In this work various sample of primary aluminum dross were investigated for composition and evaluation of hydrogen generation via hydrolysis in low concentration alkali solution. Composi-tion revealed low to moderate aluminium content and hydrolysis reactions showed low hydrogen generation volumes per sample mass as well as purity, where composition plays substantial role in the hydrogen evolution, yet showing that there is possible place for dross use in hydrogen generation. It was revealed that some dross samples in addition to hydrogen also release methane via hydrolysis. Rection rate was obtained by the shrinking core model, written for spherical solid particles. Sample composition on hydrogen generation volume is compared to known literature.

The European Green Deal poses a two-pronged challenge for the automotive industry: migrating to solutions based in light structures, requiring light weight concepts and light materials, while at the same time avoiding dependence towards the importation of these advanced materials. Aluminium alloys are lightweight and cost-effective materials that can successfully cover the requirements of many structural applications, however their production requires from bauxite and other Critical Raw Materials (CRM), such as Si and Mg. Aluminium alloys are fully recyclable, but scrap is usually contaminated and its use is related to an increment of impurities, tramp element and undesired inclusions. Traditionally, the use of secondary alloys has been restricted to low performance applications. The present work analyses the effect that the use of scrap has in the quantity of inclusions present in the alloy and in other properties relevant for the material processing. The study was carried out for common alloys belonging to 3 of the most common aluminium processes used in the car manufacturing industry: High Pressure Die Casting (HPDC) (EN AC-43500), extrusion (6063) and sheet metal forming (5754 and 6181). Reference alloy were mixed with different level of scrap (0, 20, 40, 60, 80 and 100%) trying to keep the chemical composition as unaffected as possible. The inclusions level of the alloy was characterized with the Prefil Foot-printer® test. In addition, the obtained materials, after being cast in an open mould, were subjected to metallographic characterization. Relevant properties to assess the formability quality of the alloys for the corresponding transforming process, were obtained: flowability test for HPDC alloy and high temperature compression for extrusion alloys. The results obtained suggest that the number of inclusions present in the melt highly increase with the amount of scrap used to produce the alloy. These inclusions are also related with an important lost of flowability, but do not have a noticeable impact on microstructure.

To fulfil a need of limitation automotive emissions the reduction of vehicle weight is widely recommended and achieved in many ways, both by the construction of individual elements of the vehicle, and by the selection of light materials including Al alloys. Connecting these elements with each other and with elements made of iron alloys can be realized, inter alia, by welding or stir welding. However, the quality of the welds obtained varies widely and depends on many design, operational and environmental factors. The present study focused on a review of various welding technics used to joint both similar and dissimilar Al alloys utilized in automotive industry, the effect of various process parameters on welds quality, and phenomena appeared in such welds..

In the discussion on environmental policies, the notion of eco-efficiency is often used. Eco-efficiency is defined as the delivery of products and services with competitive values, while reducing the ecological impacts and satisfying human needs. In an environment of great competitiveness in which the companies operate, the improvements in the productive process is one of the differentiating factors for guaranteeing a strong competition. Also it is essential rationalizing energy consumption and natural resources. For this it is necessary to understand the main operations and dynamics of the company. This work presents an empirical study of a Portuguese company in the industrial sector. The problematic here presented is based on the company’s growing concern to reduce the amount of scrap produced. From the literature research that was performed, a strong dependence relation between the different variables in the extrusion process was found. The main objective of this work is to model the aluminium extrusion process, with the aim of minimizing the production of scrap. For this several variables involved in the process are taking into account. Using statistical techniques, in particular multiple linear regressions, it was possible to identify the importance of the variables under study for the scrap production.

This paper presents a numerical study of topology-optimised pin-end aluminium alloy columns using finite element analysis (FEA). The FEA models integrate geometric imperfections and material nonlinearity, validated against experimental findings from existing literature. Furthermore, modern design methodologies including Eurocode 9, Direct Strength Method (DSM), and Continuous Strength Method (CSM) are employed to assess the maximum load capacity of such columns. Parametric investigations encompass diverse parameters such as varied cross-sections, column lengths, and global and local imperfections. By analysing a total of 288 FE models, incorporating 16 column cross-sections across two lengths with nine distinct imperfections, the study compares results with those derived from modern design methodologies. Thus, this research elucidates the behaviour of novel cross-sections and the application of contemporary design techniques in their analysis.

The hot rolling in the process chain of the aluminium rolled products present the critical element of material quality and influence on productivity. The desire to increase the letter demand modifications of hot rolling, consequential changes of microstructure, crystallographic texture, mechanical and formability properties must be knowledge and consistently considered in planning the rolling process and rolled product. Achieving lower thicknesses of the hot-rolled band would enable fewer passes with cold rolling; consequently, hot rolling with the same number of passes will complete with lower temperatures. Microstructural and texture characterization with the optical microscope and scanning electron microscope for the hot-rolled band 3.25 mm the smaller grains appeared in the center of the cross-section, unlike for the hot-rolled band 6 mm, the smaller grains were detected on the upper and bottom position of the cross-section. Furthermore, the comparison shows also that the hot-rolled band 6 mm has 64 % of random texture components and 83 % of recrystallized grains, and the proportional adjustment for the hot-rolled band 3.25 mm has the 42 % of random texture components and 55 % of recrystallized grains. For the mechanical testing results, the elongation values in rolling and transverse directions significantly differ just in the case of a hot rolled band of 3.25 mm. Consequently, the earing results are more than 1.5 % higher for the hot-rolled band, 3.25 mm, than the hot-rolled band, 6 mm.

The dynamic behaviour of a machine tool (MT) directly influences the machining performances. The adoption of lightweight structures may reduce the effects of undesired vibrations and increasing the workpiece quality. This paper aims to present and compare a set of hybrid materials that may be excellent candidate to fabricate the MT moving parts. The selected materials have high dynamic characteristics and capacity to damp mechanical vibrations. In this way, starting by the kinematic model of a milling machine that highlights the main critical factors, this study paper evaluates a number of prototypes made of Al Foam sandwiches (AFS), Al Corrugated sandwiches (ACS) and materials reinforced by carbon fibres (CFRP). A set of prototypes has been fabricated, represented the Z-axis ram of a commercial milling machine. The static and dynamical properties have been evaluated by using both FE simulations and experimental tests. The obtained results show that the proposed structures may be a valid alternative to the conventional materials of MT moving parts, increasing machining performances. In particular, the AFS prototype highlighted a damping coefficient that is 20 times greater than a conventional ram (e.g. steel). The CFRP structure is able to satisfy the machining requirements with a reduced weight of 48.5%, while the ACS prototype showed a good trade-off between stiffness and damping.

Understanding the interplay among organophosphorus flame-retardants (OPFRs), microplastics, and freshwater organisms is crucial for unravelling the dynamics within freshwater environments and foreseeing the potential impacts of organic pollutants and plastic contamination. For that purpose, the present research assessed the exposure impact of 10 mg L–1 flame-retardant alumin-ium diethylphosphinate (ALPI), 10 μg mg–1liver microplastics polyurethane (PU), and the combina-tion of ALPI and PU on the freshwater planarian Girardia tigrina. The exposure of G. tigrina to both ALPI and PU revealed a sequential effect, i.e., a decrease in locomotor activity, while other molecular biomarkers (oxidative stress biomarkers and metabolic response) remained unaffected. Despite this fact, it was possible to observe that the range (min-max) of responses of exposed or-ganisms were altered, in the particular case of electron transport system, cholinesterase activity, glutathione S-transferase, catalase and levels of total glutathione and proteins, showing that the energetic costs for detoxification and antioxidant capacity might be causing less energy allocated for the planarian activity. By examining the physiological, behavioural, and ecological responses of planarians to these pollutants, insights can be gained into broader ecosystem-level effects and inform strategies for mitigating environmental risks associated with OPFRs and microplastic pol-lution in freshwater environments.

This work investigates the influence of strain rate on the stress/strain behaviour of Scalmalloy. This material is an aluminium-scandium-magnesium alloy, specifically developed for additive manufacturing. The bulk yield stress of the material processed by Selective Laser Melting is approximately 340 MPa which can be increased by heat-treating to approximately 530 MPa. These numbers, combined with the low mass density of 2.7 g/cm3, make Scalmalloy an interesting candidate for lightweight crash-absorbing structures. As this application is inherently dynamic, it is of interest to study the loading rate sensitivity, which is difficult to predict: Al-Sc alloys exhibit classic strain rate sensitivity with an increased yield stress at elevated strain rates. However, Al-Mg alloys are known to show the contrary effect, they exhibit less strength as strain rate is increased. To answer the question how these effects combine, we study the dynamic behaviour at four different strain rates ranging from 10−3 /s to 1000 /s using servo-hydraulic and Split-Hopkinson testing methods. The resulting data is analysed in terms of strain rate sensitivity of tensile strength and failure strain. A constitutive model based on a simplified Johnson-Cook approach is employed to simulate the tensile tests and provides good agreement with the experimental observations.

Considering the manufacturing of automotive components, there exists a dilemma around the substitution of traditional Cast Iron (CI) with lighter metals. Nowadays, aluminium alloys, being lighter compared to traditional materials, are considered as a more environmentally friendly solution. However, the energy required for the extraction of the primary materials and manufacturing of components is usually not taken into account in this debate. In this study, an extensive literature review has been performed to estimate the overall energy required for the manufacturing of an engine cylinder block using (a) cast iron and (b) aluminium alloys. Moreover, data from over 100 automotive companies, ranging from mining companies to consultancy firms, have been collected in order to support the soundness of this investigation. The environmental impact of the manufacturing of engine blocks made of these materials is presented with respect to the energy burden; the “cradle-to-grave approach” has been implemented to take into account the energy input of each stage of the component lifecycle starting from the resource extraction and reaching to the end-of-life processing stage. Our results indicate that although aluminium components contribute towards reduced fuel consumption during their use phase, the vehicle distance needed to be covered in order to compensate for the up-front energy consumption related to the primary material production and manufacturing phases is very high. Thus, the substitution of traditional materials with lightweight ones in the automotive industry should be very thoughtfully evaluated.

Mangrove ecosystems are one of the most productive on our planet but have declined globally by 30-50%. Many species rely on mangrove habitat and thus their conversion to aquaculture farms has led to a noticeable loss in commodities such as wild fish stocks. This study aimed to assess 1) the influence of the presence of aquaculture and 2) restoration projects on the ecosystems ability to provide resources. We collected data on mangrove vegetation (i.e., biomass, richness and abundance), soil nutrients (i.e. organic carbon, aluminium and nitrogen), crab abundance and fishing pressure in six sites. We set up 15 plots in each site and collected data between May and July 2023. Via generalised linear mixed models we found that the abundance and richness of crabs was significantly higher in aquaculture plots than in no aquaculture plots. Aquaculture plots had higher topsoil aluminium, topsoil and subsoil Nitrogen, and had lower topsoil Carbon than non-aquaculture sites. Restored sites had less Nitrogen in the topsoil than unmanaged sites. Biomass did not change between aquaculture, restored and unmanaged plots. We found a negative correlation between crab abundance and richness and mangrove DBH, suggesting that the species of crabs present preferred areas with propagules for feeding (e.g., Grapsidae crabs). The content of nitrogen in the subsoil was positively correlated with mangrove richness, diversity and height, suggesting the importance of nitrogen availability for mangrove growth. The content of aluminium in the subsoil was negatively correlated with the content of organic carbon both in topsoil and subsoil, suggesting the detrimental effect of aluminium on the carbon cycle. Fishing practices were observed in all sites during the data collection period. Even if most of the vegetation parameters were not significantly affected by presence of aquaculture or management for restoration, it is clear that important variables such as aluminium carbon, and nitrogen content in the soil and crab assemblages were highly variable.

The catalytically active vanadium-containing system on γ-Al2O3 was studied using a wide range of physical and chemical methods depending on the synthesis conditions. It is shown that the vanadium-containing system includes several complexes with different thermal stability and catalytic activity. Low-active complexes are destroyed with the formation of more active ones based on V2O5 oxide as the temperature of heat treatment increases. It can be assumed that the V2O5 oxide has the decisive role in its catalytic activity. It was concluded that the vanadium-containing catalytic system on aluminum oxide, in the studied temperature range, is thermal stable and shows high activity not only in the reduction of nitrogen oxides but also in the oxidation of hydrocarbons (even of the most difficult ones, such as oxidizable methane). These properties of the system make it quite promising in the field of application for purification of exhaust gases of motor transport and industrial enterprises from environmentally harmful components as well as for understanding the mechanism of the action of catalysts in these processes, which is very important for solving the problems of decarbonization and achieving carbon neutrality.

The present paper investigates the influence of the specimen size of EN-AW6082 wrought aluminium alloy subjected to very high cycle fatigue (VHCF) tests. The hourglass specimens were tested under fully reversed loading condition, up to 10^9 cycles, by means of the ultrasonic fatigue testing machine developed by Italsigma® (Italy). Three specimens groups were considered, with a diameter in the middle cross-section ranging from 3 mm up to 12 mm. The stress field in the specimens was determined numerically and by strain gauge measurements in correspondence of the cross-section surface. The dispersion of experimental results has been accounted for, and data are reported in P-S-N diagrams. The decrease in fatigue resistance with increasing specimen size is evident. Theoretical explanation for the observed specimen-size effect is provided, based on Fractal Geometry concepts, allowing to obtain scale independent P-S*-N curves. The fatigue life expectation in the VHCF regime of the EN-AW6082 aluminium alloy full-scale components is rather overestimated if it is assessed only from standard small specimens of 3 mm in diameter. Experimental tests carried out on larger specimen, and a proper extrapolation, are required to assure safe structural design.

Selection of efficient corrosion inhibitors requires detailed knowledge regarding interaction mechanism, which depends on the type and amount of functional groups within the inhibitor molecule. Position of functional groups between different isomers is often overlooked but not less important since factors like steric hinderance may significantly affect the adsorption mechanism. In this study we have presented how different dihydroxybenzene isomers interact with aluminium alloy 5754 surface, reducing its corrosion rate in bicarbonate buffer (pH = 11). We have shown the highest inhibition efficiency among tested compounds belongs to catechol at 10 mM concentration, although differences were moderate. Utilization of novel impedance approach to adsorption isotherm determination allowed to confirm that while resorcinol chemisorbs on aluminium surface, catechol and quinol follows ligand exchange model of adsorption. Unlike catechol and quinol, the protection mechanism of resorcinol is bound to interaction with insoluble aluminium corrosion products layer and was only found efficient at concentration of 100 mM (98.7%). The aforementioned studies were confirmed with scanning electron microscopy and x-ray photoelectron spectroscopy analyses. There is a significant increase of the corrosion resistance offered by catechol at 10 mM after 24 h exposure in electrolyte: from 63 to 98%, with only negligible changes in inhibitor efficiency observed for resorcinol at the same time. However, in the case of resorcinol a change in electrolyte color was observed. We have revealed that the differentiating factor is the keto-enol tautomerism. The NMR studies of resorcinol indicate the keto form in structure in presence of NaOH, while the chemical structure of catechol does not change significantly in alkaline environment.

Phenolic antioxidants such as tert-butylhydroquinone (TBHQ) are widely used by manufacturers to prevent deterioration and more stable preservation of cooking oils. Cooking oil is a necessary substance that everyone needs to consume every day, but the overuse of TBHQ will harm the quality of food and public health, and many countries have set up limited standards for the use of TBHQ, therefore, it is very necessary to research and design an efficient detection technology for TBHQ. In this work, we grew NiAl-LDH, a nickel-aluminium double hydroxide, on glucose carbon spheres (GC), and formed porous carbon nanomaterials (named NiAl-LDH@GC-800) after the pyrolysis process. The NiAl-LDH@GC-800 material was fabricated on GCEs for sensors with remarkable sensitivity to TBHQ, with a low limit of detection (LOD) of 8.2 nM and possessed excellent detection linear range (20 nM ~ 300 µM). The prepared electrochemical sensor successfully detected TBHQ detection in edible oils in life, including chilli oil, peanut oil, and canola oil.

The present study analyses the influence of scratches and fatigue on the mechanical characteristics of aluminium alloys commonly used in the aviation industry: 2024-T4, 6061-T4, 6061-T4 uncoated, 6061-T6 uncoated, 7075-T0, and 7076-T6. 120 specimens were used for the study. Out of these, 60 samples were scratched, and the other 60 samples were also scratched under the same circumstances and then subjected to low-cycle fatigue (LCF) before undergoing the tensile test. Based on the statistical examination of the measured data, mathematical prediction models have been established. Compared to their unscratched counterparts, the results indicate a significant decrease in the mechanical properties of both scratched and scratched-fatigued sample sets. The LCF pre-treatment contributes to the negative impacts of scratches, resulting in a reduced value for the ultimate tensile strength and elongation at break. The results conclude that surface integrity plays an essential role in preserving aircraft components' structural strength.

The 1060 aluminium alloy is widely applied to electronic industry, construction area, aerospace field, traffic engineering, decoration and consumption goods market for its good chemical, physical and mechanical properties. In general, excellent processing property is necessary and important for manufacturing of complicated panels. In this paper, a special 2D ultrasonic vibration incremental forming method is designed to improve its plasticity and mechanical properties. Three kind of processing methods including traditional single point incremental forming, longitudinal ultrasonic vibration incremental forming and 2D ultrasonic vibration incremental forming are conducted for flexible manufacture of conical parts of 1060 aluminium alloy sheet. Then micro-hardness tests, residual stress tests and scanning electron microscopy tests are carried out to probe its revolution of micro-structure and mechanical properties and to analysis the effects of different types of ultrasonic vibration on plasticity and fracture characteristic of 1060 aluminium alloy. It is proved that 2D ultrasonic vibration is facilitated to improvement of plasticity and surface qualities of 1060 aluminium alloy than the other two processing methods. So, the novel 2D ultrasonic vibration incremental forming possesses substantial application values on flexible and rapid manufacturing of complicated thin-walled component of aluminium alloy.

This paper investigates the effect of shot peening on the strength and corrosion properties of EN AW 6082-T651 aluminium alloy. Surface roughness, microhardness, residual stresses and corrosion performance were investigated and compared with the untreated aluminium alloy. Cracks and delaminations in the surface layer can only be seen on the treated specimens at a working pressure of 4 bar and 8 bar, while no such effect was observed at a working pressure of 1.6 bar. The effect of dislocation densification was confirmed by the microhardness measurement of the hardened layer, where microhardness increased by up to 23 % compared to the untreated aluminium alloy. Shot peening also results in a deeper layer with higher compressive residual stresses compared to untreated specimens. With higher working pressure, surface roughness increases, which can promote localized pitting corrosion. However, all treated specimens improve the corrosion resistance and have a lower degree of anodic dissolution. The current density of the shot peened specimen with the lowest surface roughness was more than twice lower than that of the untreated specimen.

The importance of both recycling and additive manufacturing (AM) is increasing, however there has been a limited focus on development of AM alloys that are recyclably compatible with the larger scrap loops of wrought 5xxx, 6xxx and cast 3xx aluminium alloys. In this work the powder bed fusion (PBF) printability of AlMgSi alloys in the interval of 0-30wt%Mg and 0-4wt%Si is screened experimentally with a high throughput method. This method produces PBF mimicked material by PVD co-sputtering followed by laser remelting. Strong evidence was found for AlMgSi alloys being printable in two different composition ranges; Si+Mg<0.7wt% or for Si+2/3Mg>4wt% when Mg < 3wt% and Si > 3wt%. Increasing the amount of Mg and Si influence the grain structure by introducing fine columnar grains at the melt pool boundary, although the melt pool interior was unaffected. Hardness in as-built state increased with both Mg and Si, alt-hough Si had neglectable effect at low levels of Mg. Both evaporative loss of Mg and the amount of Mg in solid solution increased linearly with the amount of Mg.

Welding of dissimilar aluminium alloys has been a challenge for a long period until the discovery of the solid state welding technique called friction stir welding (FSW). The discovery of this technique encouraged different research interests revolving around the optimization of this technique. This involves the welding parameters optimization and this optimization is categorized into two classes i.e. similar alloys and dissimilar alloys. This paper reports about the mechanical properties of the friction stir welded dissimilar AA1050-H14 and AA5083-H111 joint. The main focus is to compare the mechanical properties of specimens extracted from different locations of the welds i.e. the beginning, middle and the end of the weld. The specimen extracted at the beginning of the weld showed low tensile properties compared to specimens extracted from different locations of the weld. There was no certain trend noted through the bending results. All three specimens showed dimpled fracture which is the characterization of the ductile fracture.

An ion exchange dialysis (IED) is used in the recovery of aluminium from residue. In this papers, the face-centered central composite design (FC-CCD) of the response surface methodology (RSM) and desirability approach is used for experimental design, modelling and process optimization of a counter flow IED system. The feed concentration, feed flowrate, sweep flowrate and sweep concentration are selected as the process variables, with the Al-transport across a Nafion 117 membrane as the target response. A total of 30 experimental runs were conducted with 6 center points. The response obtained was analysed by analysis of variance (ANOVA) and fitted to a second-order polynomial model using multiple regression analysis. The actual R2 and standard deviation of the model are 0.9548 and 0.2932 respectively. The influences of significant variables are plotted on 3D surface and contour plots. The designed variables were numerically optimized by applying the desirability function to achieve the maximum Al-transport. The optimised condition values were found to be feed concentration (1600 ppm), feed flowrate (61.76%), sweep flowrate (37.50%) and sweep concentration (0.75 N) for the 80% target response at 32hrs. Overall, the model can be used to effectively predict Al-recovery using the designed system

Aluminium dross is the industrial waste from aluminium refining industry and accordance with toxic waste materials, it’s also recognized as a by-product of aluminium production, has historically posed significant environmental challenges due to its toxic and reactive nature. However, recent advancements in technology have revealed the potential of transforming aluminium dross into a valuable source of white hydrogen. This review paper explores the methodologies, benefits, and challenges associated with this transformation. By analysing current research and industrial practices, our review highlighted the potential of this innovative approach to mitigate waste and contribute to sustainable energy solutions. In addition, the utilization of Aluminium dross can be considered as innovative and advancement in sustainable waste management strategy instead of direct disposal, and hot springs use advances in direct utilization. Our experimental work achieved white hydrogen maximum flowrate at 600 sec. with 120ºC.

This paper presents and demonstrates the development of a new lightweight coating for aluminium alloy using a novel multicomponent alloy based on the AlSiMgCu system. This coating was applied using a newly designed approach that combined High-Velocity Oxy-Fuel (HVOF) and Plasma Spraying processes. This hybrid technique enables the deposition of coatings with enhanced performance characteristics. The microstructure was studied using optical microscopy (OM) and scanning electron with energy dispersive X-ray spectroscopy (SEM+EDS) microscopy, revealing good adhesion and compaction between the multicomponent coating and the A6061 substrate with 50 to 150 µm thickness. Vickers indentations were performed on the substrate and the new coating material, revealing a 50% improvement in the material's hardness compared to the casted alloy. Additionally, electrical conductivity measurements showed approximative x3.3 times values compared to the alloy in as-cast condition due to high solidification rates altering the morphology of the phases. Corrosion tests demonstrated a lower corrosion rate compared to other multicomponent aluminium alloys and similar to thermal treated A6061 alloy. Finally, tribological results obtained using ball on disc (BOD) test and laser scanning confocal microscopy, confirmed that the new multicomponent coating exhibited reductions in both friction coefficient and wear rate by more than 20% and 50%, respectively. This study demonstrates that using multi-component aluminium coatings could lead to developing of new automotive parts with enhanced properties for corrosion resistance, electrical conductivity, and wear conditions. Optimizing the thermal spraying parameters could further enhance the coating, achieving greater and more homogeneous thicknesses and yielding even higher performance properties.

The regenerated magnesia-calcium brick samples that had added 0, 1.5, 3.0 wt.% aluminium oxide (Al2O3) were prepared by using spent magnesia-calcium bricks, fused magnesia and Al2O3 powder additive as the main raw materials. The phases, microstructures, room temperature and hot flexural strength, resistance to cement clinker corrosion and strength of coating adherence were investigated respectively. It indicated that the addition of Al2O3 increased mainly resulting in the content of tetracalcium aluminoferrite (C4AF) and tricalcium aluminate (C3A) increased in the regenerate samples. The bulk density, the room temperature flexural strength and the strength of coating adherence all increased, while the hot flexural strength and corrosion resistance both deteriorated along with the increase of Al2O3 addition. It was because that on the one hand the low melting point phases of C4AF and C3A improved the sinterability of the regenerated samples during the burning stage, on the other hand they melted or existed in liquid phase during the experimental temperature (1573 K and 1823 K) which degraded hot flexural strength and corrosion resistance, and enhanced the strength of coating adherence as the wettability of the liquid phase. The content of Al2O3 in the regenerated magnesia-calcium brick should not be higher than 1.1 wt.%, considering its room and high-temperature performances for cement rotary kiln.

Substituted bis(iminophosphoranyl)methanes are CH acidic compounds that can form complexes with formally dianionic central carbon centres. The reaction of H₂C(Ph₂P=NDip)₂ (≡ H₂L), Dip = 2,6-diisopropylphenyl, with one equivalent of di-n-butylmagnesium afforded the methanide complex [HLMgnBu] 1. Treatment of complex 1 with phenylsilane in aromatic solvents at elevated temperatures afforded the methanediide complex [(LMg)₂] 2 presumably via the MgH intermediate [(HLMgH)_n] (n = 1 or 2). The reaction of 1 with LiAlH₄ in diethyl ether yielded the AlH complex [HLAlH₂] 3. Alternatively, this complex was also obtained from the reaction of H₂L with AlH₃∙NMe₃. The molecular structures of [HLMgnBu] 1, [(LMg)₂] 2, and [HLAlH₂] 3 are reported. Complex 3 shows no sign of H₂ elimination to a methanediide species at elevated temperatures in contrast to the facile elimination of the putative reaction intermediate [(HLMgH)_n] (n = 1 or 2) to form [(LMg)₂] 2. The chemical properties of complex 2 were investigated and this complex appears to be stable against coordination with strong donor molecules.

Bands of interdendritic porosity and positive macrosegregation are commonly observed in pressure die castings, with previous studies demonstrating their close relation to dilatant shear bands in granular materials. Despite recent technological developments, the micromechanism governing dilatancy in the high pressure die casting (HPDC) process for alloys between liquidus and solidus temperature region is still not fully understood. To investigate the influence of fluid flow and the size of externally solidified crystals (ESCs) on the evolution of dilatant shear bands in HPDC, various filling velocities were trialled to produce HPDC samples of Al8SiMnMg alloy. This study demonstrates that crystal fragmentation is accompanied by a decrease in dilatational concentration, thus producing an indistinct shear band. Once crystal fragmentation stagnates, the enhanced deformation rate associated with a further increase in filling velocity (from 2.2 ms^-1 to 4.6 ms^-1) localises dilatancy into a highly concentrated shear band. The optimal piston velocity is 3.6 ms-1, under which the average ESC size reaches the minimum and the average yield stress and overall product of strength and elongation reaches the maximum value of 144.6 MPa and 3.664 GPa%, respectively. By adopting the concept of force chain buckling in granular media, the evolution of dilatant shear bands in equiaxed solidifying alloys can be adequately explained based on further verification with DEM-type modelling in OpenFOAM. Three mechanisms for ESC enhanced dilation are presented, elucidating previous reports relating the presence of ESCs to the subsequent shear band characteristics. By applying the physics of granular materials to equiaxed solidifying alloys, unique opportunities are presented for process optimization and microstructural modelling in HPDC.

The incorporation of plastic matrix composite materials into structural elements of the aeronautical industry requires contour machining and drilling processes along with metallic materials prior to final assembly operations. These operations are usually performed using conventional techniques, but they present problems derived from the nature of each material that avoid implementing One Shot Drilling strategies that work separately. In this work, the study focuses on the evaluation of the feasibility of Abrasive Waterjet Machining (AWJM) as a substitute for conventional drilling for stacks formed of Carbon Fiber Reinforced Plastic (CFRP) and aluminum alloy UNS A97050 through the study of the influence of abrasive mass flow rate, traverse feed rate and water pressure in straight cuts and drills. For the evaluation of the straight cuts, Stereoscopic Optical Microscopy (SOM) and Scanning Electron Microscopy (SEM) techniques are used inspection techniques have been used. In addition, the kerf taper through the proposal of a new method and the surface quality in different cutting regions have been evaluated. For the study of holes, the macrogeometric deviations of roundness, cylindricity and straightness have been evaluated. Thus, this experimental procedure reveals the conditions that minimize deviations, defects, and damage in straight cuts and holes obtained by AWJM.

Switched-mode power supplies (SMPS) often utilize electrolytic capacitors due to their substantial energy density and economical pricing. However, their ability to function at low temperatures is essential for dependable operation in several sectors, including telecommunications, automotive, and aerospace. This study includes an experimental evaluation of how well standard SMPS electrolytic capacitors operate at low temperatures. This paper investigates the suitability of standard electrolytic capacitors used in switched-mode power supplies (SMPS) for low-temperature applications. The experimental evaluation exposed the capacitors to temperatures ranging from - 5 ∘C to - 40 ∘C, assessing capacitance (Cp), impedance (Z), dissipation factor (DF), and equivalent series resistance (ESR) at each temperature. The capacitor’s time-domain electrical signals were analyzed using the Pearson correlation coefficient to extract discriminative features. These features were input into an Artificial Neural Network (ANN) for training and testing. Results indicated a significant impact of low temperatures on capacitor performance. Capacitance decreased with lower temperatures, while ESR and leakage current increased, affecting stability and efficiency. Impedance proved to be a valuable diagnostic tool for identifying potential capacitor failure, showing a 98.44% accuracy drop at - 5 degrees and 88.75% at the peak temperature, indicating proximity to the manufacturer’s specified limit. The study suggests further research and development to improve electrolytic capacitors’ performance in SMPS systems under cold conditions to enhance efficiency and reliability.

There is an increase towards reducing the weight of structures through the use of aluminium alloys in different industries like aerospace, automotive, etc. This growing interest would lead towards using dissimilar aluminium alloys which would require welding. TIG and friction stir welding are the well-known techniques that are currently suitable for joining dissimilar aluminium alloys. The welding of dissimilar alloys has its own dynamics which impact on the quality of the weld. This then suggests that there should be a process which can be used to improve the dissimilar alloys welds post their production. Friction stir processing is viewed as one of the techniques that could be used to improve the mechanical properties of the material. This paper reports on the status and the advancement of FSW, TIG and FSP technique. It further looks at the variation use of FSP on TIG and FSW welded joints with the purpose of identifying the knowledge gap.

Aluminium bronzes possess a unique combination of high strength and wear and corrosion resistance in aggressive environments; thus, these alloys find wide application in marine, shipbuilding, aviation, railway, offshore platform applications and other fields. Iron-aluminium bronzes (IABs) are the cheapest and most widely used. When the aluminium content is above 9.4 wt%, IAB is biphasic (i.e. it undergoes -transformation) and can be subjected to all heat-treatment types depending on the desired operating behaviour of the bronze component. This article presents correlations (mathematical models) between the primary mechanical characteristics (yield limit, tensile strength, elongation, hardness and impact toughness) and the ageing temperature and time of quench at 920°C in water Cu-11Al-6Fe bronze, obtained using the centrifugal casting method. The microstructure evolution was evaluated depending on the ageing temperature and time changes. Overall, the research was conducted in three successive inter-related stages: a one-factor-at-a-time study, planned experiment, and optimisations. Four optimisation tasks, which have the greatest importance for practice, were formulated and solved. The defined multiobjective optimisation tasks were solved by searching for the Pareto-optimal solution approach. The decisions were made through a nondominated sorting genetic algorithm (NSGA-II) using QstatLab. The optimisation results were verified experimentally. Additional samples were made for this purpose, quenched at 920°C in water and subjected to subsequent ageing with the optimal values of the governing factors (ageing temperature and time) for the corresponding optimisation task. The comparison of the results for the mechanical characteristics with the theoretical optimisation results presents good agreement.

Aluminium alloys are used for fabrication of fuel clad of research grade nuclear reactors as well as of several types of core components of high flux research reactors. In order to carry out design and safety analysis of these components, their mechanical and fracture properties are required by the designer. In this work, experiments have been conducted on tensile specimens machined from an aluminium alloy block to evaluate the material stress-strain curve. For evaluation of fracture properties, experiments have been conducted on disc shaped compact tension specimens in order to determine the fracture toughness of aluminium alloy. From crystal plasticity based finite element analysis and experimental data, a material damage parameter for prediction of crack initiation has been evaluated. The variation of the parameter for various values of initial a/W ratios of the disc-shaped CT specimens have been studied. It was observed that the damage parameter is independent of crack geometry and hence, it qualifies as transferable material property which can be used to predict crack initiation in a component of this material subjected to different kinds of loading conditions. In addition, the JR curves of the disc-shaped CT specimens have also been evaluated from experiments. The material damage parameter has also been used to study the crack initiation in single crystal fracture specimens with two different orientations. It was observed that the [111] orientation is more susceptible to crack initiation and propagation compared to the [100] orientation as the damage parameter is high in the ligament of the specimen ahead of the crack-tip for the same level of load. The results of the experiments and the material damage parameter shall be helpful for integrity analysis of fuel clad of research reactors as well as components of high flux research reactors.

Aluminium matrix composite’s overall quality is impacted by the friction stir process parameters, which have a major impact on the microstructure, soundness, and particle dispersion inside the stir zone. Although it requires a lot of experimentation, optimizing these factors is vital. For the purpose of optimizing the ultimate tensile strength and microhardness of the AA5083/Silicon carbide and AA5083/Coal composites fabricated by FSP, this work used the Taguchi L9 design of experiments. Three process parameters were investigated at three levels each. For the AA5083/Silicon carbide composite, the results of the ANOVA analysis showed rotational speed has a larger impact on ultimate tensile strength while forAA5083/coal tilt angle has a larger impact on ultimate tensile strength. On the other hand, rotating speed had a greater effect on microhardness and percentage elongation of the AA5083/Coal and AA5083/Silicon carbide composite joints, according to ANOVA analysis. The need for specific process optimization for each composite was highlighted by the fact that different combinations of parameters were best for obtaining the necessary attributes in the AA5083/Silicon carbide and AA5083/Coal composites.

BACKGROUND: Manufacturing costs, along with operational performance, are among the major factors determining the selection of the propulsion system for unmanned aerial vehicles (UAVs), especially for aerial targets and cruise missiles. OBJECTIVES: In this paper, the design requirements and operating parameters of small turbofan engines for single-use and reusable UAVs are analysed to introduce alternative materials and technologies for manufacturing their compressor blades, such as sintered titanium, a new generation of aluminium and an alloy based on titanium aluminides. METHODS: To assess the influence of severe plastic deformation (SPD) on the hardening efficiency of the proposed materials, the alloys in the coarse-grained and submicrocrystalline states were studied. Changes in physical and mechanical properties of materials were taken into account. The thermodynamic analysis of the compressor was performed in a finite element analysis system (ANSYS) to determine the impact of gas pressure and temperature on the aerodynamic surfaces of compressor blades of all stages. RESULTS: Based on thermal and structural analysis, the stress and temperature maps on compressor blades and vanes were obtained, taking into account the physical and mechanical properties of advanced materials and technologies of their processing. The safety factors of the components were established based on the assessment of their stress-strength reliability. Thanks to nomograms, the possibility of using the new materials and the technologies was confirmed in view of the permissible operating temperature and safety factors of blades. CONCLUSIONS: The proposed alternative materials and production technologies for the compressor blades and vanes meet the design requirements of the turbofan at lower manufacturing costs.

Our investigations show that electrochemical corrosion of copper is faster than electrochemical corrosion of aluminium at temperatures below 100oC. Literature data analysis shows that the Al atoms diffuse faster than the Cu atoms at temperatures higher than 475oC, Al rich intermetallic compounds (IMCs) are formed faster in the Cu-Al system, and the Kirkendall plane shifts toward Al side. Electrochemical corrosion occurs due to electric current and due to diffusion. An electronic devise working time, for example, depends on initial copper cover thickness on aluminium wire, connected to the electronic devise, temperature, and volume and dislocation pipe diffusion coefficients, so copper, iron, and aluminium electrochemical corrosion rates are investigated experimentally at room temperature and at temperature 100oC. Intrinsic diffusivities ratios of copper and aluminium at different temperatures and diffusion activation energies in the Cu-Al system are calculated by proposed here methods using literature experimental data. Dislocation pipe and volume diffusion activation energies of pure iron are calculated separately by earlier proposed method using literature experimental data. Aluminium dissolved into NaCl solution as the Al3+ ions at room temperature and at temperature 100oC, iron dissolved into NaCl solution as the Fe2+ (not Fe3+) ions at room temperature and at temperature 100oC, copper dissolved into NaCl solution as the Cu+ ions at room temperature and as the Cu+ and the Cu2+ ions at temperature 100oC. It is founded experimentally that copper corrosion is higher than aluminium corrosion, and ratio of electrochemical corrosion rates, kCu/kAl>1, decreases with temperature increasing, although iron electrochemical corrosion rate doesn’t depend on temperature below 100oC. It is obvious, because melting point of iron is more higher then melting point of copper or aluminium. It is calculated that copper electrochemical corrosion rate is approximately equal to aluminium electrochemical corrosion at temperature about 300oC, so copper can dissolve into NaCl solution mostly as the Cu2+ ions at temperature about 300oC. Ratio of intrinsic diffusivities, DCu/DAl <1, increases with temperature increasing, and intrinsic diffusivity of aluminium could be approximately equal to intrinsic diffusivity of copper at temperature about 460oC.

Engineering application of additively manufactured (AM) metallic materials is quite limited by their fatigue behaviors which are very inconsistent with that of conventionally wrought or cast ones. Here, based on advanced material characterization techniques, such as focused ion beam (FIB), scanning electron microscopy (SEM) and transmission electron microscopy (TEM), the mi-crostructures underneath fracture surfaces were thoroughly investigated in an AM aluminium (AlSi10Mg) alloy with horizontal and vertical building orientation endured very-high-cycle fa-tigue (VHCF) loading under stress ratios R = –1, 0 and 0.5. Two VHCF failure specimens A and B were representatively selected to further SEM examine and TEM samples preparation via FIB milling. Specimen A was horizontally printed and failed at R = –1; specimen B was vertically printed and failed at R = 0. TEM samples A1 and B1 were lifted from locations near the crack ini-tiation sites on the fracture surfaces of specimens A and B; The locations of TEM samples A2 and B2 kept away from the crack origin sites but still within the “fish-eye” region of crack steady growth. TEM observations show that there was no characteristic microstructure induced by VHCF in different oriented specimens and under various R values.