International Journal of Lightweight Materials and Manufacture最新文献

{"title":"Effect of nanoclay additives on the salt water absorption and material characteristics of nylon additive manufactured polymers","authors":"Irine Chenwi,&nbsp;Julianna Martinez,&nbsp;Dillon Fontaine,&nbsp;Catherine DuBois,&nbsp;James LeBlanc","doi":"10.1016/j.ijlmm.2025.07.011","DOIUrl":"10.1016/j.ijlmm.2025.07.011","url":null,"abstract":"<div><div>An experimental investigation of the effectiveness of nanoclay material additives on the reduction of water absorption into a nylon AM polymer and the corresponding effects on the material and mechanical properties has been performed. The primary objectives of the study were to quantify the effectiveness of nanoclay material additives to mitigate the water absorption characteristics of extruded nylon, and quantify the changes in mechanical properties of the additive based material before and after salt water exposure. In the study three unique material configurations were evaluated: (1) Baseline Nylon, (2) Nylon with 2 % by weight nanoclay, and (3) Nylon with 5 % by weight nanoclay. The nanoclay powder that was used as an additive is Montmorillonite Clay (MMT) with surface modification. Water immersion was conducted with 3.5 % NaCl solution at room temperature for a time duration of 30 days. Each material configuration was being characterized mechanically in both dry and saturated conditions. The changes in mechanical properties were quantified through the controlled tensile testing. Additionally, thermogravimetric analysis (TGA) was conducted to quantify the changes in thermal decomposition. The thermal properties including glass transition temperature (T_g) and melting temperature (T_m) were evaluated by Differential Scanning Calorimetry (DSC). Finally, Dynamic Mechanical Analyzer (DMA) tests were conducted to understand the oscillation stress-strain behavior and thermal response of the neat nylon and the nanoclay modified material. The study's findings show that the use of nanoclay additives can reduce the amount of salt water absorbed by the respective materials, from 1.77 % to 1.63 %. However, there is a corresponding degrading effect on the mechanical properties of the materials themselves, even in the absence of salt water exposure. The incorporation of the nanoclay additives are shown to change the material behavior from highly ductile to highly brittle, with the failure strain being reduced from over 20 % to less than 2.5 %. Furthermore, The thermal properties of the baseline nylon were affected by the inclusion of the nanoclays by which the Glass Transition temperature was reduced from 45 °C to 43 °C and the melting temperature was increased from 200 °C to 204 °C.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 78-90"},"PeriodicalIF":0.0,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618630","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":"Laser powder bed fusion of AlSi10Mg with increased layer thickness for higher building rate","authors":"Stanislav Chernyshikhin ,&nbsp;Leonid Fedorenko ,&nbsp;Vladimir Egorov ,&nbsp;Boris Zotov ,&nbsp;Veniamin Brykin ,&nbsp;Konstantin Korobov ,&nbsp;Anton Nalivaiko ,&nbsp;Dmitriy Zherebtsov ,&nbsp;Maria Lyange ,&nbsp;Ivan Pelevin","doi":"10.1016/j.ijlmm.2025.07.010","DOIUrl":"10.1016/j.ijlmm.2025.07.010","url":null,"abstract":"<div><div>Among existing metal additive manufacturing technologies, laser powder bed fusion (LPBF) has an outstanding resolution but, from the other side, inferior building rate. In this work, the LPBF process of AlSi10Mg with increased layer thickness was comprehensively studied to enhance productivity. The samples were manufactured at 30, 50, 70, and 90 μm layer thicknesses with an additional variation in laser power and scanning speed. To find a quasi-optimal process conditions for each layer thickness, the specimens were investigated in terms of relative density, defect generation, microstructure, mechanical properties, and surface roughness. A transition in the pores’ morphologies along the building direction was identified. Namely, small metallurgical pores at the bottom surface, and irregular pores in the rest of the volume were observed. Therefore, special attention should be provided to the downskins of parts. The surface roughness tends to increase with the layer thickness, but it has been shown that the deterioration of the top surface quality is insignificant, and Ra for the side surface can be minimized via optimization of process conditions. It was demonstrated that an increase of layer thickness up to 50 μm is possible with a minor decrease in relative density and almost complete preservation of mechanical properties.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 37-46"},"PeriodicalIF":0.0,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618686","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":"Analysis and optimisation of parent grain reconstruction for additively manufactured Ti–6Al–4V","authors":"Lu Yang ,&nbsp;Saranarayanan Ramachandran ,&nbsp;Axieh Bagasol ,&nbsp;Fan Wu ,&nbsp;Qiyu Guan ,&nbsp;David J. Browne ,&nbsp;Denis Dowling ,&nbsp;Wajira Mirihanage","doi":"10.1016/j.ijlmm.2025.07.009","DOIUrl":"10.1016/j.ijlmm.2025.07.009","url":null,"abstract":"<div><div>During solidification processing, most common titanium alloys solidify as high-temperature parent phase and it subsequently transforms into the room-temperature child phase. This parent to child transformation occurred as a solid-state transformation. Even though the parent phase is not observable at room temperature, it is considerably associated with solidification defects such as porosity. Parent grain reconstruction based on Burgers orientation relationship, which shows the crystallographic relationship between two phases, has been applied to examine the high temperature and transitional parent phases of titanium alloys and steels. This contribution presents the reconstructed high temperature parent phase and the sensitivity analysis related to a series of parameters for three crucial parent phase reconstruction steps for additively manufactured titanium alloy Ti–6Al–4V. The analysis examines the reconstruction, merging of very small and neighbouring grains together, and finally cleaning of inclusive noise, which referred as inclusions during the rendering process of the parent phase. The analysis offers an instruction for threshold selection that enables optimised parent phase reconstruction.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 91-102"},"PeriodicalIF":0.0,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618690","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":"Feasibility of electrical discharge machining (EDM) of AZ31 lightweight magnesium alloy in dielectric fluids of hydrocarbon oil and deionized water","authors":"Saeed Asghari ,&nbsp;Mohammad Reza Shabgard ,&nbsp;Maghsoud Shalvandi ,&nbsp;S. Abolfazl Roudehchi ,&nbsp;Farzad Habibi","doi":"10.1016/j.ijlmm.2025.07.004","DOIUrl":"10.1016/j.ijlmm.2025.07.004","url":null,"abstract":"<div><div>In the current study, the effect of different types of dielectric fluids, including hydrocarbon oil and deionized water, on the material removal rate (MRR) and tool wear rate (TWR) of AZ31 magnesium alloy in the EDM process was investigated. X-ray diffraction (XRD) and FE-SEM coupled with energy dispersive spectroscope (EDS) were used to characterize the machined parts, while surface roughness and microhardness tests were used to evaluate the quality of the surface. The results revealed that the machining rate was significantly lower when using deionized water as the dielectric fluid. This was attributed to the formation of a 90 μm layer of magnesium oxide (MgO) on the machined surface, which was confirmed through EDS, XRD, and microhardness analyses. On the other hand, using oil as the dielectric fluid resulted in the formation of elemental carbon and Mg₂C₃ phase due to alloying with the workpiece. It was also observed that increasing the electric discharge current led to higher MRR and TWR values, with a smaller increase observed in specimens machined with deionized water. The surface roughness of the machined surfaces also increased significantly, from 10.12 to 19.2 μm for parts machined at 48 A/100 μs, indicating poor electrical discharge machinability of magnesium alloy in an aqueous environment.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 113-121"},"PeriodicalIF":0.0,"publicationDate":"2025-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145737661","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":"Low-velocity impact response of novel hierarchical hexagonal multicell structures","authors":"M Hafid ,&nbsp;Abian Nurrohmad ,&nbsp;Dony Hidayat ,&nbsp;Riki Ardiansyah ,&nbsp;Aryandi Marta ,&nbsp;Citra Asti Rosalia ,&nbsp;Zaini Ahmad","doi":"10.1016/j.ijlmm.2025.07.008","DOIUrl":"10.1016/j.ijlmm.2025.07.008","url":null,"abstract":"<div><div>This study introduces two novel hierarchical hexagonal multicell (HHM) tube designs inspired by honeycomb and grass stem structures: full triangular hierarchical hexagonal multicell (FTHHM) and internal clone hierarchical hexagonal multicell (ICHHM). These tubes feature a triangular pattern and hierarchical arrangement with four orders (0^th-3^rd). The tubes, fabricated from PLA-ST using FDM 3D printing technology, were analyzed through finite element simulations of all hierarchical cross-sectional structures and validated against experimental results. Tubes with higher hierarchical orders consistently reduced total displacement and enhanced crashworthiness performance indices, particularly in crush force efficiency (CFE). Among the designs, the FTHHM-3 tube outperformed the ICHHM-3 tube. Furthermore, the effect of wall thickness on the FTHHM-3 tube was investigated by incrementally increasing the impactor mass until the densification phase was reached across the entire wall thickness. As a result, the FTHHM-3 model exhibited significant improvements in CFE by 24.77 % and in specific energy absorption (SEA) by 52.76 % compared to conventional hexagonal tubes. These findings indicate that 3D-printed FTHHM tubes, especially those with higher hierarchical orders, hold strong potential for application in future lightweight structural systems.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 20-36"},"PeriodicalIF":0.0,"publicationDate":"2025-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618689","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":"Development of magneto-rheological polishing process with NON-Newtonian fluid and uniform magnetic yoke for surface quality Ti–6Al–4V enhancement","authors":"Nguyen Minh Quang,&nbsp;Nguyen Tien Tung,&nbsp;Le Thi Phuong Thanh,&nbsp;Nguyen Duy Trinh","doi":"10.1016/j.ijlmm.2025.07.007","DOIUrl":"10.1016/j.ijlmm.2025.07.007","url":null,"abstract":"<div><div>Ti–6Al–4V is a widely used and crucial alloy in various industries, particularly in manufacturing. Aiming to achieve a flat and smooth Ti–6Al–4V surface, this study proposes a new magneto-rheological (MR) polishing process, enhanced by a non-Newtonian fluid (thickening fluids) and a uniformly distributed magnetic yoke. A new MR fluid formulation is presented and discussed in detail in this study to address issues of poor particle bonding and non-uniformity. The authors also analyse the magnetic field to evaluate the effectiveness and feasibility of using uniformly dispersed magnetic particles in the MR process. Through evaluations of magnetic field strength, magnetic flux distribution and field variations, the study concludes that this approach is suitable and can enhance polishing performance. A polishing process employing the novel MR suspension and uniformly distributed magnetic yoke was established. The underlying mechanisms and key characteristics of this method were examined and discussed. An experimental setup, based on the previous MR processes, was used to conduct a series of experiments to demonstrate the potential of this method. The experiments also investigated the influence of several key factors, including fluid thickness, magnetic disk speed, working gap and container speed, on surface quality improvement. After 100 min of polishing, the Ti–6Al–4V workpiece achieved a smooth and flat surface with a surface roughness of Ra = 17 nm, demonstrating the high polishing efficiency of the proposed method. This research offers a promising solution for the precision polishing of difficult-to-machine materials and contributes to the advancement of smart finishing technologies for next-generation manufacturing.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 6-19"},"PeriodicalIF":0.0,"publicationDate":"2025-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618688","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":"Investigating the role of WEDM surface texturing in the degradation and biocompatibility of Mg–Zn–Ca alloy","authors":"Ingilela Aswith Babu ,&nbsp;Prithivirajan Sekar ,&nbsp;Ashwini Prabhu ,&nbsp;S. Narendranath ,&nbsp;A.S.S. Balan","doi":"10.1016/j.ijlmm.2025.07.006","DOIUrl":"10.1016/j.ijlmm.2025.07.006","url":null,"abstract":"<div><div>Magnesium (Mg) alloy-based biodegradable implants are gaining popularity for their low density, high strength, and biocompatibility. The corrosion and wear performance of Mg is poor in physiological environments, leading to premature failure. Surface modification, particularly through surface texturing, reduces the effective contact area of Mg–Zn–Ca alloy with corrosive media and tribological partners, potentially optimizing its degradation kinetics and cytocompatibility. Wire Electric Discharge Machining (WEDM) offers a stable oxide layer on the surface, unlike laser surface texturing, which may thermally damage the Mg alloy. In this study, three types of textures, mainly Wavy Texture (WT), microchannels (MC), and micropillars (MP), were created using WEDM on the Mg–Zn–Ca samples, and their corrosion, wear, cytotoxicity, and cell adhesion performance were evaluated. Texturing on the surface of the samples enhanced the corrosion performance, from 3.14 mm/year for the untextured sample to 0.98 mm/year for the micropillar textured sample, representing a 68.8 % reduction. This improvement after texturing is attributed to the superior surface finish (1.049 μm) and increased hydrophobicity (130.3°), equating to a 50.8 % improvement. The coefficient of friction (COF) value decreased from 0.364 for an untextured sample to 0.208 for microchannels, a 42.9 % reduction, due to the entrapment of debris in the textures and effective heat transfer. The samples' cell adhesion and cell viability have been improved after texturing. The combination of cytocompatibility, appropriate mechanical properties, and a reduced bio-corrosion rate highlights the potential of this surface texturing method, utilizing WEDM, as a promising approach to enhance biodegradable implant materials.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 747-765"},"PeriodicalIF":0.0,"publicationDate":"2025-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145371063","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":"Biocidal and reinforced PETG/antibacterial blend nanocomposite for extrusion-based additive manufacturing: Optimization course and printability scores","authors":"Nectarios Vidakis ,&nbsp;Nikolaos Michailidis ,&nbsp;Nektarios K. Nasikas ,&nbsp;Constantine David ,&nbsp;Dimitrios Sagris ,&nbsp;Apostolos Argyros ,&nbsp;Ioannis Valsamos ,&nbsp;Katerina Gkagkanatsiou ,&nbsp;Vassilis Papadakis ,&nbsp;Markos Petousis","doi":"10.1016/j.ijlmm.2025.07.003","DOIUrl":"10.1016/j.ijlmm.2025.07.003","url":null,"abstract":"<div><div>Polyethylene terephthalate glycol (PETG) is an amorphous polymer that has been widely used in numerous applications, from everyday life to medical and even defense-related applications. The latter constitute very demanding environments in which, in many cases, specific multifunctionalities are required. Herein, we aim for specific functionalities to appear simultaneously, thus creating novel materials that can provide important solutions to applications. Therefore, inducing antibacterial properties along with enhanced mechanical properties for use in the defense and security domains constitutes an additional asset when disease spread becomes very important. To address this challenge, we mixed pure PETG with an antibacterial nanopowder to investigate these novel multifunctionalities in detail. Concomitantly, the enhancement of the mechanical properties of the 3D printed PETG/antibacterial nanocomposites was thoroughly examined. Several PETG nanocomposites were manufactured with different nanopowder loadings and turned into filaments for use in the AM method of material extrusion (MEX). The several 3D printed PETG/antibacterial nanocomposites were thoroughly investigated for their mechanical and rheological properties, thermal stability, and morphological, structural, and chemical characteristics, combined with antibacterial performance, against two common pathogens, <em>s. aureus</em> and <em>e. coli</em>, using the agar well diffusion method. The outcome of the nanopowder introduction to the quality metrics of the 3D printed PETG, namely the geometrical accuracy and pores of the 3D printed structure was also investigated through high-resolution micro-computed tomography. The PETG/antibacterial nanocomposites exhibited improved mechanical properties. A 13.6 % tensile strength increase was achieved with 8 wt% content. 10 wt % achieved 17 % Young's modulus increase, 19 % flexural strength and 18.2 % flexural modulus improvement and can be considered the optimum loading of the research. Nanocompounds also showed strong antibacterial activity against <em>s. aureus</em> and <em>E. coli</em>. These induced multifunctionalities can constitute a new class of materials where the desired properties can have significant applications in two or more different fields for functional, durable, and infection-resistant materials, such as in the demanding defense and security sector, the medical field, or both.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 726-746"},"PeriodicalIF":0.0,"publicationDate":"2025-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145371064","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":"Tribological aspects of AA6082/graphene/TiC hybrid composite using Taguchi and Machine Learning","authors":"Sohan Lal ,&nbsp;Rashmi Mittal ,&nbsp;Neeraj Sharma ,&nbsp;Guru Prakash","doi":"10.1016/j.ijlmm.2025.07.002","DOIUrl":"10.1016/j.ijlmm.2025.07.002","url":null,"abstract":"<div><div>In the present research, hybrid composite consists of AA6082 aluminum base with TiC and n-graphene ceramics reinforcements ranging from 1 to 6 wt.%. High-energy ball milling created homogeneous mixtures between the two reinforcing components that together occupied 50 wt.% of total content. The hybrid aluminum matrix composite was fabricated through stir casting before being examined for wear resistance against the counter surface of EN32 steel by means of a pin-on-disc tribometer. The optimization process for pin-on-disc testing parameters merged Taguchi method with machine learning (ML) approaches. Load stands as the primary factor determining the dry sliding wear rate (WR) of materials according to analysis of variance (ANOVA) results while reinforcement content and speed play additional roles. The slope of both two-factor interaction effects demonstrated meaningful change. The Taguchi and ML determined that the optimized parameters would lead to a WR of 6.94×10^-4 mg/s as the minimum value. Microstructural examination using scanning electron microscopy (SEM) finds that very small grooves are seen at optimal settings, whereas severe ploughing is shown at other settings. The wear mechanism transitions from adhesive to abrasive when the speed between the pin and disc increases.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 693-704"},"PeriodicalIF":0.0,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145371062","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":"Effects of tool geometry on the weld quality of friction stir welded ultra-thin 1060 aluminum alloy plate","authors":"Saiyu Yang,&nbsp;Shiqi Chen,&nbsp;Huiyu Song,&nbsp;Jun Shen","doi":"10.1016/j.ijlmm.2025.06.001","DOIUrl":"10.1016/j.ijlmm.2025.06.001","url":null,"abstract":"<div><div>Friction Stir Welding (FSW) has gained widespread application in aluminum alloy joining due to its ability to produce high-strength, defect-free welds. However, welding ultra-thin aluminum alloy plates (thickness &lt;2 mm) presents challenges such as joint softening, surface thinning, and warping. In this study, 1.4 mm-thick 1060 aluminum alloy plates were friction stir welded using tools with varying geometric parameters—including shoulder diameter, concave angle, and stir pin taper—under fixed welding conditions of 3000 r/min rotation speed and 300 mm/min welding speed. Through metallographic observation, Vickers microhardness testing, and tensile strength evaluation, it was found that the tool with a conical stir pin (Tool No. 2), featuring a 5 mm flat shoulder, root diameter of 2 mm, and end diameter of 1 mm, produced the highest-quality weld. The resulting joints exhibited a smooth surface finish, minimal internal defects, and a maximum tensile strength of 131.80 MPa–99.55 % of the base material strength (132.40 MPa). The fracture consistently occurred in the base material region, indicating excellent joint integrity. Additionally, the weld zones demonstrated fine-grained microstructures and maintained or exceeded the base material's hardness across all regions. This research confirms that by optimizing stir tool geometry, FSW can effectively eliminate defects such as thinning, grooves, and warping in ultra-thin aluminum sheets. The findings offer practical guidance for the reliable application of FSW in high-precision, lightweight structures such as aerospace components and new energy vehicle battery trays.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 681-692"},"PeriodicalIF":0.0,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145371017","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}