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Advanced Manufacturing of Metals and Composites: Effect of Processes on Microstructure and Mechanical Properties Volume II

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Composites".

Deadline for manuscript submissions: 10 June 2024 | Viewed by 5920

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Dr. Christophe Pinna

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Department of Mechanical Engineering, The University of Sheffield, Western Bank, Sheffield S10 2TN, UK
Interests: microstructure characterization; microstructure modelling; damage modelling; finite element modelling; fatigue/fracture; full-field strain measurements
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Dear Colleagues,

Materials manufacturing processes are constantly evolving with the emergence of new technologies, such as additive manufacturing or automated fibre placement for composites, to name a few, introduced to meet the need for better performance and innovation in various industrial sectors. Whether traditional manufacturing processes make new advancements or new technologies are developed, fundamental research is needed to understand the effect of process parameters on material microstructures and directly related mechanical properties of final products. This knowledge is indeed essential for the optimisation of manufacturing processes and the development of next-generation materials in order to meet industrial demand. The latest developments in state-of-the-art experimental characterisation techniques and multiscale modelling offer new routes for developing this understanding. Artificial intelligence with data-driven models and multiobjective optimisation techniques is also increasingly used for robust optimisation of material processes with direct industrial relevance in the age of digital manufacturing.

This forthcoming Special Issue of Materials is focused on publishing the latest research in this very active field at the forefront of new materials and process development. Research articles, communications, or reviews relating advanced manufacturing processes–microstructure–mechanical properties for metals and composites are welcome. It is therefore my pleasure to invite you to contribute to this Special Issue.

Dr. Christophe Pinna
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Published Papers (6 papers)

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Research

14 pages, 11338 KiB

Open AccessArticle

Microstructure and Properties of TiCp/Fe Hierarchical Composites Prepared by a New Pressure Infiltration Method

by Shengnian Zhao, Dehong Lu, Fengbin Wang, Jiaxing Zhong and Yehua Jiang

Materials 2024, 17(6), 1325; https://doi.org/10.3390/ma17061325 - 13 Mar 2024

Viewed by 489

Abstract

TiCp/steel composites are conventionally produced via powder metallurgy. In this paper, a liquid pressure infiltration method was developed to prepare a kind of spherical hierarchical architectured composite, in which spherical TiCp-rich hard phase regions were uniformly dispersed in TiCp-free soft phase region. The microstructure and mechanical properties of the architectured composites were carefully studied and compared with the common composite, as well as the effect of TiCp fraction on the properties. The results show that architecturual design can effectively improve both the toughness and strength of the composites. With TiCp content increasing from 30% to 50%, both the bending strength and the impact toughness of the architectured composites first increase, then decrease, and reach the highest at 40% TiCp. The highest impact toughness reaches 21.2 J/cm², being 6.2 times that of the common composite and the highest strength being 67% higher. The pressure infiltration method possesses adaptability to varying shapes and sizes of the products, allowing for large-scale preparation. Therefore, for the first time, the combination of pressure infiltration preparation and architectural design was applied to TiCp/steel composites. Full article

(This article belongs to the Special Issue Advanced Manufacturing of Metals and Composites: Effect of Processes on Microstructure and Mechanical Properties Volume II)

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14 pages, 7608 KiB

Open AccessArticle

Bidirectional-Reinforced Carbon Fiber/Polyether-Ether-Ketone Composite Thin-Walled Pipes via Pultrusion-Winding for On-Orbit Additive Manufacturing

by Yuanhao Xia, Long Jiang, Yi Chen, Yiping Zhao, Lili Yang and Dengteng Ge

Materials 2024, 17(2), 293; https://doi.org/10.3390/ma17020293 - 6 Jan 2024

Viewed by 728

Abstract

Benefitting from lightweight, high strength, long life, and green recyclability, continuous fiber reinforced thermoplastic composite (CFTPC) pipes have attracted extensive interest, especially in the on-orbit additive manufacturing of structural components. However, the preparation of CFTPC pipes remains challenging due to the on-orbit limited space and high processing temperature of thermoplastic resin. Here, we report an effective approach for high performance carbon fiber/polyether-ether-ketone (CF/PEEK) thin-walled pipes via bidirectional reinforcement using the pultrusion-winding technique. The continuous fabrication of thin-walled pipes can be achieved, but the limitation by the size of core mold is also broken. The compressive and shear performance of CF/PEEK pipes with different layer designs have been studied based on experiments and simulations. With the increase in axial prepreg tape layer, the resultant CF/PEEK pipes exhibit greatly improved axial compression strength. The finite element analysis indicates that the maximum axial stress is decreased due to the axial enhancement. The flexural strength is greatly proved with pultrusion–winding cycles. The simulation confirms that the circumferential strain is effectively reduced. The high performance of bidirectional reinforced CF/PEEK pipes and the facile controllability of this approach highlight their suitability for utilization in on-orbit manufacturing of large-scale structures. Full article

(This article belongs to the Special Issue Advanced Manufacturing of Metals and Composites: Effect of Processes on Microstructure and Mechanical Properties Volume II)

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14 pages, 6650 KiB

Open AccessArticle

Effect of a Multiaxial Load of Reverse Torsion on Open-Cell Aluminum Foams Behavior

by Solomon Bayu Huluka, Rachid Baleh, Naser A. Alsaleh, Adel Alfozan, Akrum Abdul-Latif and Sabbah Ataya

Materials 2023, 16(14), 5136; https://doi.org/10.3390/ma16145136 - 21 Jul 2023

Viewed by 663

Abstract

As a main goal of this work, a novel generation of cellular materials has been developed and manufactured by the kelvin cell model to be offered for different multifunctional applications. These Open-Cell Aluminum Foams (OCAF) have 85% porosities of spherical-shaped pores with a diameter of 11 mm. Several foamed square-section specimens were used. This work investigated the impact of different new quasi-static biaxial loading complexities on the mechanical behavior of such foams. Thus, new S-profiled rigs were already designed for examining the behavior of tested foams under biaxial loading conditions with different reverse torsional components named ACTP-S. After testing, their high specific strength and high energy absorption abilities have been characterized. Thus, in addition to the reference uniaxial test, all other tests were conducted at a speed of 5 mm/min. Thus, the mechanical responses of this foam are affected by loading complexities which are simple uniaxial, intermediate-biaxial (Bi-45°), and sever-biaxial (Bi-60°). These results were compared to the classical Absorption using Compression-Torsion Plastique (ACTP) responses. It was concluded that the highest dissipated energy increases with the increase in loading path complexity. Note that the energy absorption of the foam is essentially governed by its collapse mode. Full article

(This article belongs to the Special Issue Advanced Manufacturing of Metals and Composites: Effect of Processes on Microstructure and Mechanical Properties Volume II)

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20 pages, 10150 KiB

Open AccessArticle

Comparative Study of FSW, MIG, and TIG Welding of AA5083-H111 Based on the Evaluation of Welded Joints and Economic Aspect

by Mohamed I. A. Habba, Naser A. Alsaleh, Takwa E. Badran, Mohamed M. El-Sayed Seleman, Sabbah Ataya, Ahmed E. El-Nikhaily, Akrum Abdul-Latif and Mohamed M. Z. Ahmed

Materials 2023, 16(14), 5124; https://doi.org/10.3390/ma16145124 - 20 Jul 2023

Cited by 2 | Viewed by 1440

Abstract

Selecting an economically suitable welding technique and optimizing welding parameters to obtain high joint quality is considered a challenge for expanding the 5xxx aluminum alloy series in various industrial applications. This work aims to investigate the effect of applying different welding techniques, tungsten inert gas (TIG) and metal inert gas (MIG), as fusion welding processes compared to friction stir welding (FSW), a solid-state joining process, on the joint performance of the produced 5 mm thick similar AA5083-H111 butt weldments at different welding conditions. Different methods were used to evaluate the quality of the produced joints, including visual inspection, radiographic testing (RT), and macrostructure evaluation, in addition to hardness and tensile tests. The fracture surface of the tensile-failed specimens was also investigated using a scanning electron microscope (SEM). Furthermore, the current study ended with an economic analysis of the welding techniques used. The results showed that, for the friction stir-welded joints, the radiographic films revealed defect-free joints at the two applied travel speeds of 100 mm/min and 400 mm/min and a constant tool rotating speed of 400 rpm. In addition, only one joint was welded by MIG at a welding current of 130 Amp, with a 19 L/min flow rate of pure argon. In contrast, the radiographic films showed internal defects such as lack of fusion (LOF), lack of penetration (LOP), and porosity (P) for the two joints welded by TIG and one joint welded by MIG. The hardness of the welded joints was enhanced over the AA5083-H111 base material (BM) by 24–29, 31–35, and 46–50% for the MIG, TIG, and FSW joints, respectively. The maximum ultimate tensile strength was obtained for the FSW joint welded at a 400 mm/min travel speed. Adopting FSW in shipbuilding applications can further produce the AA5083-H11 joints with higher quality and efficiency than fusion welding techniques such as MIG and TIG processes. In addition, time and cost comparisons between TIG, MIG, and FSW were performed for five-millimeter-thick and one-meter-long AA5083-H111. Full article

(This article belongs to the Special Issue Advanced Manufacturing of Metals and Composites: Effect of Processes on Microstructure and Mechanical Properties Volume II)

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21 pages, 11623 KiB

Open AccessArticle

Additively Manufactured Parts from AA2011-T6 Large-Diameter Feedstocks Using Friction Stir Deposition

by Naser A. Alsaleh, Mohamed M. El-Sayed Seleman, Ahmed M. M. Hassan, Mohamed M. Z. Ahmed, Sabbah Ataya, Fahamsyah H. Latief, Akrum Abdul-Latif and Mohamed I. A. Habba

Materials 2023, 16(14), 4904; https://doi.org/10.3390/ma16144904 - 9 Jul 2023

Cited by 1 | Viewed by 1117

Abstract

The current work investigates the possibility of fabricating additive manufacturing products in solid-state form, from AA2011-T6 of 40 mm diameter rods as a feedstock, using an additive friction stir deposition (A-FSD) technique. The use of large diameter feedstocks, especially high-strength aluminum alloys (2XXX series), is a challenge, as it necessitates high power and the critical selection of the optimal A-FSD parameters, such as feed rate and spindle rotation speed. The study included applying a wide range of spindle rotation speeds, ranging from 400 to 1200 rpm, at three levels of feeding rates of 1, 3, and 5 mm/min. The AA2011-T6 friction stir deposited parts (FSDPs) were visually evaluated. This was followed by an examination of macrostructures through the thickness of the fabricated specimens. The characterization of microstructures was also carried out using optical microscopy and a scanning electron microscope equipped with advanced EDS analysis. Furthermore, the mechanical properties in terms of hardness and compressive strength of the AA2011-T6 base material (BM) and deposited materials were evaluated. Sound, additively manufactured products were successfully fabricated from 40 mm diameter AA2011-T6 feedstocks using the suggested deposition variables of 600 and 800 rpm spindle speeds and feeding rates of 1, 3, and 5 mm/min. The results indicated that the spindle speed and feeding rate govern the quality of the FSDPs. Furthermore, the axial load during the A-FSD process increased with increasing these parameters. In comparison to the AA2011-T6 BM, the additively deposited materials showed a refined grain structure and uniform dispersion of the fragment precipitates in their continuous multi-layers. The reduction ratio in grain size attains 71.56%, 76%, and 81.31% for the FSDPs processed at 800 rpm spindle speed and feeding rates of 1, 3 and 5 mm/min, respectively, compared to the grain size of BM. The Al₂Cu and Al₇Cu₂Fe intermetallics are detected in the AA2011-T6 BM, and their deposited parts are in different shapes of spherical, almost spherical, irregular, and rod-like shapes. The compressive strength and hardness of the deposited parts increased with increasing spindle speed and feeding speeds. At a spindle speed of 800 rpm and a 5 mm/min feeding rate, the higher hardness and compressive strength gained were 85% and 93%, respectively, from that of the AA2011-T6 feedstock. Full article

(This article belongs to the Special Issue Advanced Manufacturing of Metals and Composites: Effect of Processes on Microstructure and Mechanical Properties Volume II)

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18 pages, 10611 KiB

Open AccessArticle

Tensile Deformation and Fracture of Unreinforced AZ91 and Reinforced AZ91-C at Temperatures up to 300 °C

by Nashmi H. Alrasheedi, Sabbah Ataya, Mohamed M. El-Sayed Seleman and Mohamed M. Z. Ahmed

Materials 2023, 16(13), 4785; https://doi.org/10.3390/ma16134785 - 2 Jul 2023

Cited by 3 | Viewed by 1073

Abstract

Magnesium alloys are still attractive materials for applications that necessitate light weight due to their low density, moderate strength, and good corrosion resistance. AZ91 is one of the widely applied magnesium alloys due to its very good castability and strength. However, one of the drawbacks of magnesium alloys is the low elastic modulus. So, reinforcing AZ91 with carbon short fibers with the aim of further increasing the strength and improving the elastic modulus is investigated in this study. Squeeze cast AZ91-23 vol.% carbon short carbon (AZ91-C) and the unreinforced AZ91 are deeply examined by tensile testing at different temperatures (20, 100, 150, 200, 250, and 300 °C). Tensile stress–strain curves are measured and the tensile parameters (yield stress, ultimate tensile strength and strain) are defined and presented against the test temperature. Yield stress of AZ91 at 20 °C (109 MPa) is doubled (226 MPa) in the reinforced AZ91-C. Yield stress is found to slightly decrease with increasing the test temperature. Ultimate tensile strength of AZ91 at 20 °C (198 MPa) is increased (262 MPa) in the reinforced AZ91-C. The improvement of the ultimate tensile strength due to reinforcing increases with increasing the test temperature. Flow curves are determined and described by a modified Mecking–Kocks relationship and the flow parameters are determined and described as a function of the test temperature. Microstructure investigation was undertaken of the fractured tensile specimens at the grain boundaries rich in eutectic structure formed at the grain boundaries. Mixed brittle/ductile fracture mode is detected on the fracture surface of unreinforced AZ91, while the SEM investigations show matrix/carbon fiber detachment and fiber fracture as main fracture modes. Full article

(This article belongs to the Special Issue Advanced Manufacturing of Metals and Composites: Effect of Processes on Microstructure and Mechanical Properties Volume II)

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Planned Papers

The below list represents only planned manuscripts. Some of these manuscripts have not been received by the Editorial Office yet. Papers submitted to MDPI journals are subject to peer-review.

Title: Technology of Controlled Film Flow Granulation of Materials
Authors: Ivan Kazachkov
Affiliation: Department of Heat and Power, Faculty of Energy Technology, Royal Institute of Technology, Stockholm 10044, Sweden
Abstract: The new unique technology for granulation of metals and nonmetallic melts is presented in the paper. It was created on the newly developed controlled film flow disintegration with rapid cooling of the droplets and solidified granules in amorphous state. Three new phenomena discovered by us created the base for 3 different methods for granulation of metals and nonmetallic melts in a wide range of granules’ sizes. Electromagnetic resonance method allows producing granules of metals in the range of 1 mm and over. The soliton-like vibrational regime is available for production of any granulation material in the range 0.1-1 mm. Moreover, the shockwave regime is applicable for producing particles from 10 micrometers by size. All methods produce particles of the stated size with a narrow distribution by size: deviation from the average size no more than 50%. The other known methods do not produce granules with such high cooling rate, which can realize the amorphous state and cannot regulate size of particles in such bright but narrow range from 10 micrometers to 1-2 mm.

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