Browse Topic: Alloys

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Design and Simulation Analysis of an Integrated Honeycomb-filled Front Bumper for a Special Vehicle2026-01-0475To be published on 04/07/2026
In frontal collisions of automobiles, the bumper beam at the front of the vehicle plays a crucial role in absorbing energy and protecting the vehicle body during a collision. To enhance the collision resistance of a specific type of special vehicle with a non-load-bearing body structure, this paper focuses on this type of vehicle and conducts a study on the design and collision performance of an integrated vehicle front bumper-impact beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front impact beam of the vehicle and is integrally formed using aluminum alloy additive manufacturing technology. This integrated structure is directly connected to the vehicle frame. Firstly, based on the appearance of the special vehicle body and the form of the front impact beam of traditional passenger vehicles, an integrated design of the vehicle front bumper-impact beam structure is carried out and
王, Xufan, Yuan, Liu-Kai, Zhang, Tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo
Optimizing joint efficiency in stainless steel-aluminum alloy FSW joints through advanced parameter control2026-01-0228To be published on 04/07/2026
The present work investigates the friction stir welding (FSW) of dissimilar materials, specifically stainless steel 304 and aluminum alloy AA2024-T3, to analyze their tensile strength behavior. The significant challenges inherent in joining these materials, stemming from their vastly divergent thermal and mechanical properties, are addressed through a structured experimental and statistical methodology. The L18 Taguchi mixed orthogonal array was employed to systematically evaluate the influence of three critical process parameters: tool rotational speed, welding speed, and tool pin offset. Eighteen experimental trials were conducted using a butt joint configuration. The analysis identified tool rotational speed as the most influential parameter affecting the joint integrity. A combination of 450 rpm rotational speed, 20 mm/min welding speed, and a 1.5 mm pin offset toward the aluminum side yielded the optimum results, achieving a peak ultimate tensile strength (UTS) of 344.7 MPa and a
Mir, Fayaz Ahmad, Khan, Noor Zaman, Pali, Harveer Singh
Efficient casting system design through simulation for AlCoCrFeNi high-entropy alloy2026-01-0176To be published on 04/07/2026
This study depicts the design, simulation, and fabrication of an equiatomic Al–Co–Cr–Fe–Ni high entropy alloy (HEA) through casting using Siemens NX CAD and ADSTEFAN simulation software. The part and gating system, including the sprue, runner, pouring cup, and riser, were modeled to generate the STL file and optimization was done through iterative simulation. Fluid flow and solidification analyses were performed to simulate the filling temperature, cold shut, and soundness of the casting. The optimized gating design is expected to provide uniformity in the temperature distribution, avoid defects during solidification and to eliminate shrinkage cavities in the cast alloy. HEA was fabricated by utilizing the validated gating system using vacuum induction melting of high-purity elemental granules. Further microstructural investigation using methods like SEM and EDS showed a uniformity of Al, Co, Cr, Fe, and Ni in near-equiatomic proportions. The optimization of riser-fed design
Vashistha, Saurabh, Rawat PhD, Pankaj, singh PhD, Shailesh, Pathak, Sunil
Investigation on Microstructure and Mechanical Properties in the Dissimilar Joining of WE43 to AA7075 Alloy using FSW2026-01-0229To be published on 04/07/2026
This research investigates the alterations in microstructure, microhardness, and joint strength resulting from the dissimilar friction stir welding (FSW) of WE43 magnesium alloy to AA7075 aluminium alloy. The study specifically analyses the role of FSW process parameters in the formation of intermetallic compounds (IMCs), the evolution of grain structure, the resultant microhardness distribution across the weld zone, and the joint tensile strength. A comprehensive microstructural characterization was performed utilizing optical microscopy (OM), field emission scanning electron microscopy with energy-dispersive X-ray spectroscopy (FESEM-EDS), electron backscatter diffraction (EBSD), and X-ray diffraction (XRD). These analyses confirmed significant refinement of grain in the stir zone and the identification of various IMCs at the weld interface. Microhardness mapping indicated a gradient profile, with the weld nugget exhibiting superior hardness attributed to its dynamically
Ahmad, Tariq, Khan, Noor Zaman, Ahmad, Babar, Siddiquee, Arshad Noor
High Strain-Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-0175To be published on 04/07/2026
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of orthotropic glass, carbon and a natural
Bawa, Prashant, Deb, Anindya, Zhu, Feng
A study on Crack propagation characteristics of interlaced holes for key automotive components.2026-01-0186To be published on 04/07/2026
Aiming at the engineering problem that the stress interference of interlaced holes dominates crack propagation and directly affects driving safety in the hole group structure of key components such as chassis and body frame in the automotive field, in order to accurately reveal the quantitative influence of key parameters of interlaced hole placement (crack deflection Angle, longitudinal hole spacing) on the crack evolution of automotive hole group components, This study adopts the approach of numerical simulation combined with variable control to conduct systematic analysis. Taking an aluminum alloy thin plate with two relatively initial cracks (a commonly used structural material for automobiles) as the research object, multiple sets of typical interlocking hole structure variable models of automotive components covering different crack deflection angles and longitudinal hole spacings were constructed in the ABAQUS software. The J-integral was calculated by the circumscribed line
Chen, Yechao, Zhan, Zhenfei, Tang, Weiqin, Yang, Yutong, Gan, Yuan, Yan, Kaibo, HUANG, Shiyao
A Study on Fatigue Life Prediction Method for Point-Based Joints Considering Multiple Fracture Modes – FDS, Blind Rivet, and Blind Nut Focus2026-01-0180To be published on 04/07/2026
The application of light weight alloys for vehicle bodies such as aluminum alloys and composite materials are rapidly advancing to support the construction of multi-material vehicle bodies. These materials play a crucial role in reducing overall vehicle weight, enhancing fuel efficiency, and complying with increasingly strict environmental regulations. As the automotive industry continues to evolve toward electrification and sustainability, the integration of lightweight and high-performance materials has become a key design strategy. However, the use of multiple materials introduces new challenges in manufacturing, particularly in joining technologies. Since different materials have varying mechanical properties, thermal behaviors, and surface characteristics, selecting appropriate joining methods is essential to ensure structural integrity and durability. Depending on the material types, thicknesses, production processes, and cost constraints, various joining techniques—such as
Takuno, Sougo, Isono, Toshiyuki, Urakawa, Kazushi, Goto, Suguru, Kawamura, Hiroaki, Niisato, Eita, Ishigami, Yuta
Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures2026-01-0234To be published on 04/07/2026
Tensile and cyclic behavior of high pressure die cast AE44 magnesium alloy have been studied at room temperature and elevated temperatures up to 350°C. Anelastic behavior has been found in both tensile and cyclic deformation at the temperature below 150°C. With increasing temperature, the anelasticity disappears, and tensile and cyclic behaviors become similar to other engineering materials, such as steels and aluminum alloys, i.e. the total strain contains only elastic strain and plastic strain. A method to determine the yield strength at 0.2% plastic strain (σ0.2) is proposed. By using the proposed method, the yield strength σ0.2 is higher than that determined using the traditional method, which is more suitable to the materials that do not exhibit anelasticity. It is believed that the anelasticity is closely related to twinning in Mg alloy, which disappears at elevated temperatures.
Liu, Yi, Yang, Wenying, Coryell, Jason
A Data-Driven Model for Predicting Casting Solidification Time and Mold Thermal Stress2026-01-0233To be published on 04/07/2026
This study proposes a data-driven surrogate modeling framework for predicting solidification time and mold thermal stress during low-pressure die casting (LPDC) of aluminum alloy wheels. The methodology employed an optimal Latin hypercube design (OLHD) to sample key parameters including cooling channel geometry and process conditions. A sequential simulation methodology combining ProCAST and Abaqus was implemented to generate a comprehensive dataset of solidification times and thermal stress distributions. Based on this dataset, surrogate models were developed using Support Vector Regression, Kriging, and Polynomial Response Surface Methodology, with their hyperparameters automatically tuned through Bayesian Optimization (BO). The optimized models were rigorously evaluated using four statistical metrics: Coefficient of Determination (R²), Mean Squared Error (MSE), Mean Absolute Error (MAE), and Root Mean Squared Error (RMSE). The evaluation results show that the BO-SVR model
fuhao, Fan, Zhan, yunlang, Zhan, Zhenfei, Yang, Yutong, Xiao, yong, HUANG, SHIYAO
Minimizing Stress Corrosion Cracking in Wrought Forms of Steels and Corrosion-Resistant Steels and AlloysARP1110E (Current)3/12/2026
The purpose of this SAE Aerospace Recommended Practice (ARP) is to provide the aerospace industry with recommendations concerning the minimization of stress corrosion cracking in wrought heat-treatable carbon and low-alloy steels and in austenitic, precipitation hardenable, and martensitic corrosion-resistant steels and alloys. The detailed recommendations are based on laboratory and field experience and reflect those design practices and fabrication procedures which should avoid in-service stress corrosion cracking.
AMS E Carbon and Low Alloy Steels Committee
Alloy, Corrosion- and Heat-Resistant, Bars, Forgings, Rings and Stock for Forgings and Rings, 50Ni - 20Cr - 20Co - 5.8Mo - 2.2Ti - 0.45Al (Nimonic® Alloy 263), Consumable Electrode or Vacuum Induction Melted, 2100 °F (1149 °C) Solution Heat TreatedAMS5886E (Current)3/12/2026
This specification covers a corrosion- and heat-resistant nickel alloy in the form of bars, forgings, flash-welded rings, and stock for forging or flash-welded rings.
AMS F Corrosion and Heat Resistant Alloys Committee
Magnesium Alloy, Plate, Extra Flat, 3.0Al - 1.0Zn - 0.20Mn (AZ31B-0), AnnealedAMS4382E (Current)3/12/2026
This specification covers a magnesium alloy in the form of plate 0.250 to 6.000 inches (6.35 to 152.40 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Filler Metal, Aluminum Brazing, 12SiAMS4185G (Current)3/12/2026
This specification covers an aluminum alloy in the form of wire, sheet, foil, pig, grains, shot, and chips (see 8.6).
AMS D Nonferrous Alloys Committee
Quality Assurance Sampling and Testing, Corrosion- and Heat-Resistant Steel and Alloy ForgingsAMS2374G (Current)3/12/2026
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable material specifications of corrosion- and heat-resistant steel and alloy forgings.
AMS F Corrosion and Heat Resistant Alloys Committee
Steel Cleanliness, Special Aircraft-Quality, Magnetic Particle Inspection ProcedureAMS2304D (Current)3/12/2026
This specification covers steel cleanliness requirements for special aircraft-quality ferromagnetic steels, including hardenable corrosion-resistant steels, by magnetic particle inspection methods. This specification contains sampling, sample preparation, inspection procedures, and cleanliness rating criteria (see 8.2).
AMS E Carbon and Low Alloy Steels Committee
Aluminum Alloy, Die and Hand Forgings, and Rolled Rings, 2.3Cu - 1.6Mg - 1.1Fe - 1.0Ni - 0.18Si - 0.07Ti (2618-T61), Solution and Precipitation Heat TreatedAMS4132J (Current)3/12/2026
This specification covers an aluminum alloy in the form of die forgings, hand forgings, and rolled rings 4 inches (102 mm) and under in nominal thickness and forging stock of any size (see 8.6).
AMS D Nonferrous Alloys Committee
Steel Cleanliness, Aircraft-Quality, Magnetic Particle Inspection ProcedureAMS2301M (Current)3/12/2026
This specification covers steel cleanliness requirements for aircraft-quality ferromagnetic steels, other than hardenable corrosion-resistant steels (refer to AMS2303), by magnetic particle inspection methods. This specification contains sampling, specimen preparation, inspection procedures, and cleanliness rating criteria (see 8.2).
AMS E Carbon and Low Alloy Steels Committee
Beryllium Aluminum Alloy Investment Castings 64.9Be - 30Al - 3Ag - 1Co - 0.75Ge As CastAMS7918B (Current)3/3/2026
This specification covers a beryllium aluminum alloy in the form of investment castings.
AMS G Titanium and Refractory Metals Committee
Copper-Beryllium Alloy, Sheet and Strip, 98Cu - 1.9Be, Half Hard (TD02)AMS4532J (Current)2/25/2026
This specification covers one type of copper-beryllium alloy in the form of sheet and strip up to 0.188 inch (4.78 mm) in nominal thickness (see 8.7).
AMS D Nonferrous Alloys Committee
Titanium Alloy Bars and Forging Stock, 6.0Al - 2.0Sn - 4.0Zr - 2.0Mo, Duplex AnnealedAMS6905D (Current)2/18/2026
This specification covers a titanium alloy in the form of bars up through 3.000 inches (76.20 mm), inclusive, in diameter or least distance between parallel sides with a maximum cross-sectional area of 10 square inches (64.5 cm2) and forging stock of any size (see 8.7).
AMS G Titanium and Refractory Metals Committee
Aluminum Alloy, Die Forgings, 3.5Cu -1.0Li - 0.04Mg - 0.35Mn - 0.45Ag - 0.12Zr (2050-T852), Solution Heat Treated, Cold Worked, and Artificially AgedAMS4357A (Current)2/18/2026
This specification covers an aluminum alloy in the form of die forgings from over 2.000 to 10.000 inches (50.8 to 254 mm) in nominal thickness and forging stock of any size (see 8.6).
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate 4.4Cu - 1.5Mg - 0.60Mn (2024-T361) Solution Heat Treated and Cold WorkedAMS4269C (Current)2/16/2026
AMS4269C has been declared “STABILIZED” by SAE AMS Committee D Nonferrous Alloys and will no longer be subjected to periodic reviews for currency. Users are responsible for verifying references and continued suitability of technical requirements. Newer technology may exist.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate, Alclad 4.4Cu - 1.5Mg - 0.60Mn (2024 -T361 Sheet/Plate with 1½% Alclad) Solution Heat Treated, 6% Cold Worked and Naturally AgedAMS4194F (Current)2/13/2026
This specification covers an aluminum alloy in the form of sheet and plate, alclad both sides, supplied in the -T361 temper.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Sheet and Plate, Alclad 4.4Cu - 1.5Mg - 0.60Mn (Alclad 2024, -T361 Sheet and Plate) Solution Heat Treated, 6% Cold Worked, and Naturally AgedAMS4466C (Current)2/13/2026
This specification covers an aluminum alloy in the form of alclad sheet and plate 0.020 to 0.500 inch (0.508 to 12.70 mm), inclusive, in thickness, supplied in the -T361 temper (see 8.5).
AMS D Nonferrous Alloys Committee
Modelling and Analysis of Complex Shaped Cracks2026-28-00482/12/2026
This study provides an extensive analysis through finite element analysis (FEA) on the effects of fatigue crack growth in three different materials: Structural steel, Titanium alloy (Ti Grade 2), and printed circuit board (PCB) laminates based on epoxy/aramid. A simulation of the materials was created using ANSYS Workbench with static and cyclic loading to examine how the materials were expected to fail. The method was based on LEFM and made use of the Maximum Circumferential Stress Criterion to predict where cracks would happen and how they would progress. Normalizing SIFs while a crack was under mixed loading conditions was achieved using the EDI method [84]. We used Paris Law to model fatigue crack growth using constants (C and m) for the materials from previous studies and/or tests. For example, in the case of titanium Grade 2, we found Paris Law constants with C values from 1.8 × 10-10 to 7.9 × 10-12 m/cycle and m values from 2.4 to 4.3, which illustrate differing effects of their
T, Lokesh, Bhaskara Rao, Lokavarapu
Titanium Alloy Bars and Forging Stock, 3Al - 8V - 6Cr - 4Mo - 4Zr, Solution Heat Treated and AgedAMS6921D (Current)2/11/2026
This specification covers a titanium alloy in the form of bars up through 4.000 inches (101.60 mm) in nominal diameter or least distance between parallel sides, inclusive, and stock for forging of any size (see 8.7).
AMS G Titanium and Refractory Metals Committee
Copper-Beryllium Alloy Sheet, Strip, and Plate, 98Cu - 1.9Be, Solution Heat Treated (TB00)AMS4530K (Current)2/11/2026
This specification covers one type of copper-beryllium alloy in the form of sheet, strip, and plate (see 8.6).
AMS D Nonferrous Alloys Committee
Steel, Corrosion-Resistant, Sheet, Strip, and Plate, 15Cr - 4.5Ni - 0.30Cb (Nb) - 3.5Cu (15-5PH®), Consumable Electrode Remelted, Premium Aircraft Quality, Solution Heat Treated and Precipitation Hardened (H1025)AMS5862/H1025 (Current)2/11/2026
This specification covers a corrosion-resistant steel product in the solution and precipitation heat-treated (H1025) condition, 4 inches (102 mm) and under in nominal thickness.
AMS F Corrosion and Heat Resistant Alloys Committee
Aluminum Alloy, Rolled or Forged Rings, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-T7351, 7075-T7352), Solution Heat Treated, Mechanically Stress Relieved, and Precipitation Heat TreatedAMS4311G (Current)2/6/2026
This specification covers an aluminum alloy in the form of rolled or forged rings up to 6 inches (152 mm), inclusive, in nominal thickness at the time of heat treatment and having an OD to wall thickness ratio of 10 or greater (see 8.6).
AMS D Nonferrous Alloys Committee
Magnesium Alloy, Extrusions, 6.5Al - 0.95Zn (AZ61A-F), As ExtrudedAMS4350P (Current)2/6/2026
This specification covers a magnesium alloy in the form of extruded bars, rods, wire, tubing, and profiles.
AMS D Nonferrous Alloys Committee
Aluminum Alloy Hand Forgings and Rolled Rings, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-T652), Solution Heat Treated, Stress Relief Compressed, and Precipitation Heat TreatedAMS4248E (Current)2/6/2026
This specification covers an aluminum alloy in the form of hand forgings up to 8 inches (203 mm), inclusive, in nominal thickness and a cross-sectional area not over 256 square inches (1652 cm2) and rolled rings up to 3.5 inches (89 mm), inclusive, in nominal thickness and with an OD to wall thickness ratio of 10:1 or greater (see 8.6).
AMS D Nonferrous Alloys Committee
Plate, Magnesium Alloy, 3.0Al - 1.0Zn - 0.20Mn (AZ31B-H26), Cold Rolled and Partially AnnealedAMS4376J (Current)2/6/2026
This specification covers a magnesium alloy in the form of plate 0.250 to 2.000 inches (6.35 to 50.80 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Steel, Corrosion- and Heat-Resistant, Welding Wire, 16.5Cr - 4.5Ni - 2.9Mo - 0.10N (AM350)AMS5774F (Current)2/1/2026
This specification covers a corrosion- and heat-resistant steel in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight26AERP02_032/1/2026
Between the 1920s and 1930s, aluminum started replacing wood as the primary material in aircraft construction and soon became the backbone of modern aviation. Its popularity stemmed from a combination of properties, high strength-to-weight ratio, corrosion resistance, and ease of forming that made it ideal for demanding aerospace applications. Throughout much of the 20th century, high-strength aluminum alloys dominated aircraft design, accounting for 70-80 percent of commercial airframes and more than half of many military aircraft. Even after the introduction of fiber-polymer composites in the early 2000s, aluminum has remained a critical material because it continues to offer the strength, lightness, and versatility needed for modern aviation. Industry forecasts predict that commercial air travel will double in the next 25 years, which means more pollution will be released into the atmosphere. One way to help reduce these emissions is by building airplane fuselages and wings with
Steel, Corrosion-Resistant, Bars, Wire, Forgings, Mechanical Tubing and Forging Stock, 16Cr - 2.5Ni (SAE 51431), Aircraft QualityAMS5628G (Current)1/31/2026
This specification covers a heat-treatable, corrosion-resistant steel in the form of bars, wire, forgings, mechanical tubing, and stock for forging or heading.
AMS F Corrosion and Heat Resistant Alloys Committee
Aluminum Alloy, Alclad Sheet and Plate, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr, (7075; -T76 Sheet, -T7651 Plate), Solution and Precipitation Heat TreatedAMS4316C (Current)1/31/2026
This specification covers an aluminum alloy in the form of Alclad sheet and plate 0.040 to 1.000 inch, inclusive (1.02 to 25.40 mm, inclusive) in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 4.1Ni - 0.28Cb (Nb) - 3.2Cu (17-4), Homogenization, Solution, and Precipitation Heat Treated (H1100), 130 ksi (896 MPa) Tensile StrengthAMS5342G (Current)1/27/2026
This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 130 ksi (895 MPa) tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
Copper-Beryllium Alloy, Bars and Rods, 98Cu - 1.9Be, Solution and Precipitation Heat Treated (TF00, formerly AT)AMS4533F (Current)1/27/2026
This specification covers a copper-beryllium alloy in the form of bars and rods (see 8.5).
AMS D Nonferrous Alloys Committee
Magnesium Alloy, Investment Castings, 10Al (AM100A-T6), Solution and Precipitation Heat TreatedAMS4455J (Current)1/23/2026
This specification covers a magnesium alloy in the form of investment castings (see 8.6).
AMS D Nonferrous Alloys Committee
Steel, Corrosion-Resistant, Investment Castings, 16Cr - 4.1Ni - 0.28Cb - 3.2Cu, Homogenization, Solution, and Precipitation Heat Treated (H900), 180 ksi (1241 MPa) Tensile Strength (17-4)AMS5344H (Current)1/19/2026
This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 180 ksi (1241 MPa) tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
Niobium Alloyed Brake Disc for reduced NVH and Emission Control2026-26-02851/16/2026
Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technologies to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium and subsequently Ferritic Nitrocarburize (FNC) the disc. The Niobium addition will improve the wear resistance of the FNC case, reducing wear debris. The test methodology included: 1. Manufacture of disc samples alloyed with Niobium, 2. Finish machining and ferritic nitrocarburizing and 3. Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3
Barile, Bernardo, Holly, Mike
Comparative Study of ADC12, A356, and AlSi10Mg Alloys in Sand Casting of EV Battery Housing2026-26-02961/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Non-Metallic Inclusions in Carburizing Steels as a Contributory Factor for the Formation of Carbide Net2026-26-02901/16/2026
The article deals with the issue of identifying structural defects that contribute to the formation of a carbide net during thermochemical treatment of steel parts, which negatively affects the mechanical properties complex of finished products. Based on the available data, a theory has been put forward regarding the influence of the present non-metallic inclusions in the carburizing steels structure on carbide formation process in the hardened layer. As an experimentally the samples have been produced from the varying chemical composition alloy structure carburized steel (0.17-0.23 % C, 0.17-0.37 % Si, 0.80-1.10 % Mn, 1.00-1.30 % Cr, 0.03-0.09 % Ti). During microstructure analysis of the samples it has been establish that non-metallic inclusions, in particular sulfides, contribute to the formation of carbides and carbide net in steel due to their high chemical activity with carbon. Thus, contamination of the metal of carburizing steels with non-metallic inclusions is not only a defect
Runova, Iuliia, Chatkina, Mariia, Musienko, Aleksandr
Effect of Flow Forming Process on the Mechanical Properties and Microstructure of GDC & LPDC Cast Aluminium Alloy Wheels2026-26-02981/16/2026
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel rim production technique, which offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only enhances strength and durability but also reduces overall
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, Sundaram, Raghupathi, Paua, Ketan
Study the Tool Profile and Rotational Speed on Mechanical Attributes of FSW of Al 6063 Alloy05-19-03-00231/12/2026
Friction stir welding (FSW) of Al 6063 alloy plates of 6 mm thickness was investigated in the present study for exploring the mechanical attributes of the welded joints. The tool profile significantly influences the quality of joints produced by FSW. In the current study, the influence of tool profile and FSW process parameters on the FSW weld characteristics of similar joining of Al 6063 plates has been investigated. The effect of FSW tool rotational speed (TRS) and tool travel speed on the FSW weld properties, mainly microstructure characteristics, microhardness, and ultimate tensile strength (UTS), have been studied. Comparison of two different tool profiles, namely taper and cylindrical tool, has also been examined. The effect of transient temperature distribution has also been studied for varying FSW process parameters. When increasing the tool’s rotational speed from 800 to 1200 rpm at a fixed traverse speed of 80 mm/min, a rise in peak temperature is observed. Conversely
Kumar, Pramod, Kumar, Vikash, Kumar, Gulshan, Arif, Abdul, Prasad, Chitturi Ram, Zubairuddin, M.
Numerical Assessment of High-Cycle Fatigue Behavior of Notched Cast Aluminum Alloy A357-T6 Based on Affected Depth05-19-03-00241/9/2026
This article aims to estimate the high-cycle fatigue (HCF) behavior of a circumferential notched A357-T6 cast aluminum alloy based on the affected depth (AD) approach. This technique is applied as a useful way to anticipate the fatigue life of notched components using the multiaxial fatigue criterion proposed by Crossland. Simulations of the cyclic finite element (FE) calculations in Abaqus involve implementing an elastic–plastic combined Chaboche model. Calculations lead to determining the Kitagawa–Takahashi diagram for this type of defect under the load ratio Rσ = 0.1, showed good agreement with the experimental data. The study provides a clear quantification of the effect of the notch on fatigue resistance. The fatigue limit of the notched specimen decreases by about 16% when the radius of the notch is equal to 3 m. This cast aluminum alloy has revealed a low sensitivity to notches. The notch sensitivity factor (q) was estimated for different defects and conditions, indicating that
Majed, Nesrine, Nasr, Anouar, Youssef, Marwa
Nickel Alloy, Corrosion- and Heat-Resistant, Powder for Additive Manufacturing, 50Ni - 20Co - 17Cr - 3.1W - 2.3Ti - 2.1Al - 2.1Mo - 1.8Cb(Nb) - 1.5Ta - 0.04C - 0.005BAMS7075 (Current)12/31/2025
This specification covers a corrosion- and heat-resistant nickel alloy in the form of pre-alloyed powder.
AMS AM Additive Manufacturing Metals
Titanium Alloy Sheet, Strip, and Plate, 8Al - 1V - 1Mo, Single AnnealedAMS4915P (Current)12/19/2025
This specification covers a titanium alloy in the form of sheet, strip, and plate up to 4.000 inches (101.60 mm), inclusive (see 8.6).
AMS G Titanium and Refractory Metals Committee
Mixed Aggregation by Comprehensive Normalization Technique–Based Parametric Optimization of Turning of Ti-6Al-4V Alloy in Minimum Quantity Lubrication Environment05-19-03-002212/19/2025
Although Ti-6Al-4V alloy offers high strength-to-weight ratio, corrosion resistance, and biocompatibility properties, its machining is challenging due to low thermal conductivity, high hardness, and chemical reactivity. This study examines turning of Ti-6Al-4V under minimum quantity lubrication (soybean oil). Cutting speed (CS), feed rate (FR), and depth of cut (DOC) are considered as the input parameters. On the other hand, material removal rate (MRR), tool wear rate (TWR), surface roughness (SR), and cutting force (Fc) are treated as the responses. Optimization of the said process is carried out using the mixed aggregation by comprehensive normalization technique (MACONT), a recently developed multi-criteria decision-making (MCDM) method. The optimal parameters are identified as CS = 72.26 m/min, FR = 0.022 mm/rev, and DOC = 0.2 mm, achieving high MRR with low TWR, SR, and Fc. The effects of different turning parameters on the responses are also investigated. Sensitivity analysis
Das, Partha Protim, Sharma, Saurabh, Chakraborty, Shankar
Nickel Alloy, Corrosion- and Heat-Resistant, Sheet, Strip, and Plate, 59Ni - 22Cr - 2Mo - 14W - 0.35Al - 0.03La (Alloy No. 230®), Solution Heat TreatedAMS5878F (Current)12/18/2025
This specification covers a corrosion- and heat-resistant nickel alloy in the form of sheet, strip, and plate 0.015 to 1.5 inches (0.38 to 38 mm) in nominal thickness.
AMS F Corrosion and Heat Resistant Alloys Committee
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