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Dissimilar materials found applications in the structural fields to withstand the different types of loads and provide multi-facet properties to the final structure. Aluminum alloy materials are mostly used in aerospace and marine industries to provide better strength and safeguard the material from severe environmental conditions. The purpose of this study is to develop new material with superior strength to challenge the severe environmental conditions.

In the present investigation, friction stir welding (FSW) dissimilar joints were prepared from AA6061 and AA5083 aluminum alloys, and the weld nugget (WN) was reinforced with hard reinforcement particles such as La₂O₃ and CeO₂. The tribological and mechanical properties of the prepared materials were tested to analyze the suitability of material in the aerospace and marine environmental conditions.

The results showed that the AA6061–AA5083/La₂O₃ material exhibited better mechanical and tribological characteristics. The FSW dissimilar AA6061–AA5083/La₂O₃ material exhibited lower wear rate of 7.37 × 10⁻³ mm3/m and minimum friction coefficient of 0.31 compared to all other materials owing to the reinforcing effect of La₂O₃ particles and the fine grains formed by FSW process at WN region. Further, FSW dissimilar AA6061–AA5083/La₂O₃ material displayed a maximum tensile strength and hardness of 378 MPa and 118 HV, respectively, among all the other materials tested.

This work is original and novel in the field of materials science engineering focusing on tribological characteristics of friction stir welded dissimilar aluminum alloys by the reinforcing effect of hard particles such as La₂O₃ and CeO₂.

Aluminum alloys are applicable in marine and aero fields. Alloys AA5083 and AA6061 are aluminum alloys with different chemical and physical properties. Combination of two dissimilar materials could result in enhanced strength. Generally, dissimilar aluminum alloy joint is made by friction stir welding (FSW) to achieve improved physical properties compared with the parent alloys. The purpose of this research is to develop a new FSW dissimilar material with enhanced properties using AA5083 and AA6061 alloys.

In this research, FSW joint was made for butt joint configuration using AA5083 and AA6061 aluminum alloys. Cylindrical pin with threaded profile was used to perform the joint. The tool tilting angle was maintained as constant, and the tool rotational speed and the welding speed were varied. Wear performance and mechanical strength of the joint were analyzed.

The results revealed that the increase of tool rotational speed led to poor wear performance, whereas increase of welding speed showed a better wear performance. Further, the prepared joint was analyzed for different wear parameters such as sliding velocity and applied load. The results displayed that the increase of sliding velocity exhibited low wear rate and the increase of load showed high wear rate.

This work is original and deals with the wear performance of AA5083–AA6061 joint at different tool rotational and welding speeds.

This paper aims to present the fabrication of 6061 aluminum alloy (AA6061) using a promising laser additive manufacturing process, called the laser-foil-printing (LFP) process. The process window of AA6061 in LFP was established to optimize process parameters for the fabrication of high strength, dense and crack-free parts even though AA6061 is challenging for laser additive manufacturing processes due to hot-cracking issues.

The multilayers AA6061 parts were fabricated by LFP to characterize for cracks and porosity. Mechanical properties of the LFP-fabricated AA6061 parts were tested using Vicker’s microhardness and tensile testes. The electron backscattered diffraction (EBSD) technique was used to reveal the grain structure and preferred orientation of AA6061 parts.

The crack-free AA6061 parts with a high relative density of 99.8% were successfully fabricated using the optimal process parameters in LFP. The LFP-fabricated parts exhibited exceptional tensile strength and comparable ductility compared to AA6061 samples fabricated by conventional laser powder bed fusion (LPBF) processes. The EBSD result shows the formation of cracks was correlated with the cooling rate of the melt pool as cracks tended to develop within finer grain structures, which were formed in a shorter solidification time and higher cooling rate.

This study presents the pioneering achievement of fabricating crack-free AA6061 parts using LFP without the necessity of preheating the substrate or mixing nanoparticles into the melt pool during the laser melting. The study includes a comprehensive examination of both the mechanical properties and grain structures, with comparisons made to parts produced through the traditional LPBF method.

The purpose of this paper is to develop a chrome-free and phosphorus-free chemical conversion coating with good corrosion resistance, a novel chemical conversion coating was prepared by adding cerium nitrate hexahydrate and salicylic acid in the treatment solution containing titanium/zirconium ions on 6061 aluminum alloy.

Compared with the AA6061 aluminum alloy matrix, the self-corrosion potential of the conversion coating is significantly positively shifted, the self-corrosion current density is greatly reduced and its corrosion resistance is significantly improved. Morphology and composition of the conversion coatings were observed by scanning electron microscopy and energy-dispersive X-ray spectroscopy. The microdomain structure of conversion coatings at different formation stages was analyzed by electron probe microanalyzer.

An optimized preparation technique of titanium–zirconium chemical conversion coating for AA6061 aluminum alloy is obtained: H₂TiF₆ 4 mL/L, H₂ZrF₆ 0.4 mL/L, salicylic acid 0.35 g/L, Ce(NO₃)₃·6H₂O 0.14 g/L, reaction temperature 30°C, reaction time 120 s and pH 4.0.

The coating forms on the Al(Fe)Si intermetallic compound, and Ce³⁺ is preferentially adsorbed on the intermetallic compound. The hydrolysis of Ce³⁺ causes the local pH of the solution to decrease, which promotes matrix dissolution and charge migration. As the microanode/microcathode reaction occurs, the local pH of the solution increases, and Al₂O₃/ZrO₂/TiO₂ begins to deposit on the surface of the metal substrate.

The most promising replacements for the industrial applications are particle reinforced metal matrix composites because of their good and combined mechanical properties. Currently, the need of matrix materials for industrial applications is widely satisfied by aluminium alloys. The purpose of this paper is to evaluate the tribological behaviour of the zinc oxide (ZnO) particles reinforced AA6061 composites prepared by stir casting route.

In this study, AA6061 aluminium alloy matrix reinforced with varying weight percentages (3%, 4.5% and 6%) of ZnO particles, including monolithic AA6061 alloy samples, is cast by the most economical fabrication method, called stir casting. The prepared sample was subjected to X-ray photoelectron spectroscopy (XPS) analysis, experimental density measurement by Archimedian principle and theoretical density by rule of mixture and hardness test to investigate mechanical property. The dry sliding wear behaviour of the composites was investigated using pin-on-disc tribometer with various applied loads of 15 and 20 N, with constant sliding velocity and distance. The wear rate, coefficient of friction (COF) and worn surfaces of the composite specimens and their effects were also investigated in this work.

XPS results confirm the homogeneous distribution of ZnO microparticles in the Al matrix. The Vickers hardness result reveals that higher ZnO reinforced (6%) sample have 34.4% higher values of HV than the monolithic aluminium sample. The sliding wear tests similarly show that increasing the weight percentage of ZnO particles leads to a reduced wear rate and COF of 30.01% and 26.32% lower than unreinforced alloy for 15 N and 36.35% and 25% for 20 N applied load. From the worn surface morphological studies, it was evidently noticed that ZnO particles dispersed throughout the matrix and it had strong bonding between the reinforcement and the matrix, which significantly reduced the plastic deformation of the surfaces.

The uniqueness of this work is to use the reinforcement of ZnO particles with AA6061 matrix and preparing by stir casting route and to study and analyse the physical, hardness and tribological behaviour of the composite materials.

Heat-treatable AA-6061-T651 Aluminum alloys (Al-Mg-Si) have found considerable importance in structural and aerospace applications for their high strength to weight ratio and improved corrosion resistance properties. Intrinsic weld defects, post-weld residual stresses, and microstructural changes are the key factors for performance reductions and failures of welded structures. Gas-Tungsten-Arc-Welding (TIG/GTAW) was carried out on AA-6061-T651 plates with Argon/Helium (50/50) as the shielding gases. Non-destructive Phased-Array-Ultrasonic-Testing (PAUT) was applied for the detection and characterization of weld defects and mechanical performances. Ultrasonic technique was used for the evaluation of post-weld residual stresses in welded components. The approach is based on the acoustoelastic effect, in which ultrasonic wave propagation speed corresponds to the magnitude of stresses present within the materials. To verify the PAUT's residual stress results, a semi-destructive hole-drilling technique was used; and observed analogous results. The effects of post-weld-heat-treatment (PWHT) on the residual stresses, grain size, micro-hardness, and tensile properties are also studied. The grain size and micro-hardness values are studied through Heyn's method and Vickers hardness test, respectively. Lower residual stresses are observed in post-weld heat-treated specimens, which are also confirmed from microstructural and micro-hardness studies. The PWHT enhanced tensile properties for the redistribution of microstructures and residual stresses.

This study aims to develop a less weight high wear resistant material to fabricate brake components especially in automotive sector.

Effort was initiated to design and develop aluminium metal matrix composite by combining aluminium alloy AA6061 and zirconium oxide (ZrO₂) with the help of stir casting coupled with squeeze casting unit. Morphology analysis of advanced composite has been carried out by optical microscopy and scanning electron microscopy (SEM). The hardness of composites having different compositions was tested using Vickers micro hardness tester. The tribological property of the developed three specimens having different composition has been tested using pin-on-disc wear test equipment under dry sliding conditions. To obtain better understanding of wear mechanism, SEM image of worn-out surface was captured and analysed. SEM images and the corresponding Energy-dispersive X-ray spectroscopy (EDX) on the wear surface were carried out.

The optical and SEM images evidenced the existence of ZrO₂ particles along the metal matrix composite. Porosity values shows that the porosity level is acceptable as it falls below 7 per cent. Also, the finding proves that increase in the percentage of reinforcement particle instigates agglomeration on the AA6061 composites. Hardness test demonstrated that the inclusion of hard ZrO₂ particles leads to substantial improvement in hardness and the hardness value started deteriorating when the composition reaches 15 per cent. The wear test results substantiated the enhancement of tribological property due to the inclusion of distinct ZrO₂ particles. Also, despite of addition of reinforcements, the wear rate increased when the load increases. SEM images proved that AA6061/ZrO2-5 per cent composite fashioned steady-state mild and smooth wear. EDX spectrum analysis revealed the existence of ZrO₂ particles along with wear debris, which caused wear of 685 µm in AA6061/ZrO₂-15 per cent composite.

The developed material possesses low wear rate which is the unique property of composite and frictional force which is directly proportional to load but the coefficient of friction remains apparently constant. As a whole, investigations on developed composites introduce a new material which is suitable for manufacturing of brake components for automobile industry.

With the advent of micro‐satellites technology, passive thermal controls in the form of surface coatings have become important for onboard thermal management. The thermal coatings, however, suffer outgassing and mass loss due to their direct exposure to harsh thermal environment and high vacuum in space. The purpose of this paper is to discuss testing and evaluation on outgassing of AA6061‐T6 specimen surfaces treated with various types of anodized coatings of different thicknesses and the related mass loss before and after thermal exposure.

Samples of chromic acid, polytetrafluroethylene polymer, and black‐ and brown‐colour anodized aluminum coupons were subjected to high vacuum (∼1×10⁻⁶ mbar), before and after thermal baking at 120°C. Spectrum analysis of the outgassed material to know their quantities and proportion was conducted subsequently using a Quadrupole mass analyzer.

The surface coatings under study complied with the spacecraft requirements for the mass loss of less than 1 percent of the total mass of the coating material used for that surface. The mass spectrum analysis of the outgassed material indicated that the majority of the coating mass loss was on account of water vapours and organic solvents like ethylene.

These results provided a good insight into the reliability of the coating materials studied and the bonding between the aluminum substrates and the coatings.

The coatings and the technology needed for their application on aluminum are readily available. The present work on outgassing and mass loss in a simulated space environment will provide useful insight on their usage for micro‐satellites.

The purpose of this paper is to compile a comprehensive status report on pipes/piping networks across different industrial sectors, along with specifications of materials and sizes, and showcase welding avenues. It further extends to highlight the promising friction stir welding as a single solid-state pipe welding procedure. This paper will enable all piping, welding and friction stir welding stakeholders to identify scope for their engagement in a single window.

The paper is a review paper, and it is mainly structured around sections on materials, sizes and standards for pipes in different sectors and the current welding practice for joining pipe and pipe connections; on the process and principle of friction stir welding (FSW) for pipes; identification of main welding process parameters for the FSW of pipes; effects of process parameters; and a well-carved-out concluding summary.

A well-carved-out concluding summary of extracts from thoroughly studied research is presented in a structured way in which the avenues for the engagement of FSW are identified.

The implications of the research are far-reaching. The FSW is currently expanding very fast in the welding of flat surfaces and has evolved into a vast number of variants because of its advantages and versatility. The application of FSW is coming up late but catching up fast, and as a late starter, the outcomes of such a review paper may support stake holders to expand the application of this process from pipe welding to pipe manufacturing, cladding and other high-end applications. Because the process is inherently inclined towards automation, its throughput rate is high and it does not need any consumables, the ultimate benefit can be passed on to the industry in terms of financial gains.

To the best of the authors’ knowledge, this is the only review exclusively for the friction stir welding of pipes with a well-organized piping specification detailed about industrial sectors. The current pipe welding practice in each sector has been presented, and the avenues for engaging FSW have been highlighted. The FSW pipe process parameters are characteristically distinguished from the conventional FSW, and the effects of the process parameters have been presented. The summary is concise yet comprehensive and organized in a structured manner.

Cold forging operation is one of the widely used techniques in industry production. This paper aims to present a case study in highlighting and modelling the use of different type of palm oil-based [palm stearin (PS), palm kernel oil (PKO) and palm mid olein (PMO)] as a bio-lubricant in cold forging process using experimental and finite element method.

Ring compression test plays a fundamental role in the understanding of materials science and engineering because of the deformation, friction and wear behaviour. Aluminium (A6061) was used in this test to observe the deformation of the ring with different palm oil and its derivatives by comparing with commercial metal forming oil.

The presence of certain type of palm oil-based lubricant has a good performance compared to mineral-based oil in terms of surface roughness but when observed in terms of friction the result shows that palm oil-based lubricant has poor friction performance compared to mineral oil-based lubricant (m = 0.25), where PS has the lowest friction at m = 0.3 compared to PKO (m = 0.35) and PMO (m = 0.38).

This research is using palm oil in cold forging test to study the friction, formation and stress at certain levels of stroke. The detail of the test is explained in the manuscript as attached.

This research is trying to promote the use of biodegradable material to reduce pollution to the surrounding.

The originality of this paper has been checked using Turnitin and the result is 13%.