Granting Sensorial Properties to Metal Parts through Friction Stir Processing

Ferreira, Pedro Moura; Machado, Miguel A.; Carvalho, Marta; Vidal, Catarina

doi:10.1016/j.measurement.2022.112405

Cited by 11 publications

(13 citation statements)

References 48 publications

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“…Hardness is a property that influences mechanical strength and can be a good indicator to evaluate the mechanical properties of the produced dissimilar alloys composites. Eddy currents tests are non-destructive tests that allow the assessment of electrical conductivity variations and can be used to evaluate microstructural and hardness variations as this is inversely proportional to electrical conductivity, as confirmed by previous studies [1,42,49]. In other words, the nugget zone, which has a finer grain structure and a higher number of grain boundaries, exhibits higher electrical resistance and higher mechanical strength.…”

Section: Aluminium-based Dissimilar Alloys Surface Compositesmentioning

confidence: 81%

“…The eddy currents technique was implemented using a pencil probe operating at 1 MHz and a NORTEC 600D impedance analyzer (Olympus Corporation, Tokyo, Japan). The procedure was developed according to Ferreira et al [1].…”

Section: Schematicmentioning

confidence: 99%

“…Metal matrix composites (MMCs) have emerged as promising materials for various structural applications owing to their ability to improve the specific strength of pure metals or alloys by incorporating secondary phase particles. Materials such as aluminium, copper, magnesium, and titanium are commonly used as matrix materials, while particles such as SiC, SiO 2 , Al 2 O 3 , TiB 2 , BaTiO 3 , graphene, and WC are often used as secondary phase materials [1][2][3][4][5][6][7][8]. MMCs find applications in industries such as automobile, aerospace, marine, and power generation due to their enhanced fatigue and wear resistance.…”

Section: Introductionmentioning

confidence: 99%

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Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

et al. 2023

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Surface metal matrix composites offer an excellent solution for applications where surface properties play a crucial role in components’ performance and durability, such as greater corrosion resistance, better wear resistance, and high formability. Solid-state processing techniques, such as friction surfacing and friction stir welding/processing, offer several advantages over conventional liquid-phase processing methods. This research investigated the feasibility of producing surface composites of aluminium-based dissimilar alloys reinforced with functional microparticles through experimental validation, determined the process parameters that resulted in a more homogeneous distribution of the particles in the surface composites, and enhanced the understanding of Upward Friction Stir Processing (UFSP) technology. The production of aluminium-based dissimilar alloys (AA 7075-T651 and AA 6082-T651) surface composites reinforced with SiC particles was studied, and it was concluded that the macrography and micrography analyses, scanning electron microscopy (SEM) analysis, microhardness measurements, and eddy currents technique reveal an extensive and homogeneous incorporation of SiC particles. In the stirred zone, a decrease of approximately 20 HV 0.5 in hardness was observed compared to the base material. This reduction is attributed to the weakening effect caused by low-temperature annealing during UFSP, which reduces the strengthening effect of the T651 heat treatment. Additionally, the presence of particles did not affect the surface composite hardness in the stirred zone. Furthermore, despite the presence of significant internal defects, SEM analyses revealed evidence of the lower alloy merging with the upper zone, indicating that the lower plate had a role beyond being merely sacrificial. Therefore, the production of bimetallic composites through UFSP may offer advantages over composites produced from a monometallic matrix. The results of the eddy currents testing and microhardness measurements support this finding and are consistent with the SEM/EDS analyses.

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Section: Aluminium-based Dissimilar Alloys Surface Compositesmentioning

confidence: 81%

Section: Schematicmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

et al. 2023

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“…Recent studies [43][44][45] highlighted the influence of introducing piezoelectric ceramic particles into a metallic component, impacting both its mechanical properties and inducing an electrical response under various conditions. These studies specifically focus on integrating piezoelectric particles into aluminium parts (AA2017-T451) using FSP technology, utilizing BT and PZT particles to enhance the sensitivity and technical aspects of the resulting SSM.…”

Section: Introductionmentioning

confidence: 99%

Enabling electrical response through piezoelectric particle integration in AA2017-T451 aluminium parts using FSP technology

Ferreira,

Caçador,

Machado

et al. 2024

Smart Mater. Struct.

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In the field of structural engineering, the integration of smart materials and structural health monitoring (SHM) has given rise to self-sensing materials (SSM), leading to a paradigm shift in SHM. This paper focuses on the interplay between self-sensing capabilities and the piezoelectric properties of lead zirconate titanate (PZT) and barium titanate (BT) in aluminium components. Leveraging Friction Stir Processing (FSP), the study explores the synthesis and performance of self-sensing materials with embedded piezoelectric particles, potentially transforming structural engineering. The paper highlights FSP as a key methodology for incorporating piezoelectric particles into structural materials, showcasing its potential in developing self-sensing materials with enhanced functionalities. A specific focus is placed on integrating PZT and BT particles into AA2017-T451 aluminium parts using FSP, with metallographic assessments and mechanical property evaluations conducted to analyse particle distribution and concentration. This study shows how BT and PZT particles are incorporated into AA2017-T451 aluminium to create a self-sensing material that responds to external stimuli. Under cyclic loading, the self-sensing materials exhibit a linear load-electrical response correlation, with sensibility increasing at lower frequencies. Metallographic analysis shows homogeneous particle distribution, while PZT induces increased brittleness and brittle fractures. Yield strength remains relatively stable, but ultimate strength decreases post-FSP. Hardness variations indicate weaker bonding with PZT particles. Eddy's current testing aligns with hardness profiles, and sensorial characterization reveals a non-linear frequency-sensibility relationship, showcasing the SSMs' suitability for low-frequency applications, particularly with PZT embedment.

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“…Ultrasound Testing (UT) allows the inspection of optically opaque materials such as liquid-metal coolants, steam generator piping, and heat exchanger pipes [ 10 ]. However, the temperature at which ultrasonic transducers with piezoelectric elements may operate is limited by their Curie temperature [ 10 , 12 ]. The maximal operation temperature is also limited by the properties of the material used for the transducer’s assembly.…”

Section: Introductionmentioning

confidence: 99%

Non-Destructive Inspection of High Temperature Piping Combining Ultrasound and Eddy Current Testing

Santos

Machado

Monteiro³

et al. 2023

Sensors

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This paper presents an automated Non-Destructive Testing (NDT) system for the in-service inspection of orbital welds on tubular components operating at temperatures as high as 200 °C. The combination of two different NDT methods and respective inspection systems is here proposed to cover the detection of all potential defective weld conditions. The proposed NDT system combines ultrasounds and Eddy current techniques with dedicated approaches for dealing with high temperature conditions. Phased array ultrasound was employed, searching for volumetric defects within the weld bead volume while Eddy currents were used to look for surface and sub-surface cracks. The results from the phased array ultrasound results showed the effectiveness of the cooling mechanisms and that temperature effects on sound attenuation can be easily compensated for up to 200 °C. The Eddy current results showed almost no influence when temperatures were raised up to 300 °C.

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Granting Sensorial Properties to Metal Parts through Friction Stir Processing

Cited by 11 publications

References 48 publications

Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

Enabling electrical response through piezoelectric particle integration in AA2017-T451 aluminium parts using FSP technology

Non-Destructive Inspection of High Temperature Piping Combining Ultrasound and Eddy Current Testing

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