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The present study deals with a new design of aluminium alloy based composites reinforced with SiC particles and Si/Al2O3 powders through combined methods of powder metallurgy and thixoforming. Moreover, recycled machining chips are used as raw material, specifically AA7075 chips generated in the aeronautical industry. The proposed method is based on forming at high temperatures a compacted mixture of metal chips and reinforcing particles, with the metal in thixotropic semi-solid condition. Composites containing different SiC weight fractions (10, 20 and 30%) were produced and had their microstructure analyzed. Mechanical properties were evaluated by means of micro-indentation tests. General results show the feasibility of producing composites by the proposed route. Products with good mechanical properties could be obtained. The process, even still not completely optimized as some improvement still must be achieved, can bring a new possibility for the production of a noble material from recycled wastes, particularly important in the high energy spending Al industries.

The recently developed indentation techniques are awfully advantageous as they are performing in determination of hardness and local elasticity modulus for particular conditions; also they are being able to deal with small sample sizes. This technique is well used to characterize mechanical properties as hardness, elasticity and creep for coating thin layers. Experimental comparison of common nano and micro scales for hardness evaluation has been performed on metal samples and discussed in details in the literature review [1-3]. In fact, it was well detailed that instrumented indentation was found advantageous in both repeatability and a number of measured parameters over classical hardness methods for different materials. As far as thin materials are being very used in various industrial fields, the mechanical characterization moves to micro level scale, with micro-indentation tests of thin films and from Newton -to- micro Newton for loading conditions. A big step forward has been reached for load-depth monitoring during loading and unloading in indentation cycle. Nowadays, hardness and Young’s modulus can be easily defined using Oliver-Pharr [4-5] equations based on a micro scratch test of a very thin film. In this paper an experimental study is conducted and has been validated with a numerical FE model based on a micro indentation test of a metal matrix composite material 110A, used in aeronautic applications.

In many industrial conditions, light thin titanium shells are well used under various severe loading conditions. It is of interest to know the real conditions that govern the instability of a cracked panel subject to buckling loads in order to conserve as maximum as possible the strength of the structure. Several parameters can be varied in order to achieve this objective. The aim of this study is to determine the evolution of these parameters in order to achieve optimal crack propagation conditions while keeping these parameters within “reasonable” limits of physical and economic feasibility. For the purpose of the current study the considered structure can be regarded as thin cylindrical shell of radius r, thickness t with an initial through crack of length a. The titanium cylindrical shell is sealed on one edge and compression is applied on the other. An additional applied pressure can generates a stress and deformation field around the crack tip that has bending stresses and membrane stresses and appears as a bulge around the crack area. This paper give details of a simulation with FEA numerical analysis that determine governing instability conditions of a Titanium shell under particular loading conditions and to put in light the effect of bulging on the stress intensity factor at the crack tips. This bulging factor measures the severity of the stress intensity in the bulged crack compared to a plane shell subjected to equivalent loading conditions.

Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on thermoelectric energy between the work piece and an electrode. There are various types of products which can be produced by using the EDM such as dies and moulds. Today many parts used in aerospace and automotive industry and also final processes of surgical components can be finished by EDM process. A simple and easily understandable model was proposed for predicting the relative importance of different factors (composition of the steels and Electro Discharge Machining processing conditions) in order to obtain an efficient pieces. A detail application on the tool steels machined by EDM was given in this study. This model is based on thermal, metallurgical and mechanical and also in situ test conditions. It gives detail information on the effect of electrochemical parameters on the surface integrity and sub-surface damage of the material (Heat Affected Zone, HAZ), the level of residual stresses, and the surface texture. This approach is an efficient way to separate the responsibilities of the steel maker and machining process designer for increasing the reliability of the machined structures.