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Applications of Al Alloys on Lightweight Structures

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 25884

Special Issue Editor

Department of Advanced Materials and Technologies, Faculty of Advanced Technologies and Chemistry, Military University of Technology, Gen. W. Urbanowicza 2, 00-908 Warsaw, Poland
Interests: cellular structures; additive manufacturing; intermetallics; mechanical properties; powder metallurgy; porous materials

Special Issue Information

Dear colleague,

Lightweight components are of crucial interest for all branches of industry. Aluminum and its alloys have been the prime material of many lightweight applications. The combination of acceptable costs, low component mass, appropriate mechanical properties, structural integrity and ease of fabrication are very attractive in aircraft constructions, vehicles, electrical conductors, packaging, machined components or sporting goods. This Special Issue aims to present the latest works in the research and development of Al alloy lightweight applications. The aim of this Special Issue is to present the latest achievements of theoretical and experimental investigations of “Al Alloys on Lightweight Structures”. It is our pleasure to invite you to submit a manuscript to this Special Issue. Full papers, communications, and reviews are welcome for submission.

Dr. Krzysztof Karczewski
Guest Editor

Manuscript Submission Information

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Keywords

  • Aluminum alloys
  • Lightweight structures
  • Processing
  • Mechanical properties
  • Microstructure

Published Papers (10 papers)

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Research

17 pages, 7730 KiB  
Article
Experimental Research on Manson–Coffin Curves for the Frame Material of an Unconventional Vehicle
by Miroslav Blatnický, Ján Dižo, Milan Sága, Marek Brůna and Milan Vaško
Materials 2022, 15(5), 1768; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15051768 - 26 Feb 2022
Cited by 3 | Viewed by 1385
Abstract
The submitted research paper describes the fundamental findings in terms of multiaxial fatigue of the basic material EN AW6063 and its welds for implementation in the frame design of an unconventional vehicle. It also includes a briefly-presented conceptual design of a technical solution [...] Read more.
The submitted research paper describes the fundamental findings in terms of multiaxial fatigue of the basic material EN AW6063 and its welds for implementation in the frame design of an unconventional vehicle. It also includes a briefly-presented conceptual design of a technical solution for optimizing the functionality of a steering mechanism in a patented unconventional vehicle, designed by the authors to increase the cornering stability of a vehicle–tricycle. The most important part of this article is the description of the ongoing research and the results of multiaxial fatigue (bending–torsion combination) of the structural material for the construction of the vehicle frame. The research in this area is important due to the increased load on the frame during operation caused by the unconventional steering mechanism. The measured and constructed Manson–Coffin curves indicate that the use of material EN AW6063 is possible for this vehicle in terms of multiaxial stress. This also applies to the material affected by the technology in the frame production (TIG welding). A higher fatigue of the basic material was observed at a 90° phase shift. The difference between the 0° and 90° phases practically makes up approximately 10 to 15% of the difference in the cycle numbers with the same deformation amplitude. At the same time, the measured results show that the phase shift between loads will not play such an important role in welded joints of aluminum alloy EN AW6063. When comparing the dependences with a constant deformation amplitude in bending and in torsion, it can be said that the bending stress will react more to even a small change in the deformation amplitude. Bending has been proven to be the more dominant component of the total deformation amplitude in multiaxial tests. In terms of low-cycle multiaxial fatigue (up to 5 × 105 cycles), a higher fatigue of the basic material is found in comparison with the weld. At lower deformation amplitudes, a higher fatigue of the welded material is detected. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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12 pages, 14919 KiB  
Article
Precipitation during Quenching in 2A97 Aluminum Alloy and the Influences from Grain Structure
by Xiaoya Wang, Jiantang Jiang, Guoai Li, Wenzhu Shao and Liang Zhen
Materials 2021, 14(11), 2802; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14112802 - 25 May 2021
Cited by 5 | Viewed by 2550
Abstract
The quench-induced precipitation and subsequent aging response in 2A97 aluminum alloy was investigated based on the systematic microstructure characterization. Specifically, the influence on precipitation from grain structure was examined. The results indicated the evident influence from the cooling rate of the quenching process. [...] Read more.
The quench-induced precipitation and subsequent aging response in 2A97 aluminum alloy was investigated based on the systematic microstructure characterization. Specifically, the influence on precipitation from grain structure was examined. The results indicated the evident influence from the cooling rate of the quenching process. Precipitation of T1 and δ′ phase can hardly occur in the specimen exposed to water quenching while become noticeable in the case of air cooling. The yield strength of 2A97-T6 alloy de-graded by 234 MPa along with a comparable elongation when water quenching was replaced by air cooling. Sub-grains exhibited a much higher sensitivity to the precipitation during quenching. The presence of dislocations in sub-grains promoted the quench-induced precipitation by acting as nucleation sites and enhancing the diffusion of the solute. A quenching rate of 3 °C/s is tolerable for recrystallized grains in 2A97 Al alloy but is inadequate for sub-grains to inhibit precipitation. The study fosters the feasibility of alleviating quench-induced precipitation through cultivating the recrystallization structure in highly alloyed Al–Cu–Li alloys. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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20 pages, 6832 KiB  
Article
Effect of Heat Treatment Process and Optimization of Its Parameters on Mechanical Properties and Microstructure of the AlSi11(Fe) Alloy
by Aleksandra Jarco and Jacek Pezda
Materials 2021, 14(9), 2391; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14092391 - 04 May 2021
Cited by 5 | Viewed by 1993
Abstract
The paper presents the results of study concerning the evaluation of the precipitation hardening parameters (temperatures and times of solution treatment and artificial ageing processes) having an effect on mechanical properties, and the change in the microstructure of the EN AC-AlSi11(Fe) alloy. Based [...] Read more.
The paper presents the results of study concerning the evaluation of the precipitation hardening parameters (temperatures and times of solution treatment and artificial ageing processes) having an effect on mechanical properties, and the change in the microstructure of the EN AC-AlSi11(Fe) alloy. Based on the obtained results and performed statistical analysis, regression equations and the response surface model in the form of spatial and contour plots were determined to illustrate the effects of solution treatment and artificial ageing parameters on the mechanical properties of the investigated alloy. The performed heat treatment had a positive effect on improving the mechanical properties of the alloy versus the initial state. The maximum increase in tensile strength was by 52%, in unit elongation by 56%, in Brinell hardness by 44% and impact strength by 88%. Furthermore, a favorable change was observed in the microstructure of the investigated alloy, especially regarding eutectic silicon precipitations, which underwent partial spheroidization and coagulation after the heat treatment. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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12 pages, 3568 KiB  
Article
Effect of Pre-Stretch on the Precipitation Behavior and the Mechanical Properties of 2219 Al Alloy
by Guo-Ai Li, Zheng Ma, Jian-Tang Jiang, Wen-Zhu Shao, Wei Liu and Liang Zhen
Materials 2021, 14(9), 2101; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14092101 - 21 Apr 2021
Cited by 5 | Viewed by 1756
Abstract
The influence of pre-stretch on the mechanical properties of 2219 Al alloys sheets were systematically investigated, with the aim of examining the age-strengthening in parts draw-formed from as-quenched sheets. The precipitation was characterized based on differential scanning calorimetry (DSC) analysis and transmission electron [...] Read more.
The influence of pre-stretch on the mechanical properties of 2219 Al alloys sheets were systematically investigated, with the aim of examining the age-strengthening in parts draw-formed from as-quenched sheets. The precipitation was characterized based on differential scanning calorimetry (DSC) analysis and transmission electron microscope (TEM) observation of specimens of as-quenched and quenched-stretched condition to address the influence of pre-stretching. A tensile test was performed to evaluate the effect on mechanical properties. The introduction of pre-stretching endues increased yield strength (YS) and thus can be helpful to exert the potential of the alloy. Peak YS of 387.5 and 376.8 MPa are obtained when specimens pre-stretched for 10% are aged at 150 and 170 °C, respectively, much higher than that obtained in the non-stretched specimens (319.2 MPa). The precipitation of Guinier-Preston zone (G.P. zones) and the transition to θ″ shifts to a lower temperature when pre-stretched is performed. The high density of dislocations developed during the stretching contributes to the acceleration in precipitation. Quench-stretched specimens present a much quicker age-hardening response at the beginning stage, which endue higher peaked yield strength. The yield strength, however, decrease much more quickly due to the recovery that occurs during the aging processes. The study suggested the feasibility of aging draw-formed components of 2219 Al alloy to obtain high strength. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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15 pages, 6131 KiB  
Article
Towards Self-Organized Anodization of Aluminum in Malic Acid Solutions—New Aspects of Anodization in the Organic Acid
by Lidia Zajączkowska, Dariusz Siemiaszko and Małgorzata Norek
Materials 2020, 13(17), 3899; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13173899 - 03 Sep 2020
Cited by 8 | Viewed by 2047
Abstract
In this work, aluminum (Al) anodization in malic acid electrolytes of different concentrations (0.15 M, 0.25 M, and 0.5 M) was studied. The close-packed hexagonal pore structure was obtained for the first time in this organic acid in a 0.5 M solution, at [...] Read more.
In this work, aluminum (Al) anodization in malic acid electrolytes of different concentrations (0.15 M, 0.25 M, and 0.5 M) was studied. The close-packed hexagonal pore structure was obtained for the first time in this organic acid in a 0.5 M solution, at 250 V and temperature of 5 °C. Moreover, the process was investigated as a function of the number of cycles carried out in the same electrolyte. A repetition of anodization under seemingly the same external electrochemical parameters (applied voltage, temperature, etc.) induced serious changes in the electrolyte. The changes were reflected in the current density vs. time curves and were most evident in the higher concentrated electrolytes. This phenomenon was tentatively explained by a massive incorporation of malate anions into anodic alumina (AAO) framework. The impoverishment of the electrolyte of the malate anions changed internal electrochemical conditions making easier the attraction of the anions to the Al anode and thus the AAO formation. The electrolyte modification was advantageous in terms of pore organization: In a 0.25 M solution, already after the second anodization, the pore arrangement transformed from irregular towards regular, hexagonal close-packed structure. To the best of our knowledge, this is the first observation of this kind. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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21 pages, 12763 KiB  
Article
Application of Light Metal Alloy EN AW 6063 to Vehicle Frame Construction with an Innovated Steering Mechanism
by Miroslav Blatnický, Milan Sága, Ján Dižo and Marek Bruna
Materials 2020, 13(4), 817; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13040817 - 11 Feb 2020
Cited by 30 | Viewed by 3529
Abstract
Nowadays the automotive industry is mainly focused on competition, and this fact forces vehicle producers to constantly look for improvements in the areas of quality and reliability. Life-span, flawless operation, and safety are directly interconnected. Therefore, much attention and resources are spent on [...] Read more.
Nowadays the automotive industry is mainly focused on competition, and this fact forces vehicle producers to constantly look for improvements in the areas of quality and reliability. Life-span, flawless operation, and safety are directly interconnected. Therefore, much attention and resources are spent on research factors that affect the stated properties. Significant capital is invested in the optimization of the constructional solutions and innovative material applications related to the safety and durability of the constructions. This paper presents the results obtained while developing a new ecological three-wheeled vehicle. The main research areas were focused on replacing the original material with a light aluminum alloy, while achieving a substantial improvement in drivability for the three-wheeled vehicle by implementing a modified front wheel steering system. The submitted research achieved a weight reduction of the frame by 40 kg by applying light material substitution (EN AW 6063.T66), which will naturally have a positive impact on the range of the designed electric vehicle; furthermore, we implemented an innovative steering mechanism optimized during the experimental operations. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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13 pages, 6808 KiB  
Article
The Influence of Remelting on the Properties of AlSi9Cu3 Alloy with Higher Iron Content
by Justyna Kasińska, Dana Bolibruchová and Marek Matejka
Materials 2020, 13(3), 575; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13030575 - 25 Jan 2020
Cited by 12 | Viewed by 2490
Abstract
This article aims to evaluate the influence of remelting on the experimental Al-Si-Cu type alloy with higher iron content on mechanical properties in relation to the resulting structure. The remelting or recycling process is one of the means of reducing the production costs [...] Read more.
This article aims to evaluate the influence of remelting on the experimental Al-Si-Cu type alloy with higher iron content on mechanical properties in relation to the resulting structure. The remelting or recycling process is one of the means of reducing the production costs of the forge plant. The experimental part deals with the analysis of the results of mechanical properties, structural analysis, and the process of crystallization of structural components and their changes due to the increased iron content caused by remelting at different states of the examined alloy. The effect of remelting and ageing on microstructure was observed using a combination of different analytical techniques (light microscopy, scanning electron microscopy (SEM), and upon deep etching and energy dispersive X-ray analysis (EDX)). Tensile strength and elongation tests point to the negative effect of alloying, a gradual increase in wt% Fe and a change in the morphology of the iron phases, which began to manifest significantly after the fourth remelting. The process of natural ageing has been shown to be effective only on alloys with a lower number of remelting cycles, whereas the application of artificial ageing has resulted in improved mechanical properties in all the test alloys. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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14 pages, 4366 KiB  
Article
Hot Deformation Behavior of a New Al–Mn–Sc Alloy
by Weiqi Kang, Yi Yang, Sheng Cao, Lei Li, Shewei Xin, Hao Wang, Zhiqiang Cao, Enquan Liang, Xi Zhang and Aijun Huang
Materials 2020, 13(1), 22; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13010022 - 19 Dec 2019
Cited by 4 | Viewed by 2377
Abstract
The hot deformation behavior of a new Al–Mn–Sc alloy was investigated by hot compression conducted at temperatures from 330 to 490 °C and strain rates from 0.01 to 10 s−1. The hot deformation behavior and microstructure of the alloy were significantly [...] Read more.
The hot deformation behavior of a new Al–Mn–Sc alloy was investigated by hot compression conducted at temperatures from 330 to 490 °C and strain rates from 0.01 to 10 s−1. The hot deformation behavior and microstructure of the alloy were significantly affected by the deformation temperatures and strain rates. The peak flow stress decreased with increasing deformation temperatures and decreasing strain rates. According to the hot deformation behavior, the constitutive equation was established to describe the steady flow stress, and a hot processing map at 0.4 strain was obtained based on the dynamic material model and the Prasad instability standard, which can be used to evaluate the hot workability of the alloy. The developed hot processing diagram showed that the instability was more likely to occur in the higher Zener–Hollomon parameter region, and the optimal processing range was determined as 420–475 °C and 0.01–0.022 s−1, in which a stable flow and a higher power dissipation were achieved. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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19 pages, 5676 KiB  
Article
An Experimental and Numerical Study of Repairs on Composite Substrates with Composite and Aluminum Doublers Using Riveted, Bonded, and Hybrid Joints
by Siddharth Pitta, Francesc Roure, Daniel Crespo and Jose I. Rojas
Materials 2019, 12(18), 2978; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12182978 - 14 Sep 2019
Cited by 4 | Viewed by 3412
Abstract
In this work, experimental and numerical analyses of repairs on carbon fiber reinforced epoxy (CFRE) substrates, with CFRE and aluminum alloy doublers typical of aircraft structures, are presented. The substrates have a bridge gap of 12.7 mm (simulated crack), repaired with twin doublers [...] Read more.
In this work, experimental and numerical analyses of repairs on carbon fiber reinforced epoxy (CFRE) substrates, with CFRE and aluminum alloy doublers typical of aircraft structures, are presented. The substrates have a bridge gap of 12.7 mm (simulated crack), repaired with twin doublers joined with riveted, adhesive bonded, and hybrid joints. The performance of the repairs using different doubler materials and joining techniques are compared under static loading. The experimental results show that riveted joints have the lowest strength, while adhesive bonded joints have the highest strength, irrespective of the doubler material. Finite element analysis (FEA) of the studied joints is also performed using commercial FEA tool Abaqus. In the FEA model, point-based fasteners are used for the rivets, and a cohesive zone contact model is used to simulate the adhesive bond. The FEA results indicate that the riveted joints have higher tensile stresses on the metal doublers compared to the composite doublers. As per the failure modes, interestingly, for hybrid joints using composite doublers, the doublers fail due to net-section failure, while, for hybrid joints using metal doublers, it is the composite substrate that fails due to net-section failure. This suggests vulnerability of the composite structures to mechanical fastener holes. Lastly, the Autodesk Helius composite tool is used for prediction of first-ply failure and ply load distribution, and for progressive failure analysis of the composite substrate. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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10 pages, 2569 KiB  
Article
Influence of W Addition on Microstructure and Mechanical Properties of Al-12%Si Alloys
by Anna Zykova, Nikita Martyushev, Vadim Skeeba, Denis Zadkov and Andrey Kuzkin
Materials 2019, 12(6), 981; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12060981 - 25 Mar 2019
Cited by 25 | Viewed by 3415
Abstract
A widespread method exerting the influence on the homogeneous formation of the microstructure and enhancement of strength properties of Al-Si alloys is a modification by super- and nanodispersed particles of different chemical compositions. In spite of the significant advances in the studies of [...] Read more.
A widespread method exerting the influence on the homogeneous formation of the microstructure and enhancement of strength properties of Al-Si alloys is a modification by super- and nanodispersed particles of different chemical compositions. In spite of the significant advances in the studies of the influence of various modifying compositions on the structure and mechanical properties of casted silumins, the literature contains no data about the influence of nanodispersed W-powder on formation of the structural-phase state and mechanical properties of Al-Si alloys. The paper considers the influence of 0.01–0.5 mass % W nanopowder on the structural-phase state and mechanical properties of an Al-12%Si alloy. It has been established that 0.1 mass % of W is an optimal addition. It results in the uniform distribution of eutectic (α-Al + Si), a 1.5-time decrease in the size of the plates of eutectic Si, a change of the shape of coarse plates (coarse plate-like or acicular) into a fine fibrous one, and an enhancement of the mechanical properties by 16–20%. Full article
(This article belongs to the Special Issue Applications of Al Alloys on Lightweight Structures)
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