International Journal of Lightweight Materials and Manufacture最新文献

{"title":"An insight into high-temperature deformation mechanism of magnesium in-situ composite through development of Johnson-Cook and constitutive model","authors":"Rohit Jain,&nbsp;Harsh Soni,&nbsp;R.P. Mahto,&nbsp;B.N. Sahoo","doi":"10.1016/j.ijlmm.2023.09.002","DOIUrl":"https://doi.org/10.1016/j.ijlmm.2023.09.002","url":null,"abstract":"<div><p>The establishment of deformation mechanisms of Mg-metal matrix composite (Mg-MMC) is important to improve the high-temperature challenging applications. In this present work, an AZ91/TiC + TiB₂ hybrid <em>in-situ</em> Mg-MMC was synthesized, and its deformation mechanisms were studied through a uniaxial hot compressive test at different temperatures and strain rates. The Johnson-Cook (JC) model and constitutive equation were established using experimental stress-strain data. Through the development of JC model, it was revealed that the TiC–TiB₂ particles enhanced the yield strength parameter and increased the activation energy of the <em>in-situ</em> composite compared to the parent alloy. The load-shifting capability and grain refinement were found to be the dominating mechanisms, which effectively restricted dislocation movement during deformation, resulting in improved deformation resilience of the composite. A detailed study of JC model and constitutive equation parameters was analyzed with a focus on their microstructures.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"6 4","pages":"Pages 574-588"},"PeriodicalIF":0.0,"publicationDate":"2023-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"50177403","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Friction stir welding of carbon black reinforced high-density polyethylene tube-to-tubesheet joints","authors":"Syed Haris Iftikhar ,&nbsp;Abdel-Hamid Ismail Mourad ,&nbsp;Dinu Thomas Thekkuden ,&nbsp;Nizamudeen Cherupurakal ,&nbsp;R. Krishnapriya","doi":"10.1016/j.ijlmm.2023.09.001","DOIUrl":"10.1016/j.ijlmm.2023.09.001","url":null,"abstract":"<div><p>Industrial heat exchanger applications dealing with highly corrosive fluids demand the use of thermoplastic heat exchangers because of the chemically inert and anti-fouling nature of the thermoplastics. A non-conventional joining framework, based on the friction stir welding (FSW) technique, is used to form high-quality thermoplastic tube-to-tubesheet joints (TTJs). The proposed technique has potential applications for thermoplastic shell-and-tube heat exchangers and piping industries (as flange-to-pipe joints). In this work, the tube and tubesheet materials made of carbon black reinforced high-density polyethylene were used. The effect of different FSW parameters (rotational speed, plunge depth, tube protrusion, dwell time) on the tube pull-out behavior was investigated. The FSW technique showed capabilities at a wide range of operating conditions. The highest load bearing capacity of 517 N was achieved using the FSW process, much higher than adhesive joints. Also, it provides higher extensions at maximum load than adhesive joints, with the highest extension of 5.161 mm. Two FSW cases provided high leak paths of 77% and 58% remaining sheet thickness (greater than tube thickness) along with high load bearing capacity and corresponding extensions. The macroscopic and SEM-based fractographic studies illustrated three types of failure behavior: ductile, brittle, or mixed depending on the FSW process conditions. The DSC results showed no significant crystallinity changes in the weld material. The TGA results showed no significant thermal degradation occurring in the weld material. Further, the FTIR analysis indicated possible oxidation of the weld material. The capability to form TTJs with high leak path, high load bearing capacity, and no significant material degradations makes the FSW technique suitable for thermoplastic shell-and-tube heat exchanger applications.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"6 4","pages":"Pages 589-605"},"PeriodicalIF":0.0,"publicationDate":"2023-09-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45886145","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Accurate simulation on the forming and failure processes of fiber metal laminates: A review","authors":"Yizhe Chen ,&nbsp;Yusen Yang ,&nbsp;Zhuoqun Wang ,&nbsp;Hui Wang ,&nbsp;Jun Li ,&nbsp;Lin Hua","doi":"10.1016/j.ijlmm.2023.02.003","DOIUrl":"10.1016/j.ijlmm.2023.02.003","url":null,"abstract":"<div><p>Fiber metal laminates (FMLs) are a kind of composite material prepared by alternately arranging fiber layers and metal sheets at a certain temperature and pressure. It has been widely used in aerospace and automobile transportation for its excellent combined mechanical properties. For the forming and failure processes of FMLs, the interfacial behavior and damage evolution of components are hard to be observed experimentally. Therefore, it is of great importance to simulate them accurately. In this article, the development and application of FMLs were first introduced. Then the comparison of constitutive models in FMLs simulation was given, especially the dynamic constitutive model applied to the metal layer. After that, the important aspects of damage evolution, interface behavior, and model optimization in the simulation on the forming and failure process of FMLs were analyzed, and the emphasis is on the nonlinear progressive damage model of different materials, the construction of cohesive zone model and superior meshing methods. Furthermore, the experimental verifications of FMLs simulation were given. It is shown that the deformation behavior and damage characteristics of various kinds of FMLs during forming and failure processing can be accurately predicted by reasonable numerical simulation. Eventually, the future outlooks for numerical simulation of FMLs was proposed. Through this review, scholars and engineers who are interested in FMLs can systematically understand the numerical simulation work of FMLs, which is helpful in improving the quality of research in this field.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"6 3","pages":"Pages 344-356"},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41795540","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Application of artificial neural networks for characterisation of formability properties of sheet metals","authors":"Imre Czinege,&nbsp;Dóra Harangozó","doi":"10.1016/j.ijlmm.2023.08.003","DOIUrl":"10.1016/j.ijlmm.2023.08.003","url":null,"abstract":"<div><p>Artificial neural network models were developed to estimate forming limit diagrams from tensile test results based on our own experiments and data from the literature for steel and aluminium sheet metals. Experimental data were obtained from tensile tests and Nakazima tests. The input parameters used in the models were yield strength, ultimate tensile strength, uniform elongation, elongation at fracture, anisotropy coefficient and hardening exponent or combinations of these. The forming limit curves were defined by the measured minor and major strains using seven standard test specimens. After training the artificial neural network, the difference between measured and predicted results was evaluated by linear regression parameters and by the absolute errors. For steel sheet data taken from the literature, the estimated outputs of ANN models were compared with the results of empirical formulae developed by different authors. It was found that there was a high correlation coefficient between predicted and measured values for models using neural networks, which gave better approximations than other linear and non-linear models.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"7 1","pages":"Pages 37-44"},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2588840423000446/pdfft?md5=0ccc0f701419f0ab3f435cbab4bc051b&pid=1-s2.0-S2588840423000446-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135048777","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Improved structural uniformity and specific strength of commercially pure aluminum through variable temperature multi axial forging: Finite element analysis and experimental study","authors":"S. Deb ,&nbsp;M.B. Abhilash ,&nbsp;R.J. Immanuel ,&nbsp;S.K. Panigrahi","doi":"10.1016/j.ijlmm.2023.02.001","DOIUrl":"10.1016/j.ijlmm.2023.02.001","url":null,"abstract":"<div><p>Multi axial forging (MAF) is a forging-based severe plastic deformation (SPD) technique which is prominently used to refine grain structure and improve the strength of the material. While the advantages of MAF lie in its simple tool design and ability to process bulk materials, the main limitation is the inhomogeneity in the generated microstructure across the cross-section at initial passes. Increasing the number of MAF passes may partially help to solve the problem, but arbitrary increase in the number of passes may lead to redundant increase in manufacturing cost and time. The current work proposes a manufacturing strategy for MAF to achieve homogeneous microstructure with uniform grain refinement by using reduced number of MAF passes. To achieve structural uniformity within fewer MAF passes, a controlled thermo-mechanical based optimum MAF process strategy is developed on a commercial pure Al through the finite element analysis (FEA) simulation and the same is validated experimentally. The manufacturing strategy resulted significant grain refinement via simultaneous action of continuous dynamic recrystallization and geometric dynamic recrystallization with microstructural homogeneity which caused a significant improvement in tensile properties (more than two times than the base) with considerable ductility (more than 25%) and isotropy property across the thickness. The scientific knowhow has been established via processing–structure–property correlation-ship.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"6 3","pages":"Pages 434-449"},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48929812","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Impact of aging temperature on the metallurgical and dry sliding wear behaviour of LM25 / Al2O3 metal matrix composite for potential automotive application","authors":"Harinath Ravinath ,&nbsp;Ijas Ahammed I ,&nbsp;Harigovind P ,&nbsp;Achu Devan S ,&nbsp;Aravind Senan V R ,&nbsp;Karthik V. Shankar ,&nbsp;Nandakishor S","doi":"10.1016/j.ijlmm.2023.01.002","DOIUrl":"https://doi.org/10.1016/j.ijlmm.2023.01.002","url":null,"abstract":"<div><p>The current study exhibits the influence of aging temperatures on the metallurgical, hardness, and dry-sliding wear behaviour of LM25 (Al-6.6Si-0.2Mg) alloy reinforced with Al₂O₃ particles. The LM25 alloy reinforced with 10 wt% of alumina particles was fabricated using the liquid metallurgy route followed by solutionizing and aging. The baseline LM25 alloy and its composite were solutionized at 538 °C for 8 h and were aged at 155, 165, and 175 °C for 12 h. Optical, FESEM, EDS, and X-ray diffraction analysis were done on the fabricated alloy and its composite in all conditions. The microstructure revealed the formation of the Mg₂Si phase in the baseline alloy and the MgAl₂O₄ spinel generated at the composite interface of the aluminium matrix. The heat-treated alloy and composites were tested for their hardness on the Vickers microhardness tester. It was concluded that the aging temperature of 155 °C displayed significant enhancement in hardness values for tested samples. The heat-treated alloy and composite samples displayed an increment of 96% and 55% in hardness values relative to LM25. The wear rate and friction coefficient for the fabricated samples were analyzed using the pin-on-disc tribometer under dry sliding conditions. The hardness value increased from the as-cast state to samples aged at 155 °C and then decreased at 165 and 175 °C. Based on the wear study, a 14% and 25% decrease in the wear rate values for heat-treated alloy and composites were noted when sliding velocity was increased from 1 m/s to 3 m/s. However, the coefficient of friction (COF) decreased by 23% and 13% for the specimens in the same conditions. Furthermore, a similar trend was displayed by age-hardened LM25 alloy and the composite when subjected to varying load (5, 10, 15 N) condition. Lastly, the worn-out surface mechanisms were examined using FESEM analysis. Amongst the investigated samples, LM25/10 wt% Al₂O₃ composite aged at 155 °C revealed the least wear rate when subjected to an external load of 5 N and sliding velocity of 2 m/s. Therefore, it can be suggested to manufacture components in the automotive industry.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"6 3","pages":"Pages 416-433"},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"50188836","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Sustainable cooling/lubrication induced thermo-mechanical effects on ultrasonic vibration helical milling of CFRP/Ti–6Al–4V stacks","authors":"Jiale Wang ,&nbsp;Jiaying Ge ,&nbsp;Guang Chen ,&nbsp;Jian Liu ,&nbsp;Zhiyi Wang ,&nbsp;Chengzu Ren","doi":"10.1016/j.ijlmm.2023.02.002","DOIUrl":"10.1016/j.ijlmm.2023.02.002","url":null,"abstract":"<div><p>Sustainable cooling/lubrication strategies including dry, minimum quantity lubrication (MQL), cryogenic (LN₂) and hybrid (MQL and LN₂) were used in ultrasonic vibration helical milling (UVHM) machining to improve the performance of hole-making for CFRP/Ti–6Al–4V stacks. The machining temperatures and forces were measured to characterize the thermo-mechanical effects on UVHM with different cooling/lubrication conditions. The machining temperatures at cryogenic conditions were −146 °C, −170 °C and −53 °C at CFRP layer, interface and Ti–6Al–4V layer, respectively. Axial and radial resultant forces at different conditions were highly related to the cutting temperature. Fiber removal mechanism at different conditions was analyzed according to the cutting temperatures, forces and the kinematic analysis in UVHM. Effects of sustainable cooling strategies and ultrasonic vibration on the hole surface texture of Ti–6Al–4V alloy were discussed. The amplitudes at different conditions varied approximately from 3.5 to 7 μm due to the variation of the forces. High precision of the exit geometry was achieved, as the height of hole exit burrs at Ti–6Al–4V layer were less than 40 μm except for the cryogenic condition. Diameters at the MQL and hybrid conditions were closer to the target diameter (<em>ϕ</em>10 mm), and the precision of the cylindricity of the machined holes of the stacks with the MQL and hybrid cooling conditions was higher than those at other conditions. Tool wear at different conditions were analyzed according to the SEM and EDS results. This work provided the fundamental understand of the hybrid process with sustainable cooling/lubrication strategy in UVHM machining. High quality of holes in CFRP/Ti–6Al–4V stacks were achieved by the hybrid processes.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"6 3","pages":"Pages 311-328"},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45178407","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"An Integrated RSM - improved salp swarm algorithm for quality characteristics in AWJM of Ananas comosus-HIPS composites","authors":"A. Tamilarasan ,&nbsp;A. Renugambal","doi":"10.1016/j.ijlmm.2022.12.003","DOIUrl":"10.1016/j.ijlmm.2022.12.003","url":null,"abstract":"<div><p>Natural fiber based polymer composite materials are increasingly used in wider applications due to their low weight and improved mechanical qualities. However, due to their inherent heterogeneity, anisotropy, and temperature sensitivity, traditional machining of composite materials is difficult. Abrasive water jet (AWJ) cutting is a non-traditional machining technique that has recently been used to fabricate polymer matrix component parts. Therefore, this study focuses on the machinability of ananas comosus–high impact polystyrene composites (each wt50%) using the AWJ process. The experiments were conducted and analyzed using central composite design (four-factor, five-level) and the response surface methodology, respectively. The mathematical models between process parameters, kerf inclination, entry delamination factor (DF) and exit DF were established and confirmed by verification. Analysis of variance was utilized to examine the influence of each input parameter on the responses. The AWJ machined surfaces were examined using a SEM images. Further, the developed models were coupled to the improved salp swarm algorithm, which was used to find the best cutting parameters for the minimizing of kerf inclination, entry DF, and exit DF, which are all important quality aspects. During the confirmatory tests, only minor differences (less than 2%) between the predicted and experimental results were observed.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"6 3","pages":"Pages 297-310"},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44427266","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The effects of I-Beam thickness to microstructure and compression load of thin wall ductile iron connecting rod","authors":"Rianti Dewi Sulamet-Ariobimo ,&nbsp;Muhammad Fadhlan ,&nbsp;Yoska Oktaviano ,&nbsp;Tono Sukarnoto ,&nbsp;Yusep Mujalis ,&nbsp;Amal Witonohadi","doi":"10.1016/j.ijlmm.2023.01.001","DOIUrl":"https://doi.org/10.1016/j.ijlmm.2023.01.001","url":null,"abstract":"<div><p>Lighter automotive components are needed to reduce energy consumption. The manufacturing processes of the components should also consume less energy and be environmentally friendly. Aluminum is a lightweight material, but the manufacturing processes consume a lot of energy. Ductile iron has outstanding design flexibility and applying a thin wall casting technique to the ductile iron components will reduce the weight and make it possible for ductile iron to compete with lightweight materials<em>.</em> The achievement of making a 3 mm I-beam thickness connecting rod which fulfills the design requirement in previous research has encouraged a further reduction in the I-beam thickness. This action is taken to enhance the weight reduction gained from the connecting rod. The aims of this work are to ensure the repeatability resulting from the design of 3 mm I-beam thickness and the ability of the casting design to produce the 2 mm I-beam thickness. Solidification rates in thin wall casting are critical due to the differences in thicknesses in the product. It is also to analyze the effect of I-beam thickness on the compression load. Two types of I-beams, which differ in their thickness, 3 mm and 2 mm, were produced in the foundry scale. All the I-beams were characterized by their microstructure and compression load. The compression load was measured using the tensile method. The results of microstructure observations revealed that the microstructure in I-beam is different from the one in the end rod except for one casting position, while the result of compression load shows a similar value for average compression load between the 3 mm and 2 mm which fulfill the compression load requirement of connecting rod. The casting designs built in this research can produce thin wall ductile iron (TWDI) connecting rods that could stand similar load with the original one.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"6 3","pages":"Pages 392-404"},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"50188834","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of SiCp volume percentage on AA6063/SiCp MMC extrusion process: An experimental, theoretical and simulation analysis","authors":"Veerasundaram Jayaseelan ,&nbsp;Kani Kalaichelvan ,&nbsp;Nallamuthu Ramasamy ,&nbsp;Murugesan Seeman","doi":"10.1016/j.ijlmm.2023.03.001","DOIUrl":"10.1016/j.ijlmm.2023.03.001","url":null,"abstract":"<div><p>Composites have been the most prominent incipient materials in a variety of industries over the past decades. The present work mainly investigates the influence of the SiC particulate (SiCp) weight percentage on AA6063/SiCp metal matrix composites extrusion and, it has been evaluated in extruded MMC billets for enhancing the billet quality. Graphite lubricants are used to decrease the friction between the die and the billet surface. Subsequently, the friction factor is theoretically determined and experimentally validated. It was concluded that SiCp concentration is the predominant factor influencing the extrusion load and friction factor. As a result, the extrusion load was increased with an increase in SiCp percentage. Furthermore, the experimental results were compared and validated by simulation analysis. The extruded billet surfaces were exhibited by a scanning electron microscope.</p></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"6 3","pages":"Pages 357-366"},"PeriodicalIF":0.0,"publicationDate":"2023-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44194611","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}