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Aluminum‐silicon alloys have been widely used in automotive industries. To know mechanical properties of such materials is essential for engineers to have a superior design for components. Therefore, in this article, the sensitivity analysis of mechanical and fracture features in the aluminum alloy has been performed to find the effect of the loadi...
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In automotive industry, it is well known that cracks which are promoted by liquid metal embrittlement (LME) can occur during the resistance spot welding (RSW) of zinc-coated advanced high-strength steels (AHSS). The coating type is supposed to be one of the factors impacting LME susceptibility. Recently, Zn–Al–Mg coating is gaining increasing focus...
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... A356 Al-alloy has Si content of 7 ± 0.5 % and Mg content <0.5 %, it is utilized in automotive parts manufacturing, aerospace applications, housing covers, and pump components due to its low density and high corrosion resistance [18,19]. However, A356 Al-alloys (in the as-cast state) were not drilled by friction before due to their high brittleness [20,21]. Generally, to overcome the brittleness of the as-cast Al-alloys during friction drilling, pre-drilling of the investigated sheets was suggested [22,23]. ...
Hardness Bushing Surface roughness Microstructure SEM A B S T R A C T The friction drilling process utilizes frictional heat to increase the thickness of sheet metal parts by making holes with bushes using a non-traditional drilling tool. Unfortunately, cracks are found in the formed bushings during friction drilling of brittle materials. The purpose of the present study is to improve the quality of friction-induced bushes in brittle A356 aluminum sheets via a performance of a pre-drilling with different diameters (2, 2.5, and 3 mm). The pre-drilling is aimed to reduce cracks and petal formation as compared with the solid sheets. The friction drilling processes were carried out by a K100 conical tool, with 10 mm diameter and 58 • cone angle. The friction drilling parameters involve different rotational speeds (2000, 3000, and 4000 rpm) as well as different feed rates (40, 60, and 80 mm/min). The characteristics of the thermally induced bushes (shape, dimensions, and surface roughness) were investigated in solid and pre-drilled sheets. Furthermore, we studied the microstructure evolution and hardness distribution in the thermo-mechanical affected zone and the heat-affected zone surrounding the bush. It was found that, the formed bushings in the pre-drilled sheets did not have cracks or petal formation in comparison with the other formed bushes in the solid sheets. The pre-drilled specimens showed an average bushing height increase from 5 to 6 ± 0.8 mm with the increase of the tool rotational speed from 2000 to 4000 rpm. At rotational speeds of 2000 and 4000 rpm, the pre-drilled specimens with a diameter of 2.5 mm had a bushing height which is 0.5 ± 0.2 mm greater than the other pre-drilled specimens. In addition, the surface roughness of the pre-drilled sheets decreased with the increase of the rotational speed and/or reduction of the feed rate. Moreover, the microstructure near the drilling zone exhibited a fine Si particles distribution. However, the hardness values near the drilled surfaces were 15 ± 8 HV lower than those of the base metal in both solid and pre-drilled sheets.
... Combination of superior mechanical properties and higher strength to weight ratio are the attracting features of Metal Matrix Composites (MMCs) leading to engineering applications in various industries like aeronautical, automobile, aerospace and marine industries [1][2][3][4]. Recently the complex shaped products are produced by powder metallurgy technique using metal matrix composites as alternative options to the conventional alloys [5]. There are several interesting advantages of MMCs like possessing homogeneous mechanical properties, economical in cost and feasible processing techniques when compared to that of conventional engineering materials. ...
Metal matrix composites are the novel engineering materials finding applications in several extreme environmental and industrial requirements leading to the developments of numerous types of its kind in recent decades. Powder metallurgical techniques is one among the promising methods of producing intricate shaped end products out of the MMCs. Essentially the uniformity in distribution of the reinforcements and the accuracy in employing the percentile addition of the reinforcements decide the tailor made properties of these composites. There are several techniques to evaluate the reinforcement percentage and uniformity. This work concentrates on the analysis of effectiveness of volume fraction determination methods namely Archimedes test and acid dissolution test for 7075 Al/Al 2 O 3 composite. Using the two methods the volume fraction of 7075Al/ Al 2 O 3 composite prepared by powder metallurgy technique is determined. Advantages and disadvantages of both methods were analyzed using the result analysis and the observation indicated that the acid dissolution test produces more accurate results than the Archimedes test. In addition, the randomized selection of the specimens out of the end products leads to the corroboration of reinforcement uniformity in the composite matrix.
... Moreover, the improvement in the corrosion-fatigue lifetime of components is to be noticed in the automotive industry. Various ways to increase the service lifetime are heat treatments, in addition to the recent knowledge edge of nano-particles [3]. In this field of study, different articles have been widely published until now. ...
... In the literature review, almost all works were presented through qualitative analysis. In only rare articles such as Azadi et al. [3], the quantitative analysis was performed on fatigue and corrosion-fatigue phenomena of materials. Based on a claimed novelty in this research, the sensitivity analysis of the stress, the pre-corrosion, the addition of nano-particles, and the heat treatment was done on the fatigue lifetime of aluminum alloys. ...
... These bending stress levels were 120, 150, 180, and 210 MPa. More details for the fabrication of the studied materials could be found in the literature by Aroo et al. [1], Azadi et al. [3], Rezanezhad et al. [10], and Zolfaghari et al. [11]. In addition, more details of fatigue testing and the geometry of standard cylindrical samples could be followed in the literature by Parast et al. [12], Sharifi et al. [13], and Khisheh et al. [14]. ...
This article presents the bending fatigue behavior and the scatter-band analysis of aluminum alloys under beneficial conditions of nano-clay-particles and heat-treating, compared to detrimental conditions of the mechanical stress and the corrosion. Moreover, the sensitivity analysis was also done on the stress level, the pre-corrosion phenomenon, the addition of nano-particles and applying the heat treatment on the high-cycle bending fatigue lifetime of the aluminum-silicon alloy. For this objective, gravity and stir-casting processes were done for aluminum alloy and nano-clay-composite specimens and then, standard samples were machined from initial casted cylinders. Furthermore, rotary fatigue tests were performed under cyclic bending loadings, through the high-cycle fatigue regime. Some samples were pre-corroded in the sulfuric acid for 200 hours. Based on the sensitivity analysis on experimental data by the Minitab software, the obtained results indicated that the stress level was the effective parameter on the fatigue lifetime. The meaningful regression model was calculated and calibrated on the logarithmic scale of the fatigue lifetime. Then, the second sensitive parameter was demonstrated as the pre-corrosion, which caused a significant degradation of fatigue properties in the material. The last-ranked factor was related to nano-particles for the beneficial effect on the improvement of the high-cycle fatigue lifetime. The scatter-band analysis illustrated that nano-particles and heat-treating changed the scattering behavior of experimental data.
This article presents the sensitivity analysis of the stress level, the pre-corrosion phenomenon, the addition of nano-particles and applying the heat treatment on the high-cycle bending fatigue lifetime of the aluminum-silicon alloy. For this objective, gravity and stir-casting processes were done for aluminum alloy and nano-clay-composite specimens and then, standard samples were machined from initial casted cylinders. Furthermore, rotary fatigue tests were performed under cyclic bending loadings, through the high-cycle fatigue regime. Some samples were pre-corroded on in the sulfuric acid for 200 hours. Based on the sensitivity analysis on experimental data by the Minitab software, the obtained results indicated that the stress level was the effective parameter on the fatigue lifetime. The meaningful regression model was calculated and calibrated on the logarithmic scale of the fatigue lifetime. Then, the second sensitive parameter was demonstrated as the pre-corrosion, which caused a significant degradation of fatigue properties in the material. The last-ranked factor was related to nano-particles for the beneficial effect on the improvement of the high-cycle fatigue lifetime.
