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This research paper aims to optimize the TIG welding parameters to join dissimilar metals of AA5083 and AA7075 using the Taguchi technique. The TIG welding current and root gap of butt geometry configuration are considered input parameters, and welding characteristics such as tensile strength, 0.2% of yield strength, hardness, and impact energy are output responses. The base metals are joined according to the Taguchi L-09 design of experiments. The welded samples were inspected using the X-ray radiography method for internal defects. Tensile properties, hardness number, and impact energy of different welding coupons were evaluated by conducting the uni-axial testing, a Brinell hardness test, and an Izod impact test, respectively. A better weld strength of 224 MPa was observed at 210 A welding current, and the root gap of 1.5 mm was maintained. Better hardness and impact energy values were observed when the root gap of 1.5 mm and welding current of 220 A were maintained. The root gap is the primary factor influencing tensile strength enhancement, which accounts for 44.78% of the effect, followed by 40.5% welding current. Root gap is the parameter that affects the tensile properties, hardness number, and impact toughness the most. The findings of this paper suggest the optimal parameters for welding AA5083 and AA7075 dissimilar base metals, which are suitable for complex structures requiring both durability and resistance to harsh environments. [ABSTRACT FROM AUTHOR]

Abstract This research paper aims to optimize the TIG welding parameters to join dissimilar metals of AA5083 and AA7075 using the Taguchi technique. The TIG welding current and root gap of butt geometry configuration are considered input parameters, and welding characteristics such as tensile strength, 0.2% of yield strength, hardness, and impact energy are output responses. The base metals are joined according to the Taguchi L-09 design of experiments. The welded samples were inspected using the X-ray radiography method for internal defects. Tensile properties, hardness number, and impact energy of different welding coupons were evaluated by conducting the uni-axial testing, a Brinell hardness test, and an Izod impact test, respectively. A better weld strength of 224 MPa was observed at 210 A welding current, and the root gap of 1.5 mm was maintained. Better hardness and impact energy values were observed when the root gap of 1.5 mm and welding current of 220 A were maintained. The root gap is the primary factor influencing tensile strength enhancement, which accounts for 44.78% of the effect, followed by 40.5% welding current. Root gap is the parameter that affects the tensile properties, hardness number, and impact toughness the most. The findings of this paper suggest the optimal parameters for welding AA5083 and AA7075 dissimilar base metals, which are suitable for complex structures requiring both durability and resistance to harsh environments.

One of the important parameters influencing the formation of a weld during friction stir welding is the tool geometry, which affects the processes of heat generation and stirring of metals in their connection zone. These processes influence the formation of a high quality and strength welded joint without continuity defects. In this regard, it is relevant to analyze the influence of tool geometry on the welding mode parameters, at which the welded joint is formed without continuity defects, as well as on the welded joint strength under static tension. The work considers the influence of the cylindrical and conical shapes of the tool pin, as well as the conical shape of the pin with a thread on its outer surface and a spiral groove on the end surface of the tool shoulder on the welding mode parameters, at which the welded joint is formed without continuity defects. The study shows that changing the shape of the pin working surface from cylindrical to a conical one had no effect on the range of welding mode parameters, at which the welded joint is formed without continuity defects. It has been found that the presence of a thread on the pin outer surface and a groove on the end surface of a tool shoulder allows producing welded joints without continuity defects in a wider range of welding mode parameters compared to a simpler tool geometry. The macrostructure of the resulting welded joints was considered. It has been found that the studied tool geometry has almost no influence on the maximum strength values of welded joints produced by friction stir welding and reaches 95 % of the strength of the base metal.

The aim of this study is to develop metal-metal composites reinforced with nickel powder using an AA5083 aluminium alloy matrix by powder metallurgy methods and to investigate their properties. In order to analyse the influence of different amounts of nickel particles on the AA5083-Ni composite, specimens were prepared by incorporating nickel at 5%, 10% and 15% by weight. To achieve a uniform distribution of nickel particles, the matrix and composite powders were mixed in ball mills for five hours. These powders were then hot pressed at 500°C under a pressure of 500 MPa for two hours in an argon gas atmosphere to produce the samples. These samples were then tested for microstructure, hardness, density, tensile properties and corrosion behaviour to assess the effect of varying nickel content on the AA5083-Ni metal-metal composites. [ABSTRACT FROM AUTHOR]

Surface integrity problems during selective material removal processes are a very common limitation for process productivity and part quality, especially in difficult-to-machine materials like 5083 aluminium alloy (AA), which is known for its remarkable performance in extreme environments. In general, tuning the cutting-part material properties with cutter geometry and cutting parameters can optimize surface texture, increase parts accuracy and resistance in corrosion, and eliminate process noise and energy waste. This work is an experimental study of surface parameter optimization during finish end milling of an AA5083 under a specific range of three cutting parameters with an optimized two-flute carbide cutter by previous work. So, twenty-seven experiments were run having varied the radial depth of cut (RDOC), feed rate (f), and cutting speed (S). Surface roughness parameters (Ra and Rt) were measured in the direction of cutting speed at three different distances by the upper edge. The signal-to-noise (SN) ratios have been calculated, and the process was optimized following the analysis of means. Then, additive models with linear interactions were fitted on SN ratios, and the analysis of variances and residual normality plots were utilized to validate the models' goodness. The SN approach and analysis of means conclude that 0.5 mm RDOC, 6000 rpm speed, and 0.082 mm/tooth feed optimize the process and can effectively predict the Ra and Rt responses. The newly produced machinability data can benefit further applications of AA5083 in industrial applications such as shipbuilding and vehicle bodies. [ABSTRACT FROM AUTHOR]

In this research, dissimilar plates of AA5083 and AA6082 were used to develop the dissimilar components where high corrosion resistance and good mechanical properties required especially in aerospace industries. TIG welding set-up has been made to join these dissimilar joint using ER4043 as filler rod. The parameters such as current, time and filler rod diameter were selected at three levels. The design of experimentation was made according to L-9 orthogonal array. After welding, samples were sliced into various specimens to conduct mechanical testing's. Tensile test was conducted on UTM as per ASTM E/8 standard. Izod test was conducted to calculate the impact energy observed before fracture under Charpy testing machine. Brinell hardness values were evaluated by testing the weld surface hardness. The output response factors like UTS, impact strength and hardness were considered as response factor to study the effect of parameters. ANOVA has been performed on output response and the analysis results were presented. From the ANOVA, the welding speed (52.54%) exerted a major effect on responses followed by weld current (22.83%) and filler diameter (20.18%). The grain boundaries with fine structures were identified at AA6082 interface whereas coarse grain structures were observed at 5083 interface due to the thermal properties. [ABSTRACT FROM AUTHOR]

This research paper aims at predict the thermal and residual stresses in dissimilar welds of AA5083 and AA6082 using ANSYS®. The combination of dissimilar components are widely used where high corrosion resistance and good mechanical properties required. Thermo-mechanical properties were predicted by developing 3-Dimensional Goldak ellipsoidal model. Suitable boundary conditions were applied during simulation in order to predict accurate results in the welded structures. Element types, SOLID 70 for thermal and SOLID 185 for structural analyses were considered. Convective heat transfer co-efficient and radiation boundary conditions were considered during thermal analysis. The FE results obtained from these thermal model were taken into account to predict the stress formation along welding and transverse direction. For this, static structural analysis has been performed. The stress formation in TIG welding process were predicted at different zones of welded structures. In order to validate these stress values at different locations, XRD technique is used to measure the stress distribution experimentally. Peak temperatures were predicted during the course of process when the source model is moving along the welding direction. The predicted residual stresses are validated and which are in good agreement with measured values and the measured data values are within yield limits only. [ABSTRACT FROM AUTHOR]

AA5083 with ultrafine grain structure was produced through equal channel angular pressing using different levels of ECAP tensions, underwent a series of tensile tests. The superplasticity temperature 573 K at low temperatures. This study investigate how varying the ECAP strain influences the distinctive microstructure of the alloy and its impact on deformation mechanisms within the low-temperature superplasticity range. A fraction of the high angle borders increased when the equal channel angular pressing strain was increased from 1 to 2, while the sub-grain size stayed nearly same. This was the most applicable microstructural evolution. After double passes, the material showed superplastic elongations, but after single pass, it did not show low temperature superplasticity. Upon analyzing the mechanical data using typical deformation mechanisms, it was determined that dislocation climb controlled the samples deformation after the first pass, whereas grain boundary sliding was responsible for the sample's low temperature superplasticity after the second pass. In the present study, we explored the differences in deformation mechanisms by considering the microstructures formed under various ECAP strains. Equal channel angular pressing with a BC route and an effective strain of 1∼2, we created an ultrafine-grained AA5083. A significant increase was seen in the fraction of particles measuring 1.8–3.8 μm under the current ECAP conditions. The implementation of equal channel angular pressing, there was a significant increase in the occurrence of voids with sizes ranging from 0.8 to 1.8 μm. According to the current analysis and results, if moderate superplastic elongation is guaranteed, it may be preferable to have fewer equal channel angular pressing passes than those that result in the largest elongation while taking into account cavitation damage and the low temperature superplasticity of ultrafine grained AA5083 used in commercial applications.

This study investigated the weld joint mechanical properties and welding fume exposure associated with Gas Metal Arc Welding of aluminum AA5083-H112 in 27 different welding room environment conditions. These conditions consist of variation in temperature, as well as intake and exhaust wind velocities. The temperature varies as 19 °C, 27 °C and 35 °C. Both the intake and exhaust velocity vary as 0 m/s, 3.1 m/s and 5.5 m/s. The experimental findings underscore the pronounced influence of these factors on both weld quality and welder exposure to fumes. Notably, intake wind velocity emerges as the most critical factor, contributing significantly to 47.68 % in weld joint tensile strength. The temperature emerges as the least critical factor with 12.02 % of contribution. However, temperature became the most critical factor on weld joint impact energy with 54.89 % of contribution while exhaust wind velocity became the least with 3.89 %. Air quality monitoring highlights the importance of optimal intake and exhaust fan configuration to effectively reduce fume exposure. All examined welding room environment condition are deemed safe for the welder, as they do not exceed the Treshold Limit Value (TLV), except the condition where the welding room lacks of air circulation in intake and exhaust wind velocity of 0 m/s. The identified optimal welding room condition exerts a temperature of 27 °C, intake and exhaust wind velocity of 0 m/s and 3.1 m/s respectively. This condition not only achieves established weld quality standards but also ensures compliance with fume exposure regulation. This research provides valuable insights for optimizing welding room environment to simultaneously maintain weld quality and safeguard the well-being of welders. [ABSTRACT FROM AUTHOR]

Friction stir welding (FSW) is a non-traditional welding procedure for joining identical and divergent substances that are comparatively hard to weld using fusion techniques. The FSW is more competent and eco-responsive when correlated with the traditional processes. The tensile characteristics of thermally susceptible alloys are minimized as a result of heat iterations. The roughening of the consolidated deposits in friction stir welding induces joint moderation. For non-heat-treatable alloys, intergranular and stress corrosion cracking are developed in grain boundaries during the FSW. Because of this, the overall performance and mechanical properties were reduced. Underwater friction stir welding (UWFSW) is preferred to prevail over the problems. UWFSW is appropriate for both heat-treatable and non-heat-treatable alloys that are receptive to thermal activity throughout the procedure. This research examines the effects of response surface methodology (RSM)-based grey relational methods on the optimization of UWFSW procedural characteristics such as the straight hexagonal tool profile (SH), tool rotational speed (TRS) of 1200 rpm, tool transverse velocity (TTV) of 20 mm/min, and water head (WH) of 10 mm in military-grade AA5083 alloy. The mechanical properties of the AA5083 UWFSW joint, such as its average ultimate tensile strength (UTS) and hardness, have been greatly improved. Grey Relation Analysis was used to determine welding specifics such as UTS and hardness. The ANOVA was used to assess the formulation's significance. The micro-structural behaviour and grain structure of different weld zones were investigated with the help of the scanning electron microscope (SEM). The image processing technique can be used to quantitatively assess the UWFSW process using the non-destructive testing (NDT) ultrasonic B-scan image and radiographic image. Confirmation tests at the optimal parameter level improved the performance of each response. [ABSTRACT FROM AUTHOR]

Lightweight combat units, assault warplanes, and destroyers are being developed to increase agility and resource efficiency. This is realized using lightweight frames composed of aluminum and magnesium alloys, which decrease weight, enhance cargo-carrying capacity, and improve vehicular efficiency. This research used 18.5 mm Armour Piercing Projectiles at a target velocity of 200 m/sec to test the ballistic performance of AA5083 Base Metal and underwater friction-stir welded (UWFSW) target welded plates. The Al's joints were fabricated utilizing the UWFSW process at tool rotational speed (TRS), tool welding speed (TWS), and tool tilt angle (TTA), as well as variable tool pin shapes, cylindrical threaded, straight hexagonal, and straight cylindrical. With a TRS of 1200 rpm, TWS of 40 mm/min, TTA of 1°, and straight hexagonal tool pin shape, defect-free welds with improved tensile and impact qualities were attained. The macro hardness and microstructure of the UWFSW joints were examined. The fine grain structure has the highest hardness (135 HV). Adiabatic Shear Bands (ASBs) were confirmed by scanning electron microscopy of a projectile-pierced channel. Because of the increased amount of ASB lines on the ballistic hit UWFSW surface, there were more macro cracks. There was no fragmentation loss, reduced fissures, and lesser ASB lines in the hexagonal pin joints, all of which increased ballistic performance. In order to protect against the corrosion of UWFSWed 5083 Al alloy in seawater, electrochemical tests and nitric acid mass loss tests were conducted. [ABSTRACT FROM AUTHOR]

Purpose: Aluminium AA5083 is commonly utilised in constructing ship hull shells, which are welded with aluminium AA6063 to act as stiffeners. However, the joints often suffer structural damage, such as longitudinal and transverse cracks in the dissimilar weld area, particularly in the Heat-Affected Zone (HAZ) of AA6063, which includes frames, brackets, and collars. To enhance the mechanical properties of AA6063, T6 heat treatment is commonly employed. The given study investigates the impact of temperature in artificial ageing during the T6 heat treatment on the microstructure and mechanical properties of the dissimilar materials welding between AA5083 and AA6063. Design/methodology/approach: The T6 heat treatment variations involve a solution treatment at 540°C for 6 hours, followed by quenching and artificial ageing at temperatures of 158°C, 200°C, and 230°C for 6 hours, followed by air cooling. The T6 heat treatment variations involve a solution treatment at 540°C for 6 hours, followed by quenching and artificial ageing at temperatures of 158°C, 200°C, and 230°C for 6 hours, followed by air. The weld joints were visually inspected and examined using radiography, then characterised by microstructure investigation and tensile and impact tests. Findings: The study's findings reveal that the T6 heat treatment significantly improves the mechanical properties of AA6063. However, the T6 heat treatment does not notably affect the mechanical properties of AA5083, the fusion line and the weld metal area. Among the artificial ageing temperature variations, the highest mechanical properties are achieved at 200°C, while the lowest mechanical properties are observed at 230°C. Research limitations/implications: Aluminium AA5083 is commonly utilised in constructing ship hull shells, which are welded with aluminium AA6063 to act as stiffeners. However, the joints often suffer structural damage, such as longitudinal and transverse cracks in the dissimilar weld area, particularly in the Heat-Affected Zone (HAZ) of AA6063, which includes frames, brackets, and collars. The paper focused on the influence of artificial ageing temperature in T6 heat treatment on the microstructure and mechanical properties of the dissimilar metals welding between AA5083 and AA6063. Originality/value: The optimum artificial ageing temperature in T6 heat treatment for the dissimilar metals welding between AA5083 and AA6063 was 200°C. The method can be applied in ship structures where AA5083 is typically utilised for constructing the hull shells, while AA6063 is employed as stiffeners. [ABSTRACT FROM AUTHOR]

The 5xx series of Aluminium has strong corrosion resistance, excellent weldability, and good cold workability and also medium strength. This series is being utilized extensively in marine building applications for the construction of Oil tankers, pressure vessels, offshore, ships and other vessels. The purpose of this study is to verify and to ascertain how the welding process affects the corrosion rate and impact strength of 5083 Aluminium. In this experiment, four AA 5083 specimens were warmed to chosen variations of 50°C, 100°C, 150°C, 200°C, and 250°C. The amount of energy absorbed during the fracture process was then determined by subjecting the welding results to a Charpy impact test with varying loads. The best specimen was tested for corrosion rate using the Corrosion Tester 3-Electrode device after comparing impact toughness. According to the study's findings, the specimen with a 250°C preheating step had the maximum impact toughness (0.415) and corrosion rate (0.11353 mmPy).

Diffusion bonding is a sort of solid-state joining that allows the joining of metals with similar and dissimilar compositions by allowing them to diffuse into one another. The current study investigated the impact of process parameters on the bonding strength of AA5083. The process parameters were considered as bonding temperature, holding time, and bonding pressure. Because of micro-constituent diffusion in the interface, the bonding and shear strengths increased as pressure and temperature were raised in the sample. By increasing the temperature of the Al3Mg2 particles from 490 °C to 520 °C and the bonding pressure from 5 MPa to 15 MPa, the dispersion of secondary phase particles is improved, and pores/defects in bonded joints are reduced. Furthermore, microstructural characterization reveals that the achieved strength is contingent on boundary grain growth and grain boundary migration through the bonding process, respectively. The light optical microscope was used to characterize the microstructural test and diffusion layer configuration at the boundary.

The present study investigated the effect of hydrogen on the mechanical degradation of friction stir processed (FSPed) 5083 aluminum alloy by intense hydrogen cathodic charging (HCC). The effect of different numbers of FSP passes was investigated: 3 and 8 passes, respectively. Hydrogen-charged and uncharged specimens were subjected to tensile testing and microhardness evaluation analysis, and were examined through optical microscopy, focus variation microscopy (FVM), and scanning electron microscopy (SEM) both on the microstructure and fracture zone. The results showed that the FSP process introduced a refined microstructure with finer grains. This led to an improved mechanical response during tension tests of the uncharged specimens; the energy absorption increased from 85 MJ/m3 of the base material to 94 MJ/m3 and 97 MJ/m3 for the 3 and 8 FSP passes, respectively. The introduction of hydrogen through the HCC process led to a more brittle mechanical response with a decrease in the energy absorption capability for all the charged specimens. The more prone specimen was the 8 FSP passes specimen where the energy absorption dropped by 20% and 71% for the two different charging current densities. The 3 FSP passes specimen presented a reduction of energy absorption of 4% and 18%, respectively, where the base material presented a reduction of 8% and 14%, respectively. This brittle response is also evident from the microhardness testing where the hydrogen charging led to increased surface hardness values. The 3 FSP passes specimen presented a better mechanical response with respect to the base material specimen (and the 8 FSP passes specimen) for all the charging conditions, and this led to the conclusion that a small number FSP surface modification could be a beneficial surface modification process as it improves the mechanical response of the material and is not significantly affected by hydrogen charging environments. [ABSTRACT FROM AUTHOR]

In the current work, a Gas metal arc welding (GMAW)-based Wire Arc Additive Manufacturing (WAAM) procedure was used to build a wall construction of measuring Aluminium alloy (AA) AA5356 on an AA5083 base plate. The microstructure and mechanical properties of AA5356 were examined at two places along the wall structure’s horizontal deposition direction and in two deposition orientations (horizontal and vertical). Optical microscopy, SEM, EDAX, and fractographical examinations were used to analyse the microstructure. Tensile and microhardness tests were performed at two wall locations to evaluate mechanical parameters. A microstructure analysis reveals a mixture of columnar grain structure and coarser intermetallics in the remelting zone, with finer granular structure in the central region. The horizontal direction of AA5356 deposition exhibited a highest elongation and tensile strength of 4.4% and 249 MPa than the vertical direction. For the horizontal and vertical orientations, the average microhardness values were determined to be 80 HV and 72 HV, respectively. Fracture analysis of the tensile samples showed that the deposited metal had a ductile mode of failure with a predominance of dimples with tearing shape. This study provides valuable insights into constructing wall structures and analyzing their mechanical properties.

AA5083 bars processed by four pass ambient Equal Channel Angular Pressing were subjected to intersection annealing, where time and temperature were varied after each pass. The microstructures, texturing and compressive characteristics of the samples were meticulously examined. Due to the high annealing temperatures, both ultimate tensile strength and compressive stresses decreased with increasing grain size. However, intersection annealing at room temperature resulted in the best compressive yield strength. The deformation behavior of AA5083 billets was investigated using finite element analysis. Electron back scatter diffraction was employed to examine the texture of the Equal Channel Angular Pressed billet crystals. Extensive research was conducted on the tensile properties and Vickers microhardness. The finite element simulations revealed that the 900 die exhibited a significantly more uniform dispersion of plastic strain compared to the 1200 die. The renewal of additional slip mechanisms during the four Pass process was attributed to the grain refining that occurred after the 1-Pass and 2-Pass stages. Equal Channel Angular Pressing successfully produced a homogeneously ultra-fine grained microstructure. The increase in strength was attributed to grain refining and dislocation strengthening. Molecular dynamics simulations were employed to study the ECAPed approach of AA5083 providing insights into the deformation behavior and polycrystal formation.

This research aims to depict the thermal history, residual stress distribution, axial force applied, and material flow behavior on aluminum alloy 5083 (AA5083) plates, during the friction stir welding (FSW) process. This alloy finds most its use in shipbuilding industries and for marine constructions. It has been developed using an explicit, fully coupled thermomechanical nonlinear finite element (FE) analysis approach. The analysis was performed to simulate the effect of three stages, namely plunging, dwelling, and welding, of the FSW process. The ABAQUS/Explicit program was used for the computational modeling. To build a reliable and computationally efficient FE model, features such as arbitrary Lagrangian-Eulerian (ALE) formulation, adaptive meshing/remeshing approach, mesh sensitivity analysis, and mass scaling have been introduced. The interaction between the tool bottom surface and the plate top surface was defined using a finite sliding and a sticking property. A Coulomb friction model with a temperature-dependent coefficient of friction (COF) was used to describe the tool-workpiece interaction. In addition, a small experiment was done with the following process parameters; a rotating tool speed of 875 rpm, a traverse speed of 60 mm/min, and a tool tilt angle of 0° to produce a defect-free butt joint to validate the numerically generated thermal profiles. The temperature was found slightly higher on the advancing side (AS). Residual stress distribution created over the whole width of the plates was also investigated. [ABSTRACT FROM AUTHOR]

Diffusion bonding is a sort of solid-state joining that allows the joining of metals with similar and dissimilar compositions by allowing them to diffuse into one another. The current study investigated the impact of process parameters on the bonding strength of AA5083. The process parameters were considered as bonding temperature, holding time, and bonding pressure. Because of micro-constituent diffusion in the interface, the bonding and shear strengths increased as pressure and temperature were raised in the sample. By increasing the temperature of the Al3Mg2 particles from 490 °C to 520 °C and the bonding pressure from 5 MPa to 15 MPa, the dispersion of secondary phase particles is improved, and pores/defects in bonded joints are reduced. Furthermore, microstructural characterization reveals that the achieved strength is contingent on boundary grain growth and grain boundary migration through the bonding process, respectively. The light optical microscope was used to characterize the microstructural test and diffusion layer configuration at the boundary. [ABSTRACT FROM AUTHOR]

The Friction Stir Welding procedure (FSW) is a promising approach for a variety of joined aluminum composites. However, using FSW in the welding of aluminum materials is a challenge. In recent years, there has been significant progress. Underwater friction stir welding (UWFSW) is a skilled procedure. It is a completely new and futuristic technology. The non-consumable tool runs over the substrate inside water without emitting any fumes in this method. There are several key advantages, including minimal distortion, a lack of liquefaction caused by imperfections, and excellent joining power. The quality of FSW joints in underwater is determined by factors such as tool rotational speed (TRS), tool transverse speed (TTS), tool tilt angle (TTA), and pin profiles. Each working parameter has a significant impact on joint strength. The purpose of this study is to examine the effect of UWFSW on the mechanical properties and microstructure characteristics of AA5083 armor-grade aluminum. In this work, one of the working characteristics is changed from the lowest to the highest level while the others remain constant. The joint formed from a straight hexagonal tool pin with a TRS of 1500 rpm, TTS of 40 mm/min, and TTA of 1° provided higher tensile strength and hardness than its counterparts due to the induction of stabilized material flow and the configuration of imperfection-free and perfect weld joints. [ABSTRACT FROM AUTHOR]

The present study investigates the feasibility of achieving subsurface internal closed channels in monolithic AA5083-H111 plates using the friction stir channeling (FSC) method with the shoulder–workpiece clearance approach. Different parameters were studied for the optimization of the process. As a result of varying shoulder-to-pin diameter ratios, two friction stir welding/processing tools were utilized, and the effects of varying shoulder clearances against various traverse speeds and rotation speeds were examined. The results revealed that the maximum channel cross-sectional area was obtained by the application of the tool with the smaller shoulder-to-pin ratio and with a weld pitch of 4.93 (1000 rpm rotational speed / 203 mm/min transverse speed). As for the examination of the shoulder–workpiece clearances, the results showed that by increasing the clearance, the cross-sectional area slightly increases up to a maximum value, after which large-scale cracks and voids are introduced in the zone between the channel and the workpiece. For the microstructural characterization, specimens were examined microscopically using optical microscopy (OM) and scanning electron microscopy (SEM). The examination revealed the presence of porosity and micro-crevices located in the area between the channel and the surface. The microstructure was found to be closely related to microhardness distribution analysis. The microstructural defects introduced a slight reduction in hardness values in the area between the channel and the surface with respect to the hardness values of the rest of the examined stir zone and the TMAZ/HAZ zones where the hardness values were found to be close to the values of the base material. [ABSTRACT FROM AUTHOR]

Aluminium alloys exhibit eco-friendly aspects related to global environmental issues, such as almost unlimited recyclability. Nevertheless, some intrinsic characteristics are challenges to explore all their benefits. In the welding process, the high thermal conductivity and low melt point require high control of heat input. Alternatively, the pulsed laser mode provides a sharp beam focus with precise control enabling regulating the energy delivered. In this sense, this present work analysed the effect of pulsed laser welding parameters on 3-mm-thick AA5083 aluminium alloy sheets. Trials targeted to develop sound welds with minimum defect and high penetration depth adopting statistical methods. The optimum parameter arrangement was achieved by varying peak power, spot diameter, and pulse duration. Finally, the best parameter combination was applied using different pulse shapes to mitigate crack formation and pores. As a result, the pulse shape with step-down at the end of each pulse generated crack-free spot welds. [ABSTRACT FROM AUTHOR]

This study presents a novel approach to enhancing the properties of the AA5083 alloy by incorporating a high entropy alloy (HEA), specifically AlCrCuFeNi, through mechanical alloying. The Al/HEA composites were thoroughly characterized in terms of powder morphology, microstructure, fracture and wear surface morphology, phase composition, and oxidation behavior using XRD, SEM-EDS, and TGA. The impact of HEA, both with and without B 4 C reinforcement, on the hardness, density, tensile strength, and wear properties of the AA5083 matrix composites was comprehensively evaluated. The findings revealed that the AA5083 alloy exhibited a baseline hardness of 74.7 HB and a tensile strength of 174.1 MPa. However, with the addition of HEA + B 4 C, these properties were markedly enhanced, with the hardness increasing to 150.1 HB (a 100 % increase) and tensile strength to 247.1 MPa (a 50 % increase). Furthermore, the wear resistance of the composite experienced a substantial improvement, with a nearly six-fold increase due to the HEA + B 4 C reinforcement. [Display omitted] • First study on AA5083 metal-metal composites reinforced with HEA and HEA-B 4 C powders via powder metallurgy. • Characterization of HEA and HEA-B 4 C powders: morphology, particle size, crystallite size, and lattice strain. • Tensile strength of HEA-B 4 C reinforced composite increased 50 % compared to AA5083 matrix. • Significant enhancement in tribological properties of AA5083 matrix composite with HEA and HEA-B 4 C reinforcement. [ABSTRACT FROM AUTHOR]

5083 aluminum alloy (AA5083) is prone to produce pores and undercut defects during laser welding because of violent fluctuations and Mg alloy elements burning in a molten pool, which seriously affected the tensile properties of the welds. In this paper, the process of laser welding with filler wire was used to improve weld properties, and through experiments and finite element simulation (FES), the effects of welding wires (ER4047, 5356, and 5087) on joint properties and failure behavior were studied. The FES simulation results are very consistent with the digital image correlation (DIC) experiment measurements, which verifies the accuracy and reliability of the finite element model proposed in this work. With the FES, it was further found that the filler wire produced the weld reinforcement, which changed the stress and strain distribution around the weld. The location of the maximum strain of the weld is changed from the undercut of the no-filler wire weldment to the weld toe of the filler wire weldments. The stress concentration at the undercut of the weld is greatly reduced, and the load-carrying capacity of the filler wire welded joint is improved. Analysis shows that the high Mg content of ER5087 effectively suppressed the formation of porosity to obtain the highest tensile strength (285 MPa), reaching 85% of the base metal (BM) strength. The filling of the welding wire changed the fracture mode from ductile-brittle mixed fracture of no-filler wire to ductile fracture with filler wires. [ABSTRACT FROM AUTHOR]

Different types of SPD techniques are applicable and have been studied by various researchers. All of them have several advantages and disadvantages. Equal Channel Angular Pressing (ECAP) is one of the most popular SPD techniques and is still being developed. The aim of this paper is to improve the efficiency of ECAP process by putting forward a novel design (Twisted Variable Channel Angular Pressing (TV-CAP)) and also to achieve higher mechanical properties when compared to conventional ECAP processes. For this purpose, a new TV-CAP die was designed by combining three different methods: ECAP, Twist Extrusion, and Direct Extrusion. The new design was able to integrate the advantages of each method to the workpiece material. In this context, the design parameters of the TV-CAP die were first identified by finite element analysis (FEA) in Deform-3D. The TV-CAP die was produced according to the determined parameters and AA5083 alloy was pressed with this novel die. Hardness and tensile tests were carried out to compare mechanical properties. In addition, Optical Microscope, SEM, TEM images were taken, and XRD and EBSD analyses were carried out to examine the changes in grain structure. As a result of this experimental study, an increase of 197.3% was observed in the hardness value and an increase of 144.7% was achieved in the tensile strength value by using the novel TV-CAP die. These results also agreed with the effective strain values obtained from the FEA. [ABSTRACT FROM AUTHOR]

Indexing of Electron Backscatter Diffraction (EBSD) is a well-established method of crystalline material characterization that provides phase and orientation information about the crystals on the material surface. A deep learning Convolutional Neural Network was trained to predict crystal orientation from the EBSD patterns based on the mean disorientation error between the predicted crystal orientation and the ground truth. The CNN is trained using EBSD images for different deformation conditions of AA5083. [ABSTRACT FROM AUTHOR]

AA5083 aluminium alloy is an excellent casting material with inadequate strength and poor wear properties. To increase its deficient mechanical and wear properties, researchers have conducted a lot of research in the past decades. Based on the research, graphene can be considered a good reinforcement due to its outstanding mechanical properties. The present paper discusses the properties of AA5083 Metal Matrix Composites (MMCs) reinforced with graphene particles. Aluminium MMCs were fabricated using the stir casting method by varying graphene reinforcement (5 and 10 wt.%) with AA5083 (specimens B and C). The Scanning Electron Microscopy (SEM) and Energy-Dispersive X-ray Spectroscopy (EDAX) analysis results confirmed the presence of graphene in the AA5083 matrix. The test results show that the tensile strength, flexural strength, impact strength, and hardness were enhanced with the addition of graphene particles in the AA5083 matrix. The tribological behaviour of the MMCs was compared with the AA5083 matrix using a pin-on-disc wear test. The increase in wt.% of graphene reinforcement enhanced the wear resistance of the proposed MMCs. The large wear debris and crater were not noticed in the worn surfaces of the MMCs specimens. [ABSTRACT FROM AUTHOR]

This work aims to study the influence of the tool rotational speed and tool traverse speed on dissimilar friction stir butt welds on 3 mm thick AA5083 to commercially pure copper plates. Complex microstructures were formed in the thermo-mechanically affected zone, in which a vortex-like pattern and lamellar structures were found. Several intermetallic compounds were identified in this region, such as Al2Cu, Al4Cu9 and these developed an inhomogeneous hardness distribution. The highest ultimate tensile strength of 203 MPa and joint efficiency of 94.8% were achieved at 1400 rpm tool rotational speed and 120 mm/min traverse speed. Placing the softer material (aluminium) on the advancing side produced an excellent metallurgical bond with no requirement for tool offsetting.

Aluminium alloys have been widely accepted in manufacturing lightweight materials with high strength. Therefore, welding aluminium alloys is essential in industrial applications to attain complex shapes. In the present work, AA5083 and AA6082 dissimilar alloys were welded using pulsed tungsten inert gas (PTIG) welding since PTIG reduces welding defects more than TIG welding. But to get better mechanical strength on the weld joints, PTIG welding process parameters must be optimized. During PTIG welding, peak current, pulse frequency, and welding speed were chosen as the input parameters, and ultimate tensile strength (UTS) and microhardness were measured as output responses in the current investigation. The UTS of the welded AA5083-AA6082 alloys was predicted using an empirical relationship. For the design of experimental trials, a three-variable, five-stage central composite design is adopted. The findings indicate that the welding speed impacts tensile strength the most, followed by the peak current and the pulse frequency has the least impact. Therefore, the peak current of 197 A, pulse frequency of 4.9 Hz, and welding speed of 181 mm min ^−1 was identified as the optimal welding parameters to weld AA5083 and AA6082 alloys with high UTS values. The hardness analysis on the optimized welded samples showed that the lowest hardness values of 40 to 50 Hv0.5 and the highest value of 90 to 100 Hv0.5 were observed on the HAZ of the AA6082 side of the weldment.

In current research work, dissimilar aluminium alloys such as AA5083, AA6081, AA6082, and AA7039 are butt joined by employing friction stir welding (FSW). The present study explores the effect of material positions of aluminium alloys (i.e., advancing side (AS) and retreating side (RS)) on the mechanical and metallurgical properties of FS welded dissimilar aluminium joints. The performance characteristics of the present study are analyzed in terms of mechanical and metallurgical properties. It is concluded that maximum strength is obtained for all the joints in which higher strength aluminium alloy is placed on the AS ((i.e., 386 MPa for AA7039-AA5083, 343 MPa for AA7039-AA6082, 320 MPa for AA5083-AA6082, and 225 MPa for AA6082-Aa6061). Furthermore, two types of macrostructures (i.e., banded and an onion ring) are observed at the nugget zone (NZ) of all the welded joints during metallurgical analysis. Besides this, energy-dispersive X-ray spectroscopy (EDS) analysis at NZ of FSW joints is also carried out to find out the chemical composition at NZ. It is observed that the key element of AS material is high er in weight percent as compared to RS at NZ. Moreover, tensile fractured surface locations are also analyzed to understand the process better. It is witnessed that most joints are fractured at heat affected zone (HAZ) on the lower strength material side. [ABSTRACT FROM AUTHOR]

Application of aluminium alloys is increasing in all industries due to its combined properties of low weight, good mechanical resistance, thermal conductivity, electrical conductivity, high strength, and good corrosion resistance. In particular, AA5083-H111 alloys have been successfully used in the maritime sector. Unlike purely surface treatments, cryogenic treatment is an inexpensive one-time process that influences the core properties of the components. Cryogenic treatment has recently been introduced to Al alloys. Although the main mechanisms are still ambiguous, considerable improvements on mechanical properties are well noted. However, the effect of cryogenic treatment on the corrosion of Al alloys is limited. This study investigated the effect of shallow cryogenic treatment (-80 °C) on the corrosion of 5083- H111 aluminium alloy, which is used particularly in the shipbuilding industry. Plates of 6-mm thickness exposed to a 3.5% NaCl environment were evaluated via Brinell hardness measurements, Electrochemical Impedance Spectroscopy (EIS) and surface monitoring methods including atomic force microscopy (AFM) and optical profilometry (OP) applied before and after the effect of cryogenic treatment. Results indicated that the duration time of cryogenic treatment (24 h, 36 h and 48 h) had little effect on changing the hardness values and corrosion response of AA5083-H111 alloy in the 3.5% NaCl environment.

The modified friction stir clinching (MFSC) of 5083 aluminum alloy to brass using pure Zn interlayer has been explored and elucidated for the first time. By that, the influence of the Zn interlayer thickness on the microstructure and the mechanical properties of the 5083/brass joint was investigated. The attained data have revealed that the intermetallic compound (IMC) layer thickness was mainly influenced by the Zn interlayer. The use of the Zn interlayer restrained the creation of brittle Al–Cu IMCs such as Al4Cu9 during the MFSC process and, in return, softer phases such as Cu4Zn, CuZn5, and CuZn were formed. It was also found that with increasing the thickness of the Zn interlayer from 50 to 100 µm, the thickness of the brazed zone increased and the tensile/shear strength of the spot welds significantly improved from 5250 to 8490 N (approximately 60% increment over the welded sample with 50-µm-thick Zn) which can be ascribed to supreme bonding and homogeneous brazing zone at the interface. [ABSTRACT FROM AUTHOR]

Friction stir welding (FSW) is a well-known technology for joining similar and dissimilar materials. The quality of the weld in FSW is affected by the various process parameters such as tool rotational speed (TRS), tool transverse speed (TTS) and tool pin profiles. This study aims to investigate the effect of three different tool pin profiles on the variation of microstructure and mechanical strength of friction stir welded AA5083 and AA5754 alloys joints. Both of these alloys combinations offer excellent corrosion resistance and formability. As a result, they’re commonly seen in tanks, pressure vessels, shipyards, and trucks. In this work, the FSW methodology focused on varying the TRS of 750, 1000, 1250 and 1500 rpm and TTS as 20, 30, 40 and 50 mm min ^−1 . The surface microstructures of the weldments were analyzed using an optical microscope and scanning electron microscope. Tensile and Microhardness tests were carried out on the weldments to determine the weld strength. Three variety of tool pins, namely straight square, threaded cylinder, and straight cylinder were used for this study. The microstructural and the mechanical properties analysis of the welded samples proved that the straight square tool pin profile is suitable for joining AA5083 and AA5754 alloys. The weldments prepared using a straight square pin profile exhibited good material stream behaviour, uniform spreading of plastic deformation in the weld zone and aided in the reduction of formation of macroscopic defects on the welded zone. Among the process parameters, it was detected that the pin profile displays more impact on tensile strength followed by tool rotation speed and welding speed. According to the findings, the dissimilar weld joint formed at the optimum process parameters had the highest tensile strength of 212 MPa and hardness of 88 HV were: Square Tool Profile, 1250 rpm TRS, and 40 mm min ^−1 TTS.

The wear characteristics of Aluminium AA 5083/SiC/Fly Ash functional composites under different load conditions are an important aspect to assess the inoculation of Fly Ash for enhancing the functionality of the aluminium composites with respect to its tribological behaviour and its influence on wear properties. The present work is majorly aimed at the development of AA 5083/SiC functional composites inoculated with Fly Ash using stir casting method for different blends of the reinforcements (2.5, 5 & 7.5 wt%). The novelty of this research is majorly attributed to the incorporation of functional inoculants in the form of Fly Ash, which along with the SiC is bound to influence the tribological characteristics of the composites. The wear characteristics of these fabricated composites have been investigated considering various process parameters viz., the load, sliding distance, sliding velocity, wt% of SiC and wt% of Fly Ash, based on the operational requirements of the composites in real time considered from the earlier research studies and the influence of each parameter on the wear rate is discussed. Based on the different wear regimes obtained after characterization of the samples at different load conditions, Analysis of Variance (ANOVA) is carried out for each blend of the samples to statistically validate the experimental outcomes. The results have given sufficient substantiation to the fact that wear rate decreases with the inoculation. The wear rate and coefficient of friction (COF) is minimum viz., 0.00095 mm ^3 /m, and 0.301 respectively for L9 experimental trial, i.e., for the composite specimens synthesized by reinforcing 7.5 wt% SiC, and 7.5 wt% Fly Ash for a load of 20 N, sliding velocity of 6 m s ^−1 , and a sliding distance of 3000 m. The results have conferred that micro segregation (coring) of SiC and uniform dispersion of Fly Ash in the matrix enhances its tribological characteristics.