The study presents the hybrid joining of the third generation AA2198-T8 aluminum lithium alloy to AA2024-T3 aluminum copper alloy, which has been highly demanded recently in the aerospace industry. This investigation aims to reduce the cost of production in the industrial sector. As a result, an affordable alternative is to use hybrid designs using AA2198-T8 alloy in crucial parts and AA2024-T3 alloy in the rest of the structure. A joining method is required to create hybrid structures composed of last-generation and standard aluminum alloys. The joining process was successfully friction stir-welded using five different welding travel speeds—36, 76, 102, 146, and 216 mm/min—with an invariable spindle speed of 960 rev/min. Two reversed steps, double-sided friction stir welding (DS-FSW) and single-sided friction stir welding (SS-FSW) techniques with two appropriate tool designs, were employed to investigate the dissimilar material mechanical properties and their morphological changes. The experimental outcomes show that DS-FSW of the reversed steps has a higher joining strength than SS-FSW for all the welding parameters studied. The variation in travel speeds provided the highest strength at 102 mm/min travel welding speeds for DS-FSW. Therefore, it is found that, from the three tensile samples, tensile strength, yield strength, and elongation of the joint were 407.1 MPa, 271.2 MPa, and 9.5%, respectively. The joint efficiency reached 87% compared with the base material tensile strength of AA2024-T3. Furthermore, fractures of the tensile samples were found in the vicinity of the thermomechanically affected zone (TMAZ) of the AA2198-T8 side. The microhardness and morphology results correspondingly have precise predictions for the fracture zone of the joints in this research examination.
In the present study, the individual and combined effect of reinforcement on aluminum (Al; 6063) alloy is discussed. These Al metal matrix composites with individual and multiple reinforcements are finding increased application in aerospace, automobile industry, underwater machines, and transportation application, due to improved mechanical and tribological properties like strong, stiff, wear, and impact resistance. Al 6063 alloy reinforced with different elements such as two types of ceramic mortar ash (MA) and nanofibrillated composite (NFC), industrial waste met coke ash (MCA), and agro waste straw ash with the constant rate of 5 wt% for each reinforced element. The results show a significant effect on the mechanical properties such as tensile strength and hardness. Damping characteristic improved by mixing of MA and NFC together and the results shown that the damping characteristics can be good for MCA reinforcement. Logarithmic decrement slowly increased by adding all types of reinforced metal together. NFC has high resistance to wear loss followed by MA and MCA but for mixing all types of reinforcements together resulted in good improvement in wear loss. Microstructure analysis of Al matrix composites is the small grain size and uniform distribution with good particulate matrix interface bonding.
Metal matrix composites are an essential product used in engineering materials. This product has wide applications in automotive, aerospace, and other uses because of their lower density, good specific strength, best machinability, and better mechanical properties compared to Al 6063 alloy. In this paper, four different reinforced such as (MA), (MCA), (NFC) and (SA) with a constant rate of 5 wt.% for each reinforced element used and mixed with Al 6063 alloy as a metal matrix composite by using modified two-step mechanical stirrer and having three blades at each step. Coated carbide tool insert was carrying out the turning process. Surface roughness measured after turning of every change in cutting speed. Average chip length and its shape style formation performed within cutting speeds of 10 and 90 m/min, which appears in different length and shapes. Mechanical properties, damping characteristics, and wear loss improved dramatically by adding all reinforced composites to the base Al 6063 alloys. As the results of experiments, the surface roughness decreased by adding all four types of reinforcements. The mechanical properties, wear loss and damping characteristics improved by the constituents of all kinds of reinforcements and also by mixing of all types of constituents together. The effects of MA and NFC are more compared to MCA and SA for improving all conditions of experimental results. Microstructure observation produces compact grain boundaries with strong grains of metal matrix composites compared to Al 6063 alloys.
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