The effect of laser power density on the fatigue life of laser-shock-peened 7050 aluminium alloy

Laser shock peening (LSP) is an innovative surface treatment method that can result in significant improvement in the fatigue life of many metallic components. The process produces very little or no surface profile modification while producing a considerably deeper compressive residual stress layer than traditional shot peening operations. The work discussed here was designed to: (a) quantify the fatigue life improvement achieved by LSP in a typical high strength aircraft aluminium alloy and (b) identify any technological risks associated with its use. It is shown that when LSP conditions are optimal for the material and specimen configuration, a —three to four times increase in fatigue life over the as-machined specimens could be achieved for a representative fighter aircraft loading spectrum when applied at a representative load level. However, if the process parameters are not optimal for the material investigated here, fatigue lives of LSP treated specimens may be reduced instead of increased due to the occurrence of internal cracking. This paper details the effect of laser power density on fatigue life of 7050-T7451 aluminium alloy by experimental and numerical analysis.

Enhanced tensile ductility of an ultra-fine-grained aluminium alloy

Aluminum alloy 6082 was subjected to equal-channel angular pressing (ECAP), which resulted in an ultra-fine-grained (UFG) microstructure with an average grain size of 0.2–0.4 μm. There was a pronounced effect of the grain refinement on the strain-rate sensitivity and tensile ductility. The Hart criterion of tensile necking fails to explain the observed ductility of the UFG material at low strain rates. A correlation between the observed stronger-than-expected ductility and a tendency to microshear band formation at low strain rates was established.

Tensile deformation of a ultrafine-grained aluminium alloy: micro shear banding and grain boundary sliding

This work investigates the relationship between the strain rate and the ductility and the underlying deformation mechanisms in an ultrafine-grained Al6082 alloy. At room temperature the uniform elongation of the material exhibits a marked increase with decreasing strain rate. This effect is related to the activation of micro shear banding, which is controlled by grain boundary sliding. The contribution of these mechanisms to uniform elongation is estimated. It is proposed that the grain boundary sliding suppresses the transformation of micro shear bands into macro shear bands. The activity of other deformation mechanisms during plastic deformation of the ultrafine-grained material is also discussed.

An analysis of microband orientation in hot deformed aluminium alloy AA5052 using forward and reverse torsion

The effects of strain path reversal on the macroscopic orientation of microbands in AA5052 have been studied using high resolution electron backscatter diffraction. Deformation was carried using two equal steps of forward/forward or forward/reverse torsion at a temperature of 300°C and strain rate of 1s-1 to a total equivalent tensile strain of 0.5. In both cases microbands were found in the majority of grains examined with many having more than one set. The microbands appear to cluster at specific angles to the macroscopic deformation. For the forward/forward condition microbands clustered around -20° and +45° to the maximum principle stress direction and at ± 30-35° to the principal strain direction. For the forward/reverse condition significantly more spread in microband angle was observed though peaks were visible at ±35° with respect to principal stress direction and at -40° and +30° with respect to the principal strain direction of the reverse torsion. This suggests the microbands formed in the forward deformation have or are dissolving and any new microbands formed are related to the deformation conditions of the final strain path.

Anodising AA5083 aluminium alloy using ionic liquids

Aluminium, as the current collector in lithium batteries, has shown reduced corrosion susceptibility in room temperature molten salts (1, 2). Moreover, previous studies have established that corrosion mitigation is achieved on magnesium alloys using ionic liquids pretreatments (3, 4). This paper investigated the anodisation of AA5083 aluminium alloy in Trihexyl(tetradecyl)phosphonium bis(trifluoromethylsulfony) ([P6,6,6,14][NTf2]) ionic liquid by applying a constant current followed by holding at the maximum potential for a period of time. Potentiodynamic polarisation results show that the treated surfaces were more corrosion resistant in 0.1 M sodium chloride solution compared with the control specimen. The anodising treatment was effective both in shifting the free corrosion potential to more noble values and in suppressing the corrosion current. Optical microscope and optical profilometry images indicated that an anodising film was deposited onto the alloy surface, which is thought to have inhibited corrosion in chloride environment. Further characterisation of the anodising film will be carried out in future work.

Electrochemical etching of aluminium alloy in ionic liquids

AA5083 aluminium alloy has been shown to be partially passivated by a 2-step anodic pre-treatment in Trihexyl(tetradecyl)phosphonium bis(trifluoromethylsulfonyl)amide ([P6,6,6,14][NTf2]) ionic liquid. Surface characterisation revealed that an electrochemical etching process had occurred, comparable to acid etching of aluminium. Scanning electron microscopy/energy dispersive x-ray spectroscopy results have established that magnesium dealloyed from the Mg2Si intermetallic particles and metal fluorides were deposited onto the remaining Mg2Si sites, which subsequently led to decreased anodic corrosion kinetics (to one third of the control) as well as an increase in the corrosion and pitting potentials. This unique electrochemical etching process offers a simple and quick method to improve the corrosion resistance of an aluminium alloy as it leads to a more uniform surface, in terms of defect size and distribution, compared to conventional acid etching. This process has the potential to be used as a pre-treatment to inhibit corrosion of AA5083 alloy.

The corrosion inhibition of aluminium alloy 7075-T651 with cerium and Mischmetal di phenyl phosphate

Previous studies have shown that cerium diphenyl phosphate (Cedpp) 3 is a very effective inhibitor of corrosion of aluminium alloys in chloride solutions. This paper describes the results of further studies using electrochemical and constant immersion corrosion tests to compare the effectiveness of Ce(dpp) 3 and Mischmetal diphenyl phosphate Mm(dpp) 3 as inhibitors of corrosion pitting on AA7075-T651 aluminium alloy. The results shows that both Ce(dpp) 3 and Mm(dpp) 3 are excellent inhibitors of pitting corrosion of this alloy in very aggressive environments of continuously aerated 0.1M and 1.0M sodium chloride (NaCl) solutions. Polarisation tests indicate that these compounds act as a cathodic inhibitors by reducing the rate of the oxygen reduction reaction, which results in a decreased corrosion current density and a separation of the corrosion potential from the pitting potential. This inhibition is thought to be due to the formation of a surface film consisting of rare earth metal oxide, aluminium oxide and a cerium-aluminium organo-phosphate complex. Surface analysis data from scanning electron microscopy and X-ray Energy Dispersive Spectroscopy show the complex nature of this protective film. This work further develops our understanding about the mechanisms through which these complex films form, and how inhibition occurs in the presence of these compounds.

Mechanical response of aluminium alloy 6061-T6 after CECAP processing

The potential of new designed continues ECAP machine in intermediate industrial scale has been discussed in the present work. The improved mechanical and microstructural properties of processed materials has been investigated on commercial aluminium alloy 6061 in T6 condition. The 6061-T6 sheet was subjected to one, two, three and four passes of ECAP. The results showing the significant improvement of mechanical properties after ECAP processing.

Electrochemical treatment of AA5083 aluminium alloy in ionic liquids

 Dr Huang was one of the first people to explore the possibility of reducing corrosion on aluminium alloys by electrochemical treatments in ionic liquids. Her study showed that the corrosion rates of aluminium alloys were indeed reduced after various electrochemical treatments in the target ionic liquids.

Film formation in trihexyl(tetradecyl)phosphonium diphenylphosphate ([P6,6,6,14][dpp]) ionic liquid on AA5083 aluminium alloy

Whilst ionic liquids (IL) have been shown to inhibit corrosion on some reactive metals and alloys by forming a surface film, e.g. Li and Mg, understanding of the interaction between ionic liquids and aluminium is lacking. This research study investigated the viability of film formation on AA5083 Aluminium Alloy by electrochemical treatments in the trihexyl(tetradecyl)phosphonium diphenylphosphate ([P6,6,6,14][dpp]) IL. Two-step anodic treatments were performed on AA5083 in the IL, followed by a comparison of the corrosion behaviour of the IL-treated samples with that of a control. It has been revealed that the two-step IL-treatment led to reduced current densities on AA5083 under cyclic voltammetry scan in the IL before and after the IL-treatment. Lower corrosion rates have been shown on all samples treated in IL at room temperature. Surface characterisation showed a non-uniform porous film on the 50°C IL-treated sample with a film thickness ranging between 37nm and 155nm. The IL-film enhanced the corrosion resistance of AA5083 by protecting the Al-matrix and Fe-rich intermetallic particles (IMPs). Although findings of this study suggest similar IL-film formation as that on Li and Mg, more research needs to be conducted to optimise the electrochemical treatment conditions and ultimately to develop a robust IL-film formation procedure for corrosion protection.

Electrochemical and DFT studies of quinoline derivatives on corrosion inhibition of AA5052 aluminium alloy in NaCl solution

Two quinoline derivatives, 8-aminoquinoline (8-AQ) and 8-nitroquinoline (8-NQ), have been used as inhibitors to examine their corrosion protection effect on AA5052 aluminium alloy in 3% NaCl solution. The weight-loss and electrochemical measurement have indicated that 8-AQ and 8-NQ play as anodic inhibitor to retard the anodic electrochemical process. SEM/EDS analysis clearly shows that 8-AQ and 8-NQ form a protective film on the AA5052 alloy surface. Density functional theory (DFT) calculation confirmed the formation of strong hybridization between the p-orbital of reactive sites in the inhibitor molecules and the sp-orbital of the Al atom. 8-aminoquinoline and 8-nitroquinoline may be useful as effective corrosion inhibitors for aluminium alloys.

Processing and properties of ultrafine-grain aluminium alloy 6111 sheet

The equal channel angular processing (ECAP) technique has been applied to an automotive aluminium alloy sheet (A6111). The technique utilizes a machine that was specially designed for this purpose at Monash University. It was determined that ECAP is able to refine the grain size of the sheet, diminish the detrimental as-rolled texture components in the sheet and retain an acceptable level of bi-axial ductility such as is required during the automotive forming process. Experiments were carried out on annealed, as-received sheets that were subjected to either one or two passes through the ECAP machine. For the second ECAP pass, the sheet could be processed in the same orientation as the first pass (route A) or it could be rotated 180° about the direction of feeding (route C). It was determined that route A produced marginally improved properties compared to sheet processed via route C, and that due to the frictional heating generated during the second pass, a significant amount of recovery occurred in the sheet such that an improved combination of texture and formability resulted after two passes compared to the same sheet exposed to only a single pass.