Re-Entrant Honeycomb Auxetic Structure with Enhanced Directional Properties.

This paper presents a modified re-entrant honeycomb auxetic structure. The structure is constructed by adding an additional horizontal member between the vertical and re-entrant member of the semi-re-entrant honeycomb model to increase the overall compliance of the structure in order to obtain higher values of negative Poisson's ratio (NPR). An analytical model of the structure is presented, taking into account the bending, shear, and axial deformations. The model is verified using finite element analysis (FEA) and tensile testing. The results of FEA and tensile testing corroborate the results of the presented mathematical model. The structure is also compared to the existing re-entrant honeycomb structure. The newly added strut has shown a direct effect on the directional properties of the overall structure. With an increase in the newly added strut to re-entrant lengths, NPR was significantly enhanced in the x-direction and reduced in the y-direction loadings. The structure shows an improved Young's modulus compared to solid material in both loading directions, especially for the low values of the new strut and re-entrant lengths ratio. The structure also shows that high NPR can be achieved for low relative density compared to semi re-entrant honeycomb structure.

Corrosion Behavior of Cold-Rolled and Solution-Treated Fe36Mn20Ni20Cr16Al5Si3 HEA in Different Acidic Solutions.

New high entropy alloys with good corrosion resistance in severe environment are receiving increasing attention. This work reports upon the microstructure and the corrosion resistance of the non-equiatomic Fe36Mn20Ni20Cr16Al5Si3 alloy in different acidic solutions. This alloy was designed by thermodynamic calculations using CALPHAD SOFTWARE, fabricated through casting, subjected to cold-rolling and solution-treatment, and compared with SS304 stainless steel. The corrosion test was performed through electrochemical behavior in 0.6 M NaCl and 0.6 M NaCl with 0.5 M H2SO4 and 0.6 M NaCl with 1 M H2SO4 solutions. Experimental results indicate that the alloy is composed of FCC phase as the main constituent besides a small amount of other BCC/B2 phases and other intermetallics. The corrosion test measurements revealed that cold-rolled Fe36Mn20Ni20Cr16Al5Si3 alloy is more resistant to corrosion in 0.6 M NaCl, while it is more susceptible to localized pits in H2SO4 to 0.6 M NaCl. Experimental results indicate that the pits are preferentially occurred in the areas of BCC/B2 phase precipitates. The solution-treated Fe36Mn20Ni20Cr16Al5Si3 HEA has the highest corrosion resistance compared to others with the addition of H2SO4 to 0.6 M NaCl. Surface morphologies of the different conditions were studied, and relevant results were reported.

Studying the Effect of Cold Rolling and Heat Treatment on the Microstructure and Mechanical Properties of the Fe36Mn20Ni20Cr16Al5Si3 High Entropy Alloy.

In this study, a multi-component FeMnNiCrAlSi high-entropy alloy, chosen through Thermo-Calc® software (2021a, Stockholm, Sweden) calculation and produced by electric arc melting, was studied for phase continents and mechanical properties. The results elucidated that the cold rolled condition (area reduction ratio about 86%) was in the form of elongated grains with a dendritic structure. Also, small amounts of the BCC phase were precipitated at the grain boundaries. The annealed sample shows features of BCC phase and different sizes of intermetallics. These results coincided with the predictions of Thermo-Calc® software calculations. A cold rolled sample showed high compressive yield strength of about 950 MPa, and the annealed sample had only half the strength of the cold rolled condition. The cold rolled sample shows the highest micro-hardness. The wear resistance of the annealed condition was significantly improved at room temperature and at 200 °C. The brittle phases in the annealed condition have a positive impact on the wear resistance.

Fabrication and Characterization of Steel-Base Metal Matrix Composites Reinforced by Yttria Nanoparticles through Friction Stir Processing.

Friction Stir Processing (FSP) was used to fabricate metal matrix composite, based on steel and reinforced with nano-sized yttrium oxide powder. The powder was packed in a narrow longitudinal groove of 2 mm depth and 1 mm width cut in the steel plate's rear surface. Different rotation speeds of 500-1500 rpm were used, at a fixed traveling speed of 50 mm·min-1. Single-pass and two passes, with the same conditions, were applied. The direction of the second pass was opposite to that of the first pass. After the first pass, complete nugget zones were obtained when the rotation speeds were more than 700 rpm with some particles agglomeration. The added particles showed as narrow elliptical bands, with a band pitch equal to the rotation speed over traveling speed. Performing the second FSP pass in the opposite direction resulted in better particles distributions. Almost defect-free composite materials, with homogenously distributed yttria nano-sized particles, were obtained after two passes when rotation speeds more than 700 rpm were used. The resulting steel matrix grains were refined from ~60 µm of the base metal to less than 3 µm of the processed nugget zone matrix. The hardness and the tensile strength of the fabricated materials improved almost two-fold over the base metal. Uniform microhardness values within the nugget areas were observed at higher rotational speeds. The ductility and toughness of the fabricated composites were reduced compared to the base metal.

Experimental Evaluation of Interfacial Surface Cracks in Friction Welded Dissimilar Metals through Image Segmentation Technique (IST).

Surface cracks on the friction welded interface of dissimilar metals are one of the earliest indications of degradation of the joint, which is a critical aspect for the welding strength. By manual inspection of the friction welded joint, observations of irregularities, porosity voids, crack lengths, cracked surfaces, and depth penetrations of two dissimilar metals can be made. Manual inspection purely depends on a quality expert's experience of quantitative analysis and knowledge. In this research, an attempt has been made to effectively utilize the image segmentation technique (IST) in the estimation of the welded surface quality of a dissimilar joint by friction welding. The bonding strength between dissimilar metals in friction welding is more dependent on the coefficient of friction between the metallic surfaces. To demonstrate the capability of the image segmentation technique, experiments were conducted with various parameters, such as friction pressure, friction time, coefficient of friction, and torque speed of the rotating work piece. The effect of the coefficient of friction on friction welded surface quality by considering process parameters is estimated by using the proposed technique. Experiments were validated and the results claimed that the proposed image processing approach is efficient in fractured surface crack detection, reducing the computation cost, and providing a high-speed method with greater accuracy in the identification of welded surface defects. It was found that the friction coefficient is dependent mostly on the friction pressure and friction time. Its values range from 0.21 to 0.71, with the highest value of friction pressure at 120 MPa and 500 rpm. The present work deals with the detection of welding defects by means of segmentation based analysis of the welded interface. This method has a significant improvement in the fractured surface, crack detection, and non-welded areas' detection in terms of pixels at the desired region, and is easy when compared to conventional detection techniques by using an operator's decisions.

Development of in-Situ Al-Si/CuAl2 Metal Matrix Composites: Microstructure, Hardness, and Wear Behavior.

In the present work, in-situ metal matrix composites were fabricated through squeeze casting. The copper particles were dispersed with different weight percentages (3%, 6%, 10%, and 15%) into Al-12% Si piston alloy. Also, heat treatments were performed at 380 °C and 450 °C for holding times of 6 and 18 h. The microstructures, X-ray diffractometer (XRD) pattern, hardness, and wear characteristics were evaluated. The results showed that these copper particles have reacted with the aluminum under all of the aforementioned processing conditions resulting in the formation of fine copper aluminide intermetallics. Most of the intermetallics were CuAl2, while AlCu appeared in a small ratio. Additionally, these intermetallics were homogenously distributed within the alloy matrix with up to 6% Cu addition. The amounts of those intermetallics increased after performing heat treatment. Most of these intermetallics were CuAl2 at 380 °C, while the Cu-rich intermetallics appeared at 450 °C. Increasing the holding time to 18 h, however, led to grain coarsening and resulted in the formation of some cracks. The hardness of the resulting composite materials was improved. The hardness value reached to about 170 HV after heat treating at 380 °C for 8 h. The wear resistance of the resulting composite materials was remarkably improved, especially at lower additions of Cu and at the lower heat treatment temperature.

Characterization of Aluminum-Based-Surface Matrix Composites with Iron and Iron Oxide Fabricated by Friction Stir Processing.

Surface composite layers were successfully fabricated on an A 1050-H24 aluminum plate by dispersed iron (Fe) and magnetite (Fe3O4) particles through friction stir processing (FSP). Fe and Fe3O4 powders were packed into a groove of 3 mm in width and 1.5 mm in depth, cut on the aluminum plate, and covered with an aluminum sheet that was 2-mm thick. A friction stir processing (FSP) tool of square probe shape, rotated at a rate of 1000-2000 rpm, was plunged into the plate through the cover sheet and the groove, and moved along the groove at a travelling speed of 1.66 mm/s. Double and triple passes were applied. As a result, it is found that the Fe particles were homogenously distributed in the whole nugget zone at a rotation speed of 1000 rpm after triple FSP passes. Limited interfacial reactions occurred between the Fe particles and the aluminum matrix. On the other hand, the lower rotation speed (1000 rpm) was not enough to form a sound nugget when the dispersed particles were changed to the larger Fe3O4. The Fe3O4 particles were dispersed homogenously in a sound nugget zone when the rotation speed was increased to 1500 rpm. No reaction products could be detected between the Fe3O4 particles and the aluminum matrix. The saturation magnetization (Ms) of the Fe-dispersed nugget zone was higher than that of the Fe3O4-dispersed nugget zone. Moreover, there were good agreement between the obtained saturation magnetization values relative to that of pure Fe and Fe3O4 materials and the volume content of the dispersed particles in the nugget zone.