system, tool tilt angle of 1°, and a stream of Argon as a shielding medium. Investigation on mechanical properties shows that the tensile strength and the yield strength of the welded joint in the best case could be similar to the corresponding strengths of the base metal.

Influences of Welding Processes on Microstructure, Hardness, and Tensile Properties of AZ31B Magnesium Alloy

Abstract: This article reports the influences of welding processes such as gas tungsten arc welding (GTAW), friction stir welding (FSW), and laser beam welding (LBW) on tensile properties of AZ31B magnesium alloy. The lowest hardness distribution profile (LHDP) is constructed across the weld section to identify the fracture path. From this investigation, it is found that LBW joints exhibited superior tensile properties compared to GTAW and FSW joints and this is mainly due to the formation of very fine grains in the fusion zone and absence of heat-affected zone (HAZ).

The Effect of Coating Thickness on Corrosion Resistance of Hydroxyapatite Coated Ti6Al4V and 316L SS Implants

Abstract: Hydroxyapatite (HAP) has been coated onto Ti6Al4V and 316L SS substrates by sol-gel method. The coating thicknesses for the analysis were about 40 and 72 μm. Adhesion and corrosion tests have been conducted on uncoated and HAP-coated substrates. The coatings were characterized by XRD, SEM, and adhesion analysis. The corrosion resistance was examined in vitro by potentiodynamic polarization technique in Ringer’s solution at room temperature. Electrochemical analysis indicated that the highest corrosion susceptibility was found on 72-μm-coated 316L SS, and the 40-μm HAP-coated Ti6Al4V showed the highest corrosion resistance. It was observed that the coating thickness was an effective parameter on both adhesion and corrosion resistance. It was shown that adhesion and corrosion resistance decreased with increasing coating thickness on both substrates.

Development of a Meso-Scale Material Model for Ballistic Fabric and Its Use in Flexible-Armor Protection Systems

Abstract: A meso-scale ballistic material model for a prototypical plain-woven single-ply flexible armor is developed and implemented in a material user subroutine for the use in commercial explicit finite element programs. The main intent of the model is to attain computational efficiency when calculating the mechanical response of the multi-ply fabric-based flexible-armor material during its impact with various projectiles without significantly sacrificing the key physical aspects of the fabric microstructure, architecture, and behavior. To validate the new model, a comparative finite element method analysis is carried out in which: (a) the plain-woven single-ply fabric is modeled using conventional shell elements and weaving is done in an explicit manner by snaking the yarns through the fabric and (b) the fabric is treated as a planar continuum surface composed of conventional shell elements to which the new meso-scale unit-cell based material model is assigned. The results obtained show that the material model provides a reasonably good description for the fabric deformation and fracture behavior under different combinations of fixed and free boundary conditions. Finally, the model is used in an investigation of the ability of a multi-ply soft-body armor vest to protect the wearer from impact by a 9-mm round nose projectile. The effects of inter-ply friction, projectile/yarn friction, and the far-field boundary conditions are revealed and the results explained using simple wave mechanics principles, high-deformation rate material behavior, and the role of various energy-absorbing mechanisms in the fabric-based armor systems.

Investigation of the Hot-Stamping Process for Advanced High-Strength Steel Sheet by Numerical Simulation

Abstract: Hot forming is a new way to manufacture complex-shaped components of advanced high-strength steel (AHSS) sheet with a minimum of spring-back. Numerical simulation is an effective way to examine the hot-forming process, particularly to determine thermal and thermo-mechanical characteristics and their dependencies on temperature, strain and strain rate. The flow behavior of the 22MnB5 AHSS is investigated through hot tensile tests. A 3D finite element (FE) model of hot-stamping process for the Open image in new window shaped part is built under the ABAQUS/Explicit environment based on the solutions of several key problems, such as treatment of contact between blank and tools, determination of material characteristics and meshing, etc. Numerical simulation is carried out to investigate the influence of blank holder force (BHF) and die gap on the hot-forming process for the Open image in new window shaped part. Numerical results show the FE model is effective in simulation of hot-forming process. Large BHF reduces the amount of spring-back and improves the contact of flange with tools while avoiding cracking of stamped part. Die gap has a considerable influence on the distribution of temperature on side walls; the larger the die gap, higher is the temperature on the sidewall of Open image in new window shaped part.

Structural-Response Analysis, Fatigue-Life Prediction, and Material Selection for 1 MW Horizontal-Axis Wind-Turbine Blades

Abstract: The problem of mechanical design, performance prediction (e.g., flap-wise/edge-wise bending stiffness, fatigue-controlled life, the extent of bending-to-torsion coupling), and material selection for a prototypical 1 MW horizontal-axis wind turbine (HAWT) blade is investigated using various computer-aided engineering tools. For example, a computer program was developed which can automatically generate both a geometrical model and a full finite-element input deck for a given single HAWT-blade with a given airfoil shape, size, and the type and position of the interior load-bearing longitudinal beam/shear-webs. In addition, composite-material laminate lay-up can be specified and varied in order to obtain a best combination of the blade aerodynamic efficiency and longevity. A simple procedure for HAWT-blade material selection is also developed which attempts to identify the optimal material candidates for a given set of functional requirements, longevity and low weight.

A Study of the Tensile Deformation and Fracture Behavior of Commercially Pure Titanium and Titanium Alloy: Influence of Orientation and Microstructure

Abstract: In this paper, the tensile deformation and fracture behavior of commercially pure titanium and the titanium alloy (Ti-6Al-4V) are presented and briefly discussed. Samples of both commercially pure titanium and the Ti-6Al-4V alloy were prepared from the as-provided plate stock along both the longitudinal and transverse orientations. The specimens were then deformed to failure in uniaxial tension. The intrinsic influence of material composition and test specimen orientation on microstructure, tensile properties, and resultant fracture behavior of the two materials is presented. The conjoint influence of intrinsic microstructural features, nature of loading, and specimen orientation on tensile properties of commercially pure titanium and the Ti-6Al-4V alloy is highlighted. The fracture behavior of the two materials is discussed taking into consideration the nature of loading, specimen orientation, and the role and contribution of intrinsic microstructural effects.

Dry sliding wear properties of a 7075-T6 aluminum alloy coated with Ni-P (h) in different pretreatment conditions.

Abstract: Dry sliding wear behavior of electroless nickel-phosphorus (EN) coating of thickness 35 lm deposited on a 7075-T6 aluminum alloy was studied. EN was deposited from a bath with sodium hypophosphite as a reducing agent. In as-deposited conditions, plating with 6-9 wt.% phosphorus has a mixture of amorphous and microcrystalline phase. Three pretreatments of Zn (zincate), Ni strike and absorbed hypophosphite layer were given to the substrate before EN coating to examine their wear performance. The surface morphology of the pretreatments was studied by a confocal laser scanning microscope. The performances of these pretreatments of EN were evaluated by dry sliding wear studies and followed by SEM studies. The results suggest that the wear behavior of EN mostly depends on the pretreatment conditions. Heat treatment at temperature of 400 C can enhance the wear resistance properties for all types of pretreatment conditioned samples and in addition that the average coefficient of friction of 400 C specimens (lav) had minimum value as compared to 200 C specimens. Ni strike provided better interlocking adhesion between EN and Al and this pretreatment noticeably improved the wear, frictional and hardness behavior of the EN coatings on 7075 Al substrate and further enhanced it by heat treatment of 400 C/h.

Artificial Neural Networks for Surface Roughness Prediction when Face Milling Al 7075-T7351

Abstract: In this work, different artificial neural networks (ANN) are developed for the prediction of surface roughness (R a ) values in Al alloy 7075-T7351 after face milling machining process. The radial base (RBNN), feed forward (FFNN), and generalized regression (GRNN) networks were selected, and the data used for training these networks were derived from experiments conducted using a high-speed milling machine. The Taguchi design of experiment was applied to reduce the time and cost of the experiments. From this study, the performance of each ANN used in this research was measured with the mean square error percentage and it was observed that FFNN achieved the best results. Also the Pearson correlation coefficient was calculated to analyze the correlation between the five inputs (cutting speed, feed per tooth, axial depth of cut, chip’s width, and chip’s thickness) selected for the network with the selected output (surface roughness). Results showed a strong correlation between the chip thickness and the surface roughness followed by the cutting speed.

Investigations of White Layer Formation During Machining of Powder Metallurgical Ni-Based ME 16 Superalloy

Abstract: Surface integrity of machined parts made from the advanced Ni-based superalloys is important for modern manufacturing in the aerospace industry. Metallographic observations of the ME 16 alloy microstructure were made using optical metallography and a high-resolution scanning electron microscope with energy dispersive x-ray spectrometer (HR SEM/EDS). Tool life of cemented carbide inserts with TiAlN coating during machining (finishing turning operation) of ME 16 superalloy has been studied and wear patterns of the cutting tools were identified. Surface integrity of the machined part after completion of the turning operation was investigated. The morphology of machined parts has been examined and cross-sections of the machined surfaces have been analyzed. The formation of white layer on the surface of the machined part was studied for varied machining conditions. It was found that a 2-4 µm thick white layer forms during turning of the ME 16 superalloy. This layer was investigated using EDS and XRD. The studies show that the white layer is an oxygen-containing layer with a high amount of aluminum, enriched by chromium and tungsten. Under specific cutting conditions, the structure of white layer transforms into a γ-alumina. Formation of this thermal barrier ceramic white layer on the surface of the machined part negatively affects its surface integrity and cutting tool life.

The Effects of Hot Corrosion Pits on the Fatigue Resistance of a Disk Superalloy

Abstract: The effects of hot corrosion pits on low-cycle fatigue life and failure modes of the disk superalloy ME3 were investigated. Low-cycle fatigue specimens were subjected to hot corrosion exposures producing pits, then tested at low and high temperatures. Fatigue lives and failure initiation points were compared to those of specimens without corrosion pits. Several tests were interrupted to estimate the fraction of fatigue life that fatigue cracks initiated at pits. Corrosion pits significantly reduced fatigue life by 60 to 98%. Fatigue cracks initiated at a very small fraction of life for high-temperature tests, but initiated at higher fractions in tests at low temperature. Critical pit sizes required to promote fatigue cracking were estimated based on measurements of pits initiating cracks on fracture surfaces.

Using Microwave-Assisted Powder Metallurgy Route and Nano-size Reinforcements to Develop High-Strength Solder Composites

Abstract: In the present study, Sn-0.7Cu and Sn-3.5Ag lead-free solders used in the electronics packaging industry were reinforced with different volume percentages of nano-size alumina and tin oxide particulates, respectively, to synthesize two new sets of nanocomposites. These composites were developed using microwave-assisted powder metallurgy route followed by extrusion. The effects of addition of particulates on the physical, microstructural, and mechanical properties of the nanocomposites were investigated. Mechanical properties (microhardness, 0.2% YS, and UTS) for both composite systems increase with the presence of particulates. The best tensile strength was realized for composite solders reinforced with 1.5 vol.% alumina and 0.7 vol.% tin oxide particulates, which far exceeds the strength of eutectic Sn-Pb solder. The morphology of pores was observed to be one of the most dominating factors affecting the strength of materials.

Material Models for Simulation of Superplastic Mg Alloy Sheet Forming

Abstract: Accurate prediction of strain fields and cycle times for fine-grained Mg alloy sheet forming at high temperatures (400-500 °C) is severely limited by a lack of accurate material constitutive models. This paper details an important first step toward addressing this issue by evaluating material constitutive models, developed from tensile data, for high-temperature plasticity of a fine-grained Mg AZ31 sheet material. The finite element method was used to simulate gas pressure bulge forming experiments at 450 °C using four constant gas pressures. The applicability of the material constitutive models to a balanced-biaxial stress state was evaluated through comparison of simulation results with bulge forming data. Simulations based upon a phenomenological material constitutive model developed using data from both tensile elongation and strain-rate-change experiments were found to be in favorable accord with experiments. These results provide new insights specific to the construction and use of material constitutive models for hot deformation of wrought, fine-grained Mg alloys.

Impact Energy of Functionally Graded Steels in Crack Arrester Configuration

Abstract: Charpy impact energy of functionally graded steels produced by electroslag remelting composed of graded ferrite and austenite layers together with bainite or martensite intermediate layer in the form of crack arrester configuration has been investigated. The results obtained in the present study indicate that the notch tip position with respect to bainite or martensite layer significantly affects the impact energy. The closer the notch tip to the tougher layer, the higher the impact energy of the composite due to increment of energy absorbed by plastic deformation zone ahead of the notch and vice versa. Empirical relationships have been determined to correlate the impact energy of functionally graded steels to the morphology of layers.

Passivity and Pitting Corrosion of X80 Pipeline Steel in Carbonate/Bicarbonate Solution Studied by Electrochemical Measurements

Abstract: This work investigated the effects of chloride ions and hydrogen-charging on the passivity and pitting corrosion behavior of X80 pipeline steel in a bicarbonate-carbonate solution by electrochemical and photo-electrochemical techniques It was found that a stable passivity can be established on the steel in the absence and presence of chloride ions The hydrogen-charging does not alter the transpassive potential, but increases the passive current density When chloride ions are contained in the solution, pitting corrosion will be initiated The pitting potential is independent of the hydrogen-charging Hydrogen-charging would enhance the anodic dissolution and electrochemical activity of the steel, but does not affect the pitting potential, which indicates that the charged hydrogen is not involved in the pitting initiation However, hydrogen may accelerate the pit growth Photo illumination could enhance the activity of the steel electrode, resulting in an increase of photo-induced anodic current density

Antifungal Textiles Formed Using Silver Deposition in Supercritical Carbon Dioxide

Abstract: The antifungal properties of two silver-coated natural cotton fiber structures prepared using a supercritical carbon dioxide (scCO2) solvent were examined. Scanning electron microscopy confirmed that the scCO2 process may be used to produce cotton fiber textiles with uniform silver nanoparticle coatings. A version of the Kirby-Bauer disk diffusion test was used to assess the ability of these textiles to inhibit fungal growth. Cotton fabric samples modified with Ag(hepta) and Ag(cod)(hfac) exhibited measurable zones of inhibition. On the other hand, the uncoated fabric had no zone of inhibition. Possible applications of antifungal textiles prepared using scCO2 processing include use in hospital uniforms and wound dressings.

Characterization of Atmospheric Corrosion of 2A12 Aluminum Alloy in Tropical Marine Environment

Abstract: In this work, corrosion product formed on 2A12 aluminum (Al) alloy after 3 months of natural exposure in South China Sea atmosphere was characterized by various surface analysis techniques, including scanning electron microscopy, energy-dispersive x-ray analysis, x-ray photoelectron spectroscopy, and x-ray diffraction. The atmospheric corrosion mechanism of Al alloy in marine environment was derived. Results demonstrated that Al alloy specimen experiences serious general corrosion and pitting corrosion. Al and O are enriched in the product film, and Ca and Cl are also found in the film and corrosion pits in Al alloy substrate. The main component compounds existing in the film include Al2O3, Al(OH)3, and AlOOH while AlCl3 and CaCO3 are also identified. Al alloy encounters corrosion under tropical marine atmosphere. Although somewhat protective, the formed surface film on Al alloy specimen is attacked by chloride ions, resulting in significant pitting corrosion of Al alloy.

Effects on the Surface Texture, Superplastic Forming, and Fatigue Performance of Titanium 6AL-4V Friction Stir Welds

Abstract: The speed and feed effects of the friction stir welding (FSW) process on the surface texture along the top of a butt welded nugget were studied. The tests were conducted using fine grain (0.8-2 μm) titanium alloy 6Al-4V with a nominal thickness of 2.5 mm. It was shown that the pin tool marks along the top surface of the weld can be highly detrimental to both the superplastic forming (SPF) characteristics and the fatigue performance of welded panels. Removing the marks by machining the top surface after FSW was found to eliminate the predominant tearing of the weld during SPF and most of the fatigue life of across the weld was also restored. Through additional development of the FSW process parameters, the butt welded nugget was made to have equivalent SPF characteristics as the parent sheet material. By using a water-cooled pin tool and other cooling techniques, it is believed that the weld zone can be kept below the beta transus temperature during FSW, which enables the formation of a grain structure that is uniquely conducive to superplastic behavior, when compared to conventional fusion welding processes.

Crack Initiation Life of Materials Under Combined Pitting Corrosion and Cyclic Loading

Abstract: Pitting corrosion triggered damage is responsible for the degradation of many metallic materials affecting structural integrity. As pitting and crack initiation processes govern the overall life of such structures and components, particularly at nominal cyclic stresses, there is a need to develop simple models to estimate crack initiation life of materials. This paper presents a simple deterministic model that considers the effect of cyclic stressing under pitting corrosion conditions. The developed model is validated on an aluminum alloy 2024-T3, and 12% Cr stainless steel used in aircraft and steam turbines, respectively. The predicted critical pit depth values are in fair agreement with the limited experimental data available in the literature. The model indicates that at high stresses, the crack initiation can occur very rapidly even from relatively small pits. The crack initiation life predictions when compared with the available experimental data, suggest a probable stress-level dependency with regard to the form and extent of the influence of cyclic stresses on pit growth and subsequent crack formation.

Synthesis of TiN Reinforced Aluminium Metal Matrix Composites Through Microwave Sintering

Abstract: Al-TiN (10, 20, 30 wt.%) composites were fabricated by using microwave radiation. Al and TiN powders were selected as starting materials, mixed in a ball mill for ~10 min and sintered for various times. Results indicate that an optimum microwave sintering time of 2 min was essential and responsible for the improved densification and mechanical properties. The presence of TiN particles at grain boundaries plays a significant role in improving the densification and hardness values. Dry sliding wear results show the improved wear resistance of the composite (Al-TiN) due to the presence of TiN particles and the wear results are superior to the Al-TiN samples made by hot pressing technique.

Tensile and Fatigue Behavior of Friction-Stir Welded Tailor-Welded Blank of Aluminum Alloy 5754

Abstract: Friction stir welding is becoming increasingly desirable in many applications, including tailor-welded blanks in which two sheets of different thicknesses are joined together to form blanks that can be subsequently stamped into a final product shape. In this article, we have studied the static tensile and tension-tension fatigue behavior of friction stir welded joint in a tailor-welded blank of aluminum alloy 5754. It was observed that the yield and tensile strengths of friction stir welded specimens with weld located 90° to the tensile direction are close to the base material values, but its elongation is nearly half the elongation for the base material. The friction stir welded joints had relatively high-fatigue strength, and was even superior to that of the base aluminum alloy in the high-cycle region. Pre-straining caused by press forming lowered the elongation to failure, but improved the fatigue performance.