Mechanical and corrosion characteristics of low-density polyethylene reinforced with aluminum alloy AA6065 honeycomb structure

This research focuses on the fabrication and characterization of polymer-infiltrated aluminum honeycomb structures for lightweight composite applications. Low-density polyethylene (LDPE) is infiltrated into an AA6065 aluminum honeycomb structure to enhance its mechanical and corrosion properties. The composite is characterized for its microstructure, microhardness, tensile strength, and compressive strength. The effects of temperature (− 10 °C and 80 °C) and pH (5, 5.5, 6) on corrosion, particularly at the interface between AA6065 and LDPE, are thoroughly analyzed using advanced instrumental techniques. The study reveals significant improvements in mechanical properties due to LDPE reinforcement. Tensile tests show increased strength, elongation at break, and toughness, while compressive strength and stiffness are also enhanced, making the composite ideal for applications requiring resistance to compressive forces. Three-point bending tests confirm improved flexural strength and reduced deflection, indicating better structural integrity. Vickers hardness tests show higher hardness, suggesting improved wear resistance and durability. Corrosion testing demonstrates superior resistance in the LDPE-reinforced composite compared to the unreinforced alloy, attributed to the protective barrier properties of LDPE. The combined characteristics make the LDPE-reinforced AA6065 alloy honeycomb structure a promising candidate for aerospace, automotive, and construction industries, where lightweight, high-strength materials are in demand.