Advances in Processing of Lightweight Metal Alloys and Composites: Microstructural Characterization and Property Correlation

Foreword by Dr. T. Ram Prabhu
Foreword by Dr. Shantanu Bhowmik
Foreword by Dr. A. Srinivasan
Preface
Acknowledgements
Contents
Editors and Contributors
List of Abbreviations
List of Symbols/Formula/Notation
Overview of Lightweight Materials
1 Design of Light-Metal Alloys Using Machine Learning Techniques
1 Introduction
2 Generalised Framework
3 Data for Light-Metal Alloy Design
3.1 Acquisition
3.2 Refinement
4 Surrogate Model
4.1 Random Forest
4.2 Gradient Boost Tree
4.3 XGBoost Regression
4.4 Artificial Neural Network
4.5 Support Vector Regression
4.6 Kriging Technique
4.7 Model Validation
5 Alloy Design
5.1 Target Objective Optimisation
5.2 Multi-objective Optimisation
6 Summary
References
2 Environmental Assessment of Recycling Carbon Fibre-Reinforced Composites: Current Challenges and Future Opportunities
1 Introduction
2 Methods
3 CFRP Waste Recycling Methods
3.1 Mechanical Recycling
3.2 Pyrolysis
3.3 Fluidized Bed Process
3.4 Solvolysis
4 Life-Cycle Assessment
5 Life-Cycle Inventory
6 Environmental Assessment of CFRP Recycling: Current Status
7 Conclusions and Future Directions
References
3 Synthesis of Lightweight Metallic Foam and Their Applications in Various Engineering Sectors
1 Introduction
1.1 Materials Used for Synthesizing Foam
1.2 Types of Foam
2 Synthesizing Techniques of Metal Foams
2.1 Synthesizing of Foam Through Liquid Metallurgy Route
2.2 Manufacturing of Cellular Materials by Powder Metallurgy Route
2.3 Other Useful Methods of Foam Manufacturing
3 Summary and Conclusion
References
4 Overview of Lightweight Metallic Materials
1 Introduction
2 Aluminum Alloys
2.1 Types of Alloying Elements
3 Applications
4 Magnesium Alloys
4.1 Types of Alloying Elements
5 Applications
6 Titanium Alloys
7 Applications
8 Conclusion
References
5 Surface Engineered Titanium Alloys for Biomedical, Automotive, and Aerospace Applications
1 Introduction
2 Potential Applications on Surface Engineered Titanium Alloys
2.1 Biomedical
2.2 Aerospace
2.3 Automotive Applications
2.4 Case Studies of Surface Engineered Titanium Alloys for Biomedical, Aerospace, and Automotive Applications
3 Future Trends
4 Summary
References
Liquid State Processing and Solid State Welding of Lightweight Alloys
6 Solid-State Welding of Aluminium Alloys
1 Introduction
2 Why Friction Stir Welding (FSW)?
2.1 Tool
2.2 Process
2.3 Microstructure and Grain Formation
2.4 Process Parameters
2.5 The Sequence of Operations
2.6 Aluminium Alloys—Solid-State Welding
2.7 Welding Zones in FSW
3 Commercial Designation of AL alloys
3.1 Microstructure
3.2 Mechanical Properties
3.3 Strength and Ductility
3.4 Corrosion Properties and Corrosion Characteristics
4 Application of FSW in Al Alloys
4.1 Armour
4.2 Aerospace
4.3 Marine
4.4 Automotive
4.5 Railways
5 Advantages of FSW
6 Flaws/Limitations in FSW
7 Conclusion Remarks
Reference
7 Solid-State Welding of Magnesium Alloys
1 Introduction
2 Solid-State Welding
2.1 Cold Welding (CW)
2.2 Diffusion Welding (DFW)
2.3 Explosion Welding (EXW)
2.4 Forge Welding (FOW)
2.5 Friction Welding (FRW)
2.6 Hot-Pressure Welding (HPW)
2.7 Roll Welding (ROW)
2.8 Ultrasonic Welding (USW)
3 Summary
4 Conclusion
References
8 Solid-State Friction Welding Technology for Joining of Lightweight Metal and Alloys
1 Introduction
2 Friction Welding
3 Mechanism of FW Process
3.1 Heat Generation
3.2 Heat-Affected Zone and Microstructure
4 Variants of FW Process
5 Process Parameters
6 Process Capabilities
7 Discussion and Future Directions
8 Summary
References
9 Fractographic Analysis of Friction Stir Welded Aluminium Alloy
1 Introduction
2 Experimental Procedure
2.1 Tensile Testing
2.2 Fracture Testing
3 Results and Discussions
3.1 Failure and Fracture Surface Analysis of Tensile Tested Specimens
3.2 Failure and Fracture Surface Analysis of CT Specimens
4 Conclusions
References
10 Production of Al–TiB2 Composites with Grain Modification by Strontium and Magnesium
1 Introduction
2 Materials and Methods
2.1 Fabrication Process
3 Results and Discussion
3.1 Optical Emission Spectroscopy and Microstructural Characterization
3.2 Mechanical Behaviour of the Samples
3.3 Fractography Analysis
4 Conclusion
References
11 Stir Casting Process Parameters and Their Influence on the Production of AA6061/B4C Metal Matrix Composites
1 Introduction
2 Materials and Methods
2.1 Stir Casting
2.2 Experimental Design
3 Development of Mathematical Model
3.1 Validation of Regression Equation
4 Result and Discussion
4.1 Influence of Process Parameters
4.2 ANOVA Results
4.3 Regression Analysis
4.4 Microstructure Analysis
5 Conclusion
References
Solid State Processing of Lightweight Alloys and Composites
12 Microstructure and Mechanical Properties of Severely Deformed Aluminum Alloys
1 Introduction
2 Relevant Topics
2.1 Principles of Severe Plastic Deformation (SPD) Processing
2.2 Mechanical Properties After SPD Processes
2.3 Microstructural Evolution After SPD Processing
3 Future Directions
4 Summary and Conclusion
References
13 A Comprehensive Survey on Friction-Based Processing of AZ Series Magnesium Alloys
1 Introduction
2 Friction-Based Processing
2.1 Influence of Process Parameters in FSW
2.2 Effects of Rotational and Transverse Speed
3 Fabrication Methods of Mg-based Composites
3.1 Friction Stir Processing (FSP)
3.2 Strengthening Mechanisms
4 Summary and Conclusion
References
14 An Investigation on Friction Stir Processing of Aluminum Alloy-Boron Carbide Surface Composite
1 Introduction
2 Experimental Method
3 Results and Discussions
4 Conclusions
References s
15 Performance Studies of Process Parameters on Friction Stir Processed AA5052 by Grey Analysis
1 Introduction
2 Materials and Methods
3 Results and Discussions
3.1 Macrostructure
3.2 Microstructure
3.3 Tensile and Hardness Strength
3.4 Fractography and EDS Studies on Optimal Specimen
4 Grey Relation Analysis (GRA)
5 Contour Plot of GRG with FSP Parameters
5.1 Computing the Mean Values of GRG and S/N Ratios
5.2 ANOVA
5.3 Validation Test of Optimal Parameters
6 Conclusion
References
16 Analysis into Mechanical Properties and Microstructural Behavior of Friction Stir Welded Al 6061-T6 Alloy Joints
1 Introduction
2 Experiment
2.1 Material Selection
2.2 Tool Specifications
2.3 Experimental Procedure
2.4 Mechanical Testing and Result Analysis
2.5 Microscopic Characterization
3 Discussion
4 Conclusion
References
17 Microstructure, Tribology, and Corrosion Characteristics of Hot-Rolled AZ31 Magnesium Alloy
1 Introduction
2 Materials and Methods
2.1 Material
2.2 Hot Rolling
2.3 Microstructure
2.4 Microhardness
2.5 Tribological Characterization
2.6 Corrosion Testing
2.7 Surface Morphology, Elemental Analysis, and TEM Analysis
3 Results and Discussion
3.1 Hot Rolling
3.2 Microstructure
3.3 Microhardness
3.4 Tribological Characterization
3.5 Wear Mechanism
3.6 Corrosion Test
3.7 Surface Morphology and Elemental Composition of Corroded Specimens
3.8 Corrosion Mechanism
4 Conclusion
References
18 Investigations on the Texture, Formability, and Corrosion Characteristics of AA3003-Y2O3 Surface Composite Fabricated by Friction Stir Processing
1 Introduction
2 Materials and Method
2.1 Materials
2.2 Methodology
3 Results and Discussion
3.1 Defect Analysis
3.2 Microstructure
3.3 Microhardness
3.4 Tensile Test
3.5 Fractography
3.6 Formability
3.7 Electrochemical Corrosion Analysis
4 Conclusion
References
Machinability Characteristics of Lightweight Alloys and Composites
19 Machinability Study of Amorphous Bulk Metallic Glass in Micro Milling
1 Introduction
2 Micro-milling Process Overview
3 Micro-milling Process Enabling Elements
4 Study of Micro-milling Forces and Specific Cutting Energy
5 Study of Surface Quality
6 Study of Burr Formation in Micro Milling
7 Conclusions
References
20 Machinability Studies on Al–Fe–Si Alloy-Based Composites
1 Introduction
2 Materials and Methods
2.1 Composite Fabrication
2.2 Design of Experiments
2.3 WEDM of Composite
2.4 Taguchi Technique
3 Results and Discussion
3.1 Effect of Machining Parameters on MRR
3.2 Effect of Machining Parameters on SR
3.3 Analysis of Variance (ANOVA)
3.4 Regression Model
3.5 Surface Morphology of Machined Surface
4 Conclusion
References
21 Optimization of Machining Parameters in EDM Using GRA Technique
1 Introduction
2 Experimental Details
2.1 Matrix and Reinforcement
2.2 Fabrication of Composite
2.3 Design of Experiments
2.4 EDM of Composite
2.5 GRA Technique
3 Result and Discussion
3.1 Analysis of EDM Parameters on GRG
3.2 Anova
3.3 Effect of the Machining Parameters on MRR
3.4 Effect of Machining Parameters on SR
3.5 Effect of Machining Parameters on TWR
3.6 Verification Test
4 Conclusion
References
22 Parametric Optimization of Dry Turning on Zirconia-Reinforced Magnesium Matrix Composites Using Taguchi-GRA Approach
1 Introduction
2 Materials and Method
2.1 Fabrication of Magnesium Matrix Composite
2.2 Measuring Cutting Forces, Power Consumption, and MRR
2.3 Optimization Using GRA
2.4 Calculation of Grey Relational Grade from Grey Relational Coefficient
3 Results and Discussion
3.1 Material Removal Rate
3.2 Cutting Forces
3.3 MRR Versus Power, Cutting Forces
3.4 Chip Analysis
3.5 Grey Relational Analysis
4 Conclusion
References
Current Trends in Additive Manufacturing of Materials
23 Light Metals and Composites in Additive Manufacturing
1 Introduction
2 Applications of Light Metals and Composites in AM
3 Powder Bed-Based Technologies for AM Processing of Light Metals and Composites
4 Wire-Arc Welding-Based Technologies for AM Processing of Light Metals and Composites
5 Input Material Properties for AM Processes of Light Metals and Composites
6 The Processing Parameters of AM Technologies
7 Quality Assessment of AM Parts
8 AM Part Design of Light Metals and Composites
9 Post-Processing of AM Parts from Light Metals and Composites
10 Mechanical Properties of AM Parts from Light Metals and Composites
11 Fatigue Behavior of AM Parts from Light Metals and Composites
12 Conclusion
References
24 Additive Manufacturing of Titanium Alloys for Aerospace and Biomedical Applications
1 Introduction
2 Additive Manufacturing (AM) Processes
3 Additive Manufacturing of Titanium Alloys
3.1 Selective Laser Melting (SLM)
3.2 Electron Beam Melting (EBM)
3.3 Properties of Additively Manufactured Titanium Alloy Materials
4 Conclusion and Future Trends
References
25 Process Modeling of Laser-Based Metal Additive Manufacturing of Metal Alloy
1 Introduction to Laser-Based Metal Additive Manufacturing
2 Process Modeling of Laser-Based Metal Additive Manufacturing
2.1 Multi-Physics-Based Modeling
2.2 Experimental Data-Driven Statistical Modeling
2.3 Data-Driven Artificial Intelligence (AI)-Based Modeling
3 Result and Discussion
3.1 Data-Driven Statistical Modeling of DED
3.2 Data-Driven AI Modeling Result of DED
4 Conclusion
5 Future Scope
References