Pub Date : 2025-02-04DOI: 10.1016/j.ijlmm.2025.02.001
Equbal Ahmed , Muhammed Muaz , Sajjad Arif , Ravi Kant , Syed Mohd Hamza , Md Kashif Alim , Musab Ahmad Khan , Jaber Abu Qudeiri , Sanan H. Khan
Friction Stir Welding (FSW) is a solid-state joining technique that has garnered significant attention for its ability to weld aluminum alloys while mitigating common issues such as porosity and thermal defects inherent in fusion welding. This study systematically evaluates the impact of inter-layers and powder additives on the mechanical properties of aluminum FSW joints. Magnesium (Mg) ribbons and Lead–Tin (Sn–Pb) alloy ribbons were employed as inter-layers, while Boron Carbide (B4C), Titanium Dioxide (TiO2), and Manganese (Mn) served as reinforcement powders. Quantitative analysis demonstrated that the combination of Manganese (Mn) powder and Sn–Pb alloy inter-layer achieved a remarkable 28 % improvement in hardness, a 35 % reduction in wear rate, and a 42 % increase in shear strength. Additionally, Mn powder alone yielded the highest shear strength, while Sn–Pb inter-layer with Mn powder provided maximum hardness and wear resistance. Mg ribbon combined with Mn powder produced the lowest surface roughness. These enhancements were corroborated by mechanical testing and morphological characterization, including scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and microstructural mapping. The findings highlight the effectiveness of tailored inter-layer and powder combinations in enhancing weld quality, providing insights into the underlying mechanisms responsible for these improvements. This study underscores the industrial relevance of these advancements, offering transformative potential for sectors such as aerospace and automotive manufacturing where superior joint properties are critical.
{"title":"Lightweight aluminum joint design: Enhancement of mechanical properties through novel inter-layer and powder additives in friction stir welding","authors":"Equbal Ahmed , Muhammed Muaz , Sajjad Arif , Ravi Kant , Syed Mohd Hamza , Md Kashif Alim , Musab Ahmad Khan , Jaber Abu Qudeiri , Sanan H. Khan","doi":"10.1016/j.ijlmm.2025.02.001","DOIUrl":"10.1016/j.ijlmm.2025.02.001","url":null,"abstract":"<div><div>Friction Stir Welding (FSW) is a solid-state joining technique that has garnered significant attention for its ability to weld aluminum alloys while mitigating common issues such as porosity and thermal defects inherent in fusion welding. This study systematically evaluates the impact of inter-layers and powder additives on the mechanical properties of aluminum FSW joints. Magnesium (Mg) ribbons and Lead–Tin (Sn–Pb) alloy ribbons were employed as inter-layers, while Boron Carbide (B<sub>4</sub>C), Titanium Dioxide (TiO<sub>2</sub>), and Manganese (Mn) served as reinforcement powders. Quantitative analysis demonstrated that the combination of Manganese (Mn) powder and Sn–Pb alloy inter-layer achieved a remarkable 28 % improvement in hardness, a 35 % reduction in wear rate, and a 42 % increase in shear strength. Additionally, Mn powder alone yielded the highest shear strength, while Sn–Pb inter-layer with Mn powder provided maximum hardness and wear resistance. Mg ribbon combined with Mn powder produced the lowest surface roughness. These enhancements were corroborated by mechanical testing and morphological characterization, including scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and microstructural mapping. The findings highlight the effectiveness of tailored inter-layer and powder combinations in enhancing weld quality, providing insights into the underlying mechanisms responsible for these improvements. This study underscores the industrial relevance of these advancements, offering transformative potential for sectors such as aerospace and automotive manufacturing where superior joint properties are critical.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 341-354"},"PeriodicalIF":0.0,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791544","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}
Pub Date : 2025-02-01DOI: 10.1016/j.ijlmm.2025.01.003
Vimukthi Dananjaya , Chamil Abeykoon
This study investigates the thermo-mechanical properties of graphene nanoplatelet (GNP)-filled recycled polypropylene (rPP) nanocomposites to enhance their performance and sustainability. It examines the influence of GNP loading on mechanical, thermal, and electrical behaviour, focusing on tensile strength, Young’s modulus, impact strength, heat deflection temperature, thermal conductivity, and electrical resistivity. The GNP-PP composites are fabricated by functionalizing GNPs through mild acid treatment to enhance compatibility with the rPP matrix, followed by melt mixing in a twin-screw extruder at varying GNP loadings (0–20 Phr). The tensile strength, Young's modulus, and flexural strength of recycled polypropylene increased by 15.6 MPa, 3.7 MPa, and 2.41 MPa, respectively, as the GNP loading increased from 0 to 20 Phr. AddingAdding GNP up to 20 Phr into the rPP matrix also increased the crystallization, melting, onset, and maximum decomposition temperatures by 5, 4.7, 8.36, and 7.02 ˚C, respectively. Additionally, the thermal conductivity shows an increasing trend, with an improvement of 221 mW/mK. However, including fillers reduced electrical resistivity by 105 Ω cm and impact strength by 64.27 Jm⁻1. The significance of this work lies in providing eco-friendly alternatives to conventional polymers, promoting the adoption of recycled materials, and contributing to sustainable product design. The outcomes offer valuable insights for industries promoting a circular economy with cleaner production while reducing the carbon footprint. Also, the recycling and reuse of synthetic polymers uncover a valuable prospect for tackling the escalating global polymeric waste problem.
{"title":"Thermo-mechanical and electrical properties of graphene nanoplatelets reinforced recycled polypropylene nanocomposites","authors":"Vimukthi Dananjaya , Chamil Abeykoon","doi":"10.1016/j.ijlmm.2025.01.003","DOIUrl":"10.1016/j.ijlmm.2025.01.003","url":null,"abstract":"<div><div>This study investigates the thermo-mechanical properties of graphene nanoplatelet (GNP)-filled recycled polypropylene (rPP) nanocomposites to enhance their performance and sustainability. It examines the influence of GNP loading on mechanical, thermal, and electrical behaviour, focusing on tensile strength, Young’s modulus, impact strength, heat deflection temperature, thermal conductivity, and electrical resistivity. The GNP-PP composites are fabricated by functionalizing GNPs through mild acid treatment to enhance compatibility with the rPP matrix, followed by melt mixing in a twin-screw extruder at varying GNP loadings (0–20 Phr). The tensile strength, Young's modulus, and flexural strength of recycled polypropylene increased by 15.6 MPa, 3.7 MPa, and 2.41 MPa, respectively, as the GNP loading increased from 0 to 20 Phr. AddingAdding GNP up to 20 Phr into the rPP matrix also increased the crystallization, melting, onset, and maximum decomposition temperatures by 5, 4.7, 8.36, and 7.02 ˚C, respectively. Additionally, the thermal conductivity shows an increasing trend, with an improvement of 221 mW/mK. However, including fillers reduced electrical resistivity by 105 Ω cm and impact strength by 64.27 Jm⁻<sup>1</sup>. The significance of this work lies in providing eco-friendly alternatives to conventional polymers, promoting the adoption of recycled materials, and contributing to sustainable product design. The outcomes offer valuable insights for industries promoting a circular economy with cleaner production while reducing the carbon footprint. Also, the recycling and reuse of synthetic polymers uncover a valuable prospect for tackling the escalating global polymeric waste problem.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800356","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}
Pub Date : 2025-01-09DOI: 10.1016/j.ijlmm.2025.01.002
Núria Latorre , Norbert Blanco , Daniel Casellas , Josep Costa
Single-Step Punch Interlocking (SSPI) is a recently developed joining methodology between aluminium and Carbon Fibre Reinforced Polymer (CFRP) aiming to contribute to multi-material design of structural parts. This hybrid joint technology combines adhesive bonding with mechanical interlocking. Elucidating the failure mechanism of the developed joint is relevant to provide insights for future enhancements in performance, increase its lifespan and prevent premature failure. Therefore, the different subcritical failure events were identified through interrupted Single-Lap Shear (SLS) tests and subsequent non-destructive ultrasonic inspection, and the global failure mechanism was described. Results indicate that the addition of the SSPI joint delayed the onset and propagation of adhesive failure between both substrates, providing residual strength and increasing the ultimate load in a 65 % and the absorbed energy of the joint in a 156 %.
{"title":"Failure mechanism of aluminium – carbon fibre reinforced polymer interlocking joints through punching","authors":"Núria Latorre , Norbert Blanco , Daniel Casellas , Josep Costa","doi":"10.1016/j.ijlmm.2025.01.002","DOIUrl":"10.1016/j.ijlmm.2025.01.002","url":null,"abstract":"<div><div>Single-Step Punch Interlocking (SSPI) is a recently developed joining methodology between aluminium and Carbon Fibre Reinforced Polymer (CFRP) aiming to contribute to multi-material design of structural parts. This hybrid joint technology combines adhesive bonding with mechanical interlocking. Elucidating the failure mechanism of the developed joint is relevant to provide insights for future enhancements in performance, increase its lifespan and prevent premature failure. Therefore, the different subcritical failure events were identified through interrupted Single-Lap Shear (SLS) tests and subsequent non-destructive ultrasonic inspection, and the global failure mechanism was described. Results indicate that the addition of the SSPI joint delayed the onset and propagation of adhesive failure between both substrates, providing residual strength and increasing the ultimate load in a 65 % and the absorbed energy of the joint in a 156 %.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 611-622"},"PeriodicalIF":0.0,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654019","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}
Pub Date : 2025-01-06DOI: 10.1016/j.ijlmm.2025.01.001
Ferhat Kadioglu
Thermoplastic composites as emerging materials for aerospace and automotive industries are suitable for mass-production and recycling. Healing is one of their inherent features when being damaged. This study aims to focus on the fusion bonding of a thermoplastic composite reinforced with carbon fibers. The material was fabricated in the Single Lap Joints (SLJs) configuration using a co-cured manufacturing method. First, the joints were subjected to quasi-static tensile tests to failure. The pristine joints with a 20 mm overlap length gave an average maximum load of about 5.5 kN. Then, the damaged joints were healed and subjected to the same test conditions to see their performance. It was observed that the thermoplastic adherends were able to be healed almost fully, giving a joint strength of about 5.2 kN, implying about 5 % of a decrement. Numerical works were also undertaken to see stress distributions in the joint and to predict the joint failure. Further investigations have shown the lap shear performance of such joints could be improved through different designs with no additional weight in the joint, which is feasible using the co-cured manufacturing methods.
{"title":"Improving healing capability of the thermoplastic composites reinforced with carbon fibres in a Single Lap Joint (SLJ) using a co-cured method","authors":"Ferhat Kadioglu","doi":"10.1016/j.ijlmm.2025.01.001","DOIUrl":"10.1016/j.ijlmm.2025.01.001","url":null,"abstract":"<div><div>Thermoplastic composites as emerging materials for aerospace and automotive industries are suitable for mass-production and recycling. Healing is one of their inherent features when being damaged. This study aims to focus on the fusion bonding of a thermoplastic composite reinforced with carbon fibers. The material was fabricated in the Single Lap Joints (SLJs) configuration using a co-cured manufacturing method. First, the joints were subjected to quasi-static tensile tests to failure. The pristine joints with a 20 mm overlap length gave an average maximum load of about 5.5 kN. Then, the damaged joints were healed and subjected to the same test conditions to see their performance. It was observed that the thermoplastic adherends were able to be healed almost fully, giving a joint strength of about 5.2 kN, implying about 5 % of a decrement. Numerical works were also undertaken to see stress distributions in the joint and to predict the joint failure. Further investigations have shown the lap shear performance of such joints could be improved through different designs with no additional weight in the joint, which is feasible using the co-cured manufacturing methods.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 385-392"},"PeriodicalIF":0.0,"publicationDate":"2025-01-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800357","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}
Pub Date : 2025-01-03DOI: 10.1016/j.ijlmm.2024.12.005
Farah M. Abdul Razzaq, Adnan S. Jabur
The development of the aluminum industry is intricately connected to its special characteristics that have made aluminum a highly desired material in engineering and structural applications. In the present work, the effect of alumina nanoparticle addition on the properties of Al-based nanocomposites was investigated. Al-based nanocomposite samples were fabricated by solid-state route using powder metallurgy and hot forging as a finishing process. The addition of alumina nanoparticles varied from 0 to 10 wt percentage. The structural, mechanical, tribological, and corrosion properties of the prepared Al- nanocomposites samples were studied. It was found that with an increase in the alumina nanoparticles addition up to 10 wt% to the Al-based nanocomposite samples, the hardness and yield strength increased while the reduction percentage, crystallite and grain size decreased. On the other hand, the wear rate decreased up to 5 wt% of addition and then increased again at 10 wt%, but the corrosion rate decreased up to 3 wt% of addition and then increased again up to 10 wt%.
{"title":"The effect of alumina nanoparticles on the properties of Al-based nanocomposites prepared by powder Metallurgy–Hot forging","authors":"Farah M. Abdul Razzaq, Adnan S. Jabur","doi":"10.1016/j.ijlmm.2024.12.005","DOIUrl":"10.1016/j.ijlmm.2024.12.005","url":null,"abstract":"<div><div>The development of the aluminum industry is intricately connected to its special characteristics that have made aluminum a highly desired material in engineering and structural applications. In the present work, the effect of alumina nanoparticle addition on the properties of Al-based nanocomposites was investigated. Al-based nanocomposite samples were fabricated by solid-state route using powder metallurgy and hot forging as a finishing process. The addition of alumina nanoparticles varied from 0 to 10 wt percentage. The structural, mechanical, tribological, and corrosion properties of the prepared Al- nanocomposites samples were studied. It was found that with an increase in the alumina nanoparticles addition up to 10 wt% to the Al-based nanocomposite samples, the hardness and yield strength increased while the reduction percentage, crystallite and grain size decreased. On the other hand, the wear rate decreased up to 5 wt% of addition and then increased again at 10 wt%, but the corrosion rate decreased up to 3 wt% of addition and then increased again up to 10 wt%.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 637-647"},"PeriodicalIF":0.0,"publicationDate":"2025-01-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654021","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}
The proliferation of Wire Arc Additive Manufacturing (WAAM) has significantly enhanced the production capabilities for lightweight and structurally robust components. This study investigates the microstructural characteristics, tensile properties, and preliminary wear performance of AA 5083 aluminum alloy processed via WAAM, focusing on applications for lightweight structures. Using SEM and XRD, microstructural changes during the WAAM process are analyzed, and tensile testing evaluates the mechanical properties, including ultimate tensile strength (UTS) and elongation. The results reveal that the microstructure consists of α-Al and β-(Al5Mg8) phases, with the Al5Mg8 phase distributed along grain boundaries and within grains. Notably, the grain size in the Y-direction (building direction) is larger than in the X-direction (deposition direction) due to temperature variations during processing. Tensile testing shows that horizontal samples (X-direction) have a UTS of 295 ± 5 MPa and elongation of 20.08 ± 0.8 %, while vertical samples (Y-direction) have a UTS of 267 ± 10 MPa and elongation of 16.43 ± 2.1 %. This results in an anisotropy of 9.4 % in tensile strength, reflecting the differences in mechanical properties between the two directions. The WAAM AA 5083 aluminum part exhibits a maximum wear rate of 5.22 × 10⁻³ mm³/m and a coefficient of friction of 0.52 at a load of 3.5 kg and 450 rpm. Under these conditions, deep grooves, layer separation, and load-induced deformation are observed. The primary wear mechanisms include delamination, adhesion, and abrasion. Hardness levels are consistent in the X-direction and show minimal variance in the Y-direction, with an average hardness of 89.4 ± 5.14 HV0.5. The study demonstrates that WAAM-produced AA 5083 aluminum alloy, with an anisotropy below 10 %, is suitable for real-time lightweight structures, offering effective performance in engineering applications such as aerospace and automotive industries. Future research should focus on further quantifying wear behavior and optimizing processing conditions to enhance material performance for specific applications.
{"title":"Microstructural analysis and preliminary wear assessment of wire arc additive manufactured AA 5083 aluminum alloy for lightweight structures","authors":"Prasanna Nagasai Bellamkonda , Maheshwar Dwivedy , Kaushik N.Ch","doi":"10.1016/j.ijlmm.2024.09.003","DOIUrl":"10.1016/j.ijlmm.2024.09.003","url":null,"abstract":"<div><div>The proliferation of Wire Arc Additive Manufacturing (WAAM) has significantly enhanced the production capabilities for lightweight and structurally robust components. This study investigates the microstructural characteristics, tensile properties, and preliminary wear performance of AA 5083 aluminum alloy processed via WAAM, focusing on applications for lightweight structures. Using SEM and XRD, microstructural changes during the WAAM process are analyzed, and tensile testing evaluates the mechanical properties, including ultimate tensile strength (UTS) and elongation. The results reveal that the microstructure consists of α-Al and β-(Al<sub>5</sub>Mg<sub>8</sub>) phases, with the Al<sub>5</sub>Mg<sub>8</sub> phase distributed along grain boundaries and within grains. Notably, the grain size in the Y-direction (building direction) is larger than in the X-direction (deposition direction) due to temperature variations during processing. Tensile testing shows that horizontal samples (X-direction) have a UTS of 295 ± 5 MPa and elongation of 20.08 ± 0.8 %, while vertical samples (Y-direction) have a UTS of 267 ± 10 MPa and elongation of 16.43 ± 2.1 %. This results in an anisotropy of 9.4 % in tensile strength, reflecting the differences in mechanical properties between the two directions. The WAAM AA 5083 aluminum part exhibits a maximum wear rate of 5.22 × 10⁻³ mm³/m and a coefficient of friction of 0.52 at a load of 3.5 kg and 450 rpm. Under these conditions, deep grooves, layer separation, and load-induced deformation are observed. The primary wear mechanisms include delamination, adhesion, and abrasion. Hardness levels are consistent in the X-direction and show minimal variance in the Y-direction, with an average hardness of 89.4 ± 5.14 HV0.5. The study demonstrates that WAAM-produced AA 5083 aluminum alloy, with an anisotropy below 10 %, is suitable for real-time lightweight structures, offering effective performance in engineering applications such as aerospace and automotive industries. Future research should focus on further quantifying wear behavior and optimizing processing conditions to enhance material performance for specific applications.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 1","pages":"Pages 1-13"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143099457","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}
This study examines the microstructure, mechanical and electrical properties of the copper-clad wires with a core of Al-0.5Fe alloy, obtained by casting into an electromagnetic crystallizer (EMC). The outer copper layer with a thickness of 90 ± 10 μm was applied via electrochemical deposition. Copper cladding of the aluminum wire leads to (without loss of strength and electrical conductivity) a decrease in the ductility to the value less than 2% which is the minimal recommended level of the elongation to failure for the commercially used aluminium alloys. Such drop in ductility also results in the shift of the fracture type to a brittle one. The cause of brittle fracture is the presence of a transition nickel layer required by the technological process of the electrochemical deposition of copper onto aluminium alloy. Annealing at 300 °C for 1 h leads to recovery of the ductility to the original level (4.3% for the cold-drawn Al-0.5Fe alloy wires) with a slight decrease in the ultimate tensile strength to 184 MPa and an increase in the specific electrical conductivity of the bimetallic wire to 60.9%IACS, as well as a change in fracture behavior to ductile. This method is promising for creating the bimetallic aluminum wires with a thin copper layer of controlled thickness and chemical composition to produce conductive elements in which the skin effect could be realized.
{"title":"Microstructure and properties of the Al-0.5 wt.% Fe alloy wire, copper-clad by electrochemical deposition","authors":"A.E. Medvedev , K.E. Kiryanova , E.B. Medvedev , M.V. Gorbatkov , M.M. Motkov","doi":"10.1016/j.ijlmm.2024.08.001","DOIUrl":"10.1016/j.ijlmm.2024.08.001","url":null,"abstract":"<div><div>This study examines the microstructure, mechanical and electrical properties of the copper-clad wires with a core of Al-0.5Fe alloy, obtained by casting into an electromagnetic crystallizer (EMC). The outer copper layer with a thickness of 90 ± 10 μm was applied via electrochemical deposition. Copper cladding of the aluminum wire leads to (without loss of strength and electrical conductivity) a decrease in the ductility to the value less than 2% which is the minimal recommended level of the elongation to failure for the commercially used aluminium alloys. Such drop in ductility also results in the shift of the fracture type to a brittle one. The cause of brittle fracture is the presence of a transition nickel layer required by the technological process of the electrochemical deposition of copper onto aluminium alloy. Annealing at 300 °C for 1 h leads to recovery of the ductility to the original level (4.3% for the cold-drawn Al-0.5Fe alloy wires) with a slight decrease in the ultimate tensile strength to 184 MPa and an increase in the specific electrical conductivity of the bimetallic wire to 60.9%IACS, as well as a change in fracture behavior to ductile. This method is promising for creating the bimetallic aluminum wires with a thin copper layer of controlled thickness and chemical composition to produce conductive elements in which the skin effect could be realized.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 1","pages":"Pages 28-37"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143099863","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}
Pub Date : 2025-01-01DOI: 10.1016/j.ijlmm.2024.07.007
Anna Didenko , Alexey Astapov
A review and critical analysis of recent advances in the field of oxidation and ablation resistance of carbon-ceramic composite materials, which are the most promising for high temperature applications in load-bearing structures and heat-protective systems of rocket and aerospace engineering, is carried out. The focus of this study is on the behavior of Cf/UHTC, Cf/C–UHTC, Cf/SiC–UHTC, and Cf/C–SiC–UHTC composites under thermochemical interaction with oxidizing gas flows. The workability of the composites is provided by the formation and evolution of passivating heterogeneous oxide films, which are represented mainly by the refractory MeO2 phase and the glass phase modified by Me4+ cations (Me – Zr and/or Hf). The protective oxide layers slow down the mass transfer of reagents (due to the high gas density caused by the presence of phases in a viscous-fluid state) and resist mechanical erosion and denudation (due to the framework structure provided by the partial sintering of refractory phase grains). Systematization and generalization of experimental data for composites of various compositions was carried out, including consideration of fire exposure modes, realized temperatures and obtained characteristics of linear and mass ablation rates. The results of the generalization are presented in the form of tables and schematic images of microstructures of forming oxide films with layer detailing. It is demonstrated that a promising approach for improving developments is the introduction of additional refractory components, which facilitate the formation of solutions with the structure of Me1-xTixO2, Me1-yTayO2+0.5y, Me1-yNbyO2+0.5y, and/or complex compounds such as Me6Ta2O17, Me6Nb2O17 and so on during operation. The formation of oxide films leads to an increase in the fraction of viscous-fluid substances, and, consequently, to a decrease in porosity and an increase in the gas density of protective layers. The processes of melting and transporting a portion of the mass from the surface facilitate the removal of a portion of the heat from the reaction zone, which in turn reduced the overall thermal load on the composites.
{"title":"Advances in the carbon-ceramic composites oxidation and ablation resistance: A review","authors":"Anna Didenko , Alexey Astapov","doi":"10.1016/j.ijlmm.2024.07.007","DOIUrl":"10.1016/j.ijlmm.2024.07.007","url":null,"abstract":"<div><div>A review and critical analysis of recent advances in the field of oxidation and ablation resistance of carbon-ceramic composite materials, which are the most promising for high temperature applications in load-bearing structures and heat-protective systems of rocket and aerospace engineering, is carried out. The focus of this study is on the behavior of C<sub>f</sub>/UHTC, C<sub>f</sub>/C–UHTC, C<sub>f</sub>/SiC–UHTC, and C<sub>f</sub>/C–SiC–UHTC composites under thermochemical interaction with oxidizing gas flows. The workability of the composites is provided by the formation and evolution of passivating heterogeneous oxide films, which are represented mainly by the refractory MeO<sub>2</sub> phase and the glass phase modified by Me<sup>4+</sup> cations (Me – Zr and/or Hf). The protective oxide layers slow down the mass transfer of reagents (due to the high gas density caused by the presence of phases in a viscous-fluid state) and resist mechanical erosion and denudation (due to the framework structure provided by the partial sintering of refractory phase grains). Systematization and generalization of experimental data for composites of various compositions was carried out, including consideration of fire exposure modes, realized temperatures and obtained characteristics of linear and mass ablation rates. The results of the generalization are presented in the form of tables and schematic images of microstructures of forming oxide films with layer detailing. It is demonstrated that a promising approach for improving developments is the introduction of additional refractory components, which facilitate the formation of solutions with the structure of Me<sub>1-x</sub>Ti<sub>x</sub>O<sub>2</sub>, Me<sub>1-y</sub>Ta<sub>y</sub>O<sub>2+0.5y</sub>, Me<sub>1-y</sub>Nb<sub>y</sub>O<sub>2+0.5y</sub>, and/or complex compounds such as Me<sub>6</sub>Ta<sub>2</sub>O<sub>17</sub>, Me<sub>6</sub>Nb<sub>2</sub>O<sub>17</sub> and so on during operation. The formation of oxide films leads to an increase in the fraction of viscous-fluid substances, and, consequently, to a decrease in porosity and an increase in the gas density of protective layers. The processes of melting and transporting a portion of the mass from the surface facilitate the removal of a portion of the heat from the reaction zone, which in turn reduced the overall thermal load on the composites.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 1","pages":"Pages 87-126"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143099866","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}
Pub Date : 2025-01-01DOI: 10.1016/j.ijlmm.2024.07.003
Iman Faridmehr , Moncef L. Nehdi , Mohammad Ali Sahraei , Kiyanets Aleksandr Valerievich , Chiara Bedon
This study rigorously assesses the shear capacity of fiber-reinforced polymer (FRP) reinforced concrete (RC) beams as a lightweight material alternative, scrutinizing the efficacy of the Eurocode and ACI design codes. Leveraging a dataset of 260 experimental FRP-RC beam cases, two distinct Artificial Neural Network (ANN) models were developed using the Levenberg-Marquardt algorithm. Beams with and without stirrups were considered, with parameters including beam width (), depth (), length (), concrete compressive strength (), FRP modulus of elasticity (, ) and FRP reinforcement ratios (, ). Multi-objective optimization was deployed to integrate Genetic Algorithms (GA) and fmincon to optimize beam parameters for maximizing the shear capacity, . Sensitivity analysis allowed to quantify the influence of each parameter, revealing that and significantly affect , with sensitivity scores of 0.39 and 0.35, respectively. The optimization process, highlighted by a 3D scatter plot, dynamically illustrated trade-offs among key design parameters (, , ), giving insights into the complex interplay in FRP beam design. The hybrid intelligence models reached superior predictive accuracy over traditional codes, achieving values of 0.89. Notably, for beams without stirrups, model predictions closely matched experimental data, with a lower average ratio (1.02) compared to Eurocode (1.65) and ACI (1.58). Principal Component Analysis (PCA) has elucidated the intricate interactions among variables, thereby deepening insights into the structural dynamics of FRP-RC beams. Incorporating artificial intelligence, sophisticated optimization methodologies, and thorough statistical evaluations establishes a holistic approach for the structural examination of FRP-RC beams, providing improved precision and valuable viewpoints for the refinement of future desi
{"title":"Hybrid intelligence framework for optimizing shear capacity of lightweight FRP-reinforced concrete beams","authors":"Iman Faridmehr , Moncef L. Nehdi , Mohammad Ali Sahraei , Kiyanets Aleksandr Valerievich , Chiara Bedon","doi":"10.1016/j.ijlmm.2024.07.003","DOIUrl":"10.1016/j.ijlmm.2024.07.003","url":null,"abstract":"<div><div>This study rigorously assesses the shear capacity of fiber-reinforced polymer (FRP) reinforced concrete (RC) beams as a lightweight material alternative, scrutinizing the efficacy of the Eurocode and ACI design codes. Leveraging a dataset of 260 experimental FRP-RC beam cases, two distinct Artificial Neural Network (ANN) models were developed using the Levenberg-Marquardt algorithm. Beams with and without stirrups were considered, with parameters including beam width (<span><math><mrow><mi>b</mi></mrow></math></span>), depth (<span><math><mrow><mi>d</mi></mrow></math></span>), length (<span><math><mrow><mi>L</mi></mrow></math></span>), concrete compressive strength (<span><math><mrow><msubsup><mi>f</mi><mi>c</mi><mo>′</mo></msubsup></mrow></math></span>), FRP modulus of elasticity (<span><math><mrow><msub><mi>E</mi><mrow><mi>f</mi><mi>r</mi></mrow></msub></mrow></math></span>, <span><math><mrow><msub><mi>E</mi><mrow><mi>f</mi><mi>s</mi></mrow></msub></mrow></math></span>) and FRP reinforcement ratios (<span><math><mrow><msub><mi>ρ</mi><mi>f</mi></msub></mrow></math></span>, <span><math><mrow><msub><mi>ρ</mi><mrow><mi>f</mi><mi>s</mi></mrow></msub></mrow></math></span>). Multi-objective optimization was deployed to integrate Genetic Algorithms (GA) and <em>fmincon</em> to optimize beam parameters for maximizing the shear capacity, <span><math><mrow><msub><mi>V</mi><mi>c</mi></msub></mrow></math></span>. Sensitivity analysis allowed to quantify the influence of each parameter, revealing that <span><math><mrow><mi>b</mi></mrow></math></span> and <span><math><mrow><mi>d</mi></mrow></math></span> significantly affect <span><math><mrow><msub><mi>V</mi><mi>c</mi></msub></mrow></math></span>, with sensitivity scores of 0.39 and 0.35, respectively. The optimization process, highlighted by a 3D scatter plot, dynamically illustrated trade-offs among key design parameters (<span><math><mrow><msub><mi>ρ</mi><mi>f</mi></msub></mrow></math></span>, <span><math><mrow><msub><mi>ρ</mi><mrow><mi>f</mi><mi>s</mi></mrow></msub></mrow></math></span>, <span><math><mrow><mi>d</mi></mrow></math></span>), giving insights into the complex interplay in FRP beam design. The hybrid intelligence models reached superior predictive accuracy over traditional codes, achieving <span><math><mrow><msup><mi>R</mi><mn>2</mn></msup></mrow></math></span> values of 0.89. Notably, for beams without stirrups, model predictions closely matched experimental data, with a lower average ratio (1.02) compared to Eurocode (1.65) and ACI (1.58). Principal Component Analysis (PCA) has elucidated the intricate interactions among variables, thereby deepening insights into the structural dynamics of FRP-RC beams. Incorporating artificial intelligence, sophisticated optimization methodologies, and thorough statistical evaluations establishes a holistic approach for the structural examination of FRP-RC beams, providing improved precision and valuable viewpoints for the refinement of future desi","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 1","pages":"Pages 14-27"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141705508","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}
Pub Date : 2025-01-01DOI: 10.1016/j.ijlmm.2024.08.003
Arunkumar Thirugnanasamabandam , B. Prabhu , Varsha Mageswari , V. Murugan , Karthikeyan Ramachandran , Kumaran Kadirgama
Recently, efforts have been done to capitalize on the potential of multidisciplinary research in order to produce unique features in polymer technology. To improve its physical and chemical properties for any intended use, the most promising Polylactic acid (PLA) has recently been copolymerized using other polymeric or non-polymeric components. This investigation aims to employ the material extrusion (MEX) process to develop a new functionally grade structural material (FGSM) by alternate layer deposition of wood flour reinforced PLA (WPLA) and ceramic reinforced PLA (CPLA). The mechanical properties of the printed laminates are examined using tensile, compression and three point bend tests. The microscopic investigation is used to assess fracture morphologies. A numerical simulation is also performed using ABAQUS under standardized parametric settings to investigate the mechanical behaviour of the laminates. The experimental and numerical results are consistent, with a deviation about ∼1 %. The tensile, compressive, and flexural strength of the newly developed FGSM are 61.39, 95.4, and 107.8 % higher than those of WPLA printed laminates. Furthermore, the acquired mechanical behaviour results are merely comparable to those of CPLA printed laminates. DSC thermograms demonstrate that FGSM has a better glass transition temperature (66°C) and a cold crystalline temperature (87.63°C), which contributes to its thermal stability. Overall, the newly developed FGSM might be considered a viable alternative, mechanically strong, and less expensive polymer composite material for structural built applications in any engineering and related fields.
{"title":"Wood flour / ceramic reinforced polylactic acid based 3D–printed functionally grade structural material for integrated engineering applications: A numerical and experimental characteristic investigation","authors":"Arunkumar Thirugnanasamabandam , B. Prabhu , Varsha Mageswari , V. Murugan , Karthikeyan Ramachandran , Kumaran Kadirgama","doi":"10.1016/j.ijlmm.2024.08.003","DOIUrl":"10.1016/j.ijlmm.2024.08.003","url":null,"abstract":"<div><div>Recently, efforts have been done to capitalize on the potential of multidisciplinary research in order to produce unique features in polymer technology. To improve its physical and chemical properties for any intended use, the most promising Polylactic acid (PLA) has recently been copolymerized using other polymeric or non-polymeric components. This investigation aims to employ the material extrusion (MEX) process to develop a new functionally grade structural material (FGSM) by alternate layer deposition of wood flour reinforced PLA (WPLA) and ceramic reinforced PLA (CPLA). The mechanical properties of the printed laminates are examined using tensile, compression and three point bend tests. The microscopic investigation is used to assess fracture morphologies. A numerical simulation is also performed using ABAQUS under standardized parametric settings to investigate the mechanical behaviour of the laminates. The experimental and numerical results are consistent, with a deviation about ∼1 %. The tensile, compressive, and flexural strength of the newly developed FGSM are 61.39, 95.4, and 107.8 % higher than those of WPLA printed laminates. Furthermore, the acquired mechanical behaviour results are merely comparable to those of CPLA printed laminates. DSC thermograms demonstrate that FGSM has a better glass transition temperature (66°C) and a cold crystalline temperature (87.63°C), which contributes to its thermal stability. Overall, the newly developed FGSM might be considered a viable alternative, mechanically strong, and less expensive polymer composite material for structural built applications in any engineering and related fields.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 1","pages":"Pages 74-86"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143099867","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}
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