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The aviation and automobile sectors have witnessed significant expansion and demand for lightweight metals. The friction stir welding (FSW) procedure is used for joining lightweight and low melting temperature materials. A Finite Element Analysis (FEA) utilising COMSOL® Multiphysics 6.0 software is utilised in this article to combine dissimilar metals AA6061-T6 and Mg AZ31-B, and their thermo-mechanical characteristics are explored. The peak temperature was observed to increase to 448K and 928K when the coefficient of friction (COF) increased from 0.01 to 0.4, while other parameters remained constant. When the tool rotational speed is increased to 500, 600, or 700 rpm, the peak temperature climbs to 658 K, 706 K, and 759 K, while all other parameters stay constant. When the welding speed is increased, the peak temperature reduces from 665K, 649K, and 638K to 45mm/min, 60mm/min, and 75mm/min, with all other parameters remained constant in this study. The peak temperature climbed to 632K, 684K, and 759K when the axial force increased to 10 kN, 15 kN, and 20 kN, respectively, which is a tolerable temperature less than the point of melting of materials. Peak temperatures increase to 628K, 630K, and 635K when the shoulder-to-pin diameter ratio increases to 2.5, 3.0 and 3.5 with all other parameters remaining constant. As a result, the peak temperature is directly related to tool rotational speed, coefficient of friction, axial force, and shoulder-to-pin diameter ratio, whereas welding speed is inversely proportional.

Manufacture of intricate components, products without the need for tooling, shorter lead times and material grading are the most beneficial applications of Additive Manufacturing (AM). The goal of this study is to develop a design optimization framework for developing an aircraft component using additive manufacturing utilizing topology and lattice optimization techniques. Solid works were used to create a 3D model of an aircraft bracket made of Titanium alloy. To minimize mass and maximize frequency and stiffness, the optimization was performed using Altair Inspire 2022.1 software. Component optimization was performed using the finite element method, which entails reducing material while maintaining the proper function of the modelled component. The optimal performance of the designed aerospace component using topology with lattice infill is achieved with minimization of mass from 2.24810 kg to 0.16235 kg and the volume from 5.07579x105 mm3 to 4.70922x102 mm3, frequency is increased from 0.02 kHz to 13.9537 kHz, stiffness is maximized from 1,485,884.1 N/m to 4,558,924.0939 N/m with a factor of safety of 1.73. Therefore, the mechanical properties of the optimized model can full fill its overall performance.

The goal of this research is to examine the influence of temperature affects the forging of a rectangular billet of AISI 4120 alloy steel using the 3D Deform version 11 software. The simulation was performed with 0.3 coefficient of friction on a metal forming (lubricated) process and the part is intended for application in aerospace and oil and gas industries. Three modules of deform software were defined to execute the simulation: pre-processing, simulation, and post-processing. The pre-processing in forging employed standard data— material selection, billet drawing, top and bottom dies design, meshing and simulation control. After 120 steps, the post-process estimation of deformation temperature, effective strain and stress, total velocity, and total displacement were obtained on the billet of material at temperatures of 800o C, 1000o C, and 1200° C. The results show that when forging temperatures climb, effective strain and stress decrease, total displacement and velocity decrease, and the final temperature increases.