In the frame of the common research project, manufacturing of thin sheet Ni-Ti based composites reinforced with Nb and TiB2 have been carried out through hot-forged bonding process for a high strength sandwich structure for the aeronautical engineering applications. Interface and bonding characteristics of hot forged composites have been evaluated heat treated at 550–600 °C depending on the operational parameters under laboratory conditions. Formability behaviour and delamination phenomenon have also been analysed by 3P Bending tests. An intermetallic phase layer has been carried out between the titanium and nickel sheet layers containing of hard particles reinforcements between the sheets by using hot forging process. Finally a high strength bonding has been carried out by mechanical joining and very strong chemical bonding diffusion during this process depending on the temperature and the time. With the finite element model developed with reference to these tests, the mechanical behaviour of the material is supported by simulations made with the Abaqus software. Finally, more detailed mechanical/physical properties of this developed material were investigated by applying wear and creep tests. Certain area in the microstructure have been analysed with SEM.

In this study, a novel recycled Al 431 + 1050 based composites reinforced with “TiC” were designed for aeronautical applications with high resistant structure against to choc and static loading under service conditions. Static/dynamic compression behaviours of these composites were evaluated. Basically, laboratory-scale test samples were produced using combined “sinter + forging” production methods. Al 431 + 1050, a mixture of recycled and modified aluminium alloys, was used as the main matrix material. Different proportions of TiC (10, 15 and 20 wt %) were used as a major reinforcement element. As minor reinforcements, Mo and Cu metal powders and a small amount of Graphene Nano Platelets, (GNPs), and Alumina, (γ-Al2O3) fibre were used to compare their influence on the mechanical properties of these hybrid composite structures.

In the present work, the hybrid aluminium based composites coming from recycled AA7075 chips are produced by using the different levels of reinforcements. As a major one is TiC ceramic carbide (d ≤ 1–3 micron) at three levels (2.5%, 5%, 10%), whereas the minor addition of MoS2, Nb2Al and γ-Al2O3 fibre were fixed as 2, 3 and 3 wt %, respectively. These compositions are targets for the application of the connection link in a mechanism to transfer motion in aeronautical industry. For this reason, the machinability of these composites should be significant engineering case for the tailored behaviour of the composites produced through combined method of powder metallurgy route: sintering + Forging. Certain characteristics of the composites were carried out according to the optimization conditions of the reinforcements. Static and dynamic-crash tests will be performed. The microstructure analyses (matrix/interface) were carried out by Scanning Electron Microscope (SEM). A three-dimensional non-linear finite element model was used to simulate the static compression tests behaviour of these composites. A subroutine, VUMAT, will be written to use with ABAQUS/Explicit to analyze the effect of sintered-forging on the micro- and macrostructure of the manufactured materials. Different ratios of reinforcing particulates using in the experimental specimens were used in Representative Volume Element (RVE) (and other distribution techniques, etc.) for the microstructure modelling. Then, numerical models for the macrostructure were created using these micro-structures under the multiscale modelling process conditions.

In this project, design of niobium-aluminium (Nb2Al) intermetallics based composites is proposed by using the fresh scrap recycled niobium and aluminium alloy AA7075. These compositions will be the target for aeronautical engineering applications for high temperature service conditions. Manufacturing of these composites is an important engineering case for tailored behaviour of the composites produced through combined method of powder metallurgy route; sintering followed by forging. Different materials and operational (process) parameters will be used for optimization of the compositions. All of the analyses will be devoted to the static (compression, 3-point bending) test conditions. Microstructure analyses (matrix/interface) will be carried out by Scanning Electron Microscope (SEM). At this stage of the project, the primary objective would be to establish a continuum-based material model in order to capture the macroscopic behaviour of the targeted composite materials and numerically reproduce the results from the basic characterization tests (3P bending). The model will be implemented for Finite Element Analysis Software ABAQUS/Explicit as a user subroutine VUMAT for explicit nonlinear finite element calculations. The second step would be modelling of the microstructure of the proposed hybrid Nb2Al based composites and simulate the behaviour of several RVEs and see the effect of the sintered-forging and different ratios of reinforcing particulates.

In this research, devulcanized recycled rubber modified phenolic epoxy based composites reinforced with different ceramic carbon, and/or glass fibres and also graphene nano plates (GnPs) based composites were designed for aircraft internal structure. After determination of the reinforcements and matrix, a hot bonding process was applied to complete successfully the manufacturing of these composites. After that, the relevant toughening mechanisms given by the reinforcements were analyzed in detail to evaluate the damage tolerance of aircraft internal structures. For this purpose, mechanical and physical properties, KIC—Fracture toughness stress intensity factor and GIc—Critical energy release rate in mode I) have been determined by fracture toughness tests (static 3P bending test with single edge notch specimens, drop weight test, etc.).

In this study, the microstructural formation and static/dynamic compression behaviour of recycled AA7075 based hybrid composites reinforced with ZrO2and Al2O3 fibres were investigated. The effects of the hybrid metal matrix composites on the mechanical behaviour (quasi-static compression, dynamic compression, three-point bending and microhardness) have been investigated in detail by using ZrO2 as a reinforcement element in two different proportions. It is aimed to be an alternative to traditional alloys used in the aeronautic industry. These composites were produced using by combined sinter + forging processes. The static and dynamic properties have been evaluated in detail, taking into account the relevant Scanning Electron Microscopy (SEM) microstructures (including the distribution of reinforcement elements).

The copper-aluminium (Cu-Al-Zn) based structures show shape memory behaviours that are low cost engineering applications, such as actuators, valves, etc., regarding to Ni-Ti-Al structures. These alloys have a useful transformation temperature that can be modified to lie between −100 and 100 °C. For a low cost production, a combined method through powder metallurgy processes (sinter-Forging) have been performed for the production the composite called “Zn-Cu-Al-1X” with addition of small amount of reinforcements. For two basic production methods, sintered-forging process have been carried out at the temperature of 550 °C and 650 °C with 1 h dwell time followed slow quenching and final cooling operation respectively. In the frame of the common research project, production of the scrap thin sheet copper based composites reinforced with pure nano aluminium (~5 wt %) and fine zinc particles were produced with addition of small amount of fine particles as secondary reinforcements. These composites will be used for the applications of the coupling and actuators in the aeronautical area. For mechanical basically for the tailored behaviour of this composite, three point bending (3 PB) and impact tests were performed. Microstructural analyses was carried out with Scanning Electron Microscopy (SEM). Ductility and tailored behaviour of this composite will be discussed through the toughness mechanism depending on the processing parameters.

The present work, reviews the toughening mechanisms and microstructural analyses of recycled aluminium matrix composites reinforced with γ-alumina and pure recycled copper. This composite was manufactured by sintering and sinter + forging called the combined process. Static compression, 3-point bending, impact (drop-weight) tests were conducted to evaluate mechanical response of the composites. Additionally, wear and creep tests were carried out with a nanoindenter to evaluate wear and time dependent behaviour of this composite. Detailed analyses of microstructure of the composites was performed with Scanning Electron Microscopy (SEM) supported by EDS analyses. The results showed that, the composites have homogeneous structure without porosity and very homogeneous distribution of fine γ-alumina (Al2O3) and copper particles. Sinter + forging process yielded a material that had higher strength, hardness and better resistance to wear. This composite will be targeted for linkage applications where high toughness and high surface damage resistance is required.

The present work, reviews the mechanical and microstructural analyses, of copper and silicon carbide reinforced recycled aluminium matrix (Alumix 431) composites manufactured by sinter+forging technique. Static compression, impact tests and also scratch damage tests were carried out. Detail analyses of Scanning Electron Microscopy (SEM) supported by XRD, thermal and electrical conductivity measurements have been carried out on the specimens before and after the tests.

Abstract Hybrid intermetallic composites (HICs-aluminum based matrix, new hybrid design) reinforced with titanium nitride (TiN) and alumina (γ-Al2O3) were designed and manufactured through the innovative combined method of sinter + forging. This method results in highly dense materials with, in general, improved mechanical properties. In the composites TiN content was varied (10, 20 and 30 wt %) but γ-Al2O3 content was kept constant at 10 wt%. Additionally, 5 wt% each of Cu and Ni were mixed in to improve processing of the composites. The mechanical properties were specified by different destructive test methods (wear performance, micro hardness, quasi-static compression, three-point bending tests). Wear performance was investigated by scratch experiments. Scanning electron microscopy (SEM) was used to determine the microstructure, interface characteristics and the fracture surfaces. The SEM analysis yielded that TiN powders were located at the grain boundaries and this can be attributed to the improvement observed in the mechanical properties and wear performance with the addition of TiN.

In the frame of the common research project, the mechanical behaviour of recycled thin sheet Ti-Al based composites reinforced with scrap pure aluminium (AA1050) and boron, B reinforcement elements have been used with thin Ti-Al sheet recycled by hot forging method. The effects of chemical bonds during the production of these multifunctional sandwich composite structures were analyzed by 3-point bending tests to evaluated hyper elasticity behaviour. The same idea has been carried out this time on the Ti-Al based composites performed by sintered + forging through the powder metallurgy route by using different reinforcements such as TiB2, TiC, and B4C. Quasi static compression and low velocity impact (drop weight) tests have been performed on the sintered + forging specimens with a drop tower to observe the response of theses composites under the dynamic loading conditions. Interface and microstructure of these composites have been evaluated by Scanning Electron Microscope (SEM).

Aluminium Metal Matrix Composites (AMMCs) have very light weight, high strength, and show better resistance to corrosion, oxidation, and wear. Impact resistance is an especially important property of these AMMCs which is essential for automotive applications. In this study, recycled aluminium matrix composites were designed through the powder metallurgy route. As matrix, fresh scrap aluminium chips (Alumix-123), by-product of machining coming from the French aeronautical company, were used. Fine -alumina particles (γ-Al2O3, 10 wt %), were used as main reinforcement element for the present work. As secondary reinforcements, Mo and Cu were added in the matrix. In this study, a typical low cost but high performance metal matrix composite was designed by using recycled aluminum chips (Alumix-123). This process comprises of the mixing, blending and compacting of aluminum chips through press moulding and pre-sintering and finally forging. In the final stage, material parameters were optimized for improving physical and mechanical properties of these composites. Further, the influence of reinforcement’s type and content on the mechanical properties has also been reviewed and discussed. Damping capacities and damage were analysed by drop weight and quasi static compression tests. Microstructures were analysed by the Scanning Electron Microscope (SEM).

In this study, a new recycled aluminum-based hybrid composite was developed. The basic idea in this work is to create low-cost novel composites with practical manufacturing techniques, called sinter and forging. This research aims to manufacture stabile pieces in aircraft engineering. Reinforcements such as nickel–aluminum (NiAl), titanium diboride (TiB2) and titanium carbide (TiC) were used to improve the mechanical properties and thermal stability under the service conditions. Aluminium matrices were atomized from fresh scrap chips (50 wt.% Al 431 + %50 wt.% AA1050). For this work, two main ways were followed. The mechanical properties have been examined by: (1) Experimental methods, mechanical tests such as static compression and drop weight/low velocity impact tests and scanning electron microscopy (SEM) analysis for the detailed microstructural analyses and (2) numerical modeling, finite element method (FEM) to predict very easily certain behaviors of these composites. In the application of the FEM, a commercial Abaqus®/explicit was used with the VUMAT subroutine application to compare the compatibility of the results with the ones obtained from the experimental studies. It has been observed that there is a satisfactory convergence (±%5) between experimental and numerical results.

Niobium is the best and excellent metal for many different industrial applications. Europe has not a Niobium reserve whereas Brazil has a major Niobium mining and produce %90 of the Niobium in the world as a raw material.

Recycled AA7075 aluminum alloy and pure electrolytic copper were used as the matrix to manufacture new aluminum-copper metal matrix composites (ACMMCs). Powder metallurgy methods were used and the green compacts were finalized by sintering only and sinter thorn forging. Experimental and numerical investigation of recycled hybrid metal matrix composites manufactured by the two methods was performed. Al-Cu matrix combined with the reinforcements ZnO, Nb2Al and SiC. Two basic formulations were used where the contents Nb2Al and SiC was kept constant and the content of ZnO were 15 wt% and 30 wt%, respectively. The effects of these reinforcements used in the hybrid metal matrix composite structure on the mechanical and physical properties were investigated. The Nb2Al, SiC ratios used in the structure (chemical interaction in the internal structure, the effects on static-dynamic compression and wear behaviors) were kept constant, in particular the ZnO component (interactions with other components and their effects on electrical properties) were investigated. Micro-hardness analyses, surface scratch tests, quasi-static and dynamic compression tests were conducted. Also, electrical conductivity of the composites were determined. The effect of the composite's formulations and production method on the results were investigated. It was found when ZnO content was reduced the yield stress and ultimate strength values increased, but their resistance to impact loading reduced. Also, sinter thorn forged samples exhibited higher yield stress and ultimate strength than the just sintered samples. The damage and microstructural analyses were performed by Scanning Electron Microscope (SEM). Moreover, a non-linear numerical model was utilized to simulate quasi-static compression and dynamic compression (low velocity impact) behaviors of the composites for both formulations and manufacturing methods. Finite element simulations were performed using the ABAQUS T/Explicit dynamic finite element software. It was determined that there was a satisfactory agreement between experimental and finite element model results.

The present work reviews the toughening mechanisms and microstructural analyses of recycled hybrid metal matrix composites (aluminium based) reinforced with

In this study powder metallurgy and thixoforming methods are used together to manufacture aluminum alloy based composite materials reinforced with Nb2Al particles and glass bubbles (GB). Fresh scrap recycled aluminum chips, AA7075 received mainly from Brazilian aeronautic industry, are used as the raw material. Processing parameters of the manufacturing techniques were optimized and the distribution of the reinforcing particles as well as their interfaces with the matrix were analyzed. The mechanical properties of the newly designed composite material were determined by compression and bending tests. Very detailed interface analysis and microstructure and fracture surface evaluations were performed by Scanning Electron Microscopy (SEM). The results indicate that the proposed combined powder metallurgy and thixoforming method yields metal matrix composites with good mechanical properties. A non-linear finite element model (three dimensional) was used to simulate the bending and compression behaviour of Al-Nb2Al composites. A subroutine, VUHARD, was written to use with ABAQUS to analyze the effect of thixoforming and sintering on the micro and macrostructure of the manufactured materials. Different ratios of reinforcing particulates (Nb2Al, Glass Bubbles) used in the experimental specimens were used in Representative Volume Element (RVE) for the microstructure modeling. Numerical models for the macrostructure were created using these micro-structures. It has been observed that there is a good agreement between numerical analysis and experimental results. Proposed process offers an original method for the production of newly designed composite material from recycled waste aluminum that can have a major impact on the energy consumption in the aluminum industry, and when enhanced with the numerical tools for simulation it can lead to the development of better performing materials for the aviation industry.

This work presents the results of experimental and finite element modeling studies of impact behavior on the response of a high content of manganese steel blanks with a 1.2 mm thickness of sheets, known also commercially as Hadfield steel (an austenitic structure with a basic composition containing C 1.2% and Mn 12%). The study was done with a standard drop weight test device under certain variable parameters (velocity: 3 m/s and 5 m/s and temperature: room temperature, 70 °C, 100 °C, and 140 °C). In this study, the evolution of force and energy values were analyzed depending on the time in the case of impact. Special care was given to the evolution of peak stress counters of finite element simulation for different temperatures. The results of the force-time, energy-time, and force-displacement curves under different temperatures and impact velocities are compared experimentally and numerically. Then the discussion are built on the effect of the operational parameters on the damage behavior of this steel. Both of these works (experimental and finite element modeling) were compared and highly satisfying results were obtained.

In this article, mechanical behaviors of adhesive tape VHB 4950 elastomeric material, which is an element of acrylic polymer group and which is in viscoelastic behavior, under different pre-stress conditions and complex forces of different geometric parameters created by combining loadings have been experimentally and numerically investigated. In experimental studies, loading-unloading cyclic tests, one of the different standardized tests for the mechanical characterization of viscoelastic material, have been applied which give the most suitable convergent optimization parameters for the finite element model. Different material models were also investigated by using the data obtained from loading-unloading test results in all numerical models. According to the experimental results, the most suitable material parameters were determined with the Abaqus Parallel Rheological Framework Model (PRF) for 4 Yeoh Networks with Bergstrom-Boyce Flow model created in the Mcalibration software for finite element analysis. Subsequently, using these material parameters, finite element analysis was performed as three dimension non-linear viscoelastic with a commercial finite element software Abaqus. The finite element analysis results showed good correlation to the Force (N)-Displacement (mm) experimental data for maximum load-carrying capacity of structural specimens.

An experimental and numerical analysis of the influence of impactor shapes on the low velocity impact performance of aluminium sandwich composite plates has been carried out. The aluminium composite panels were manufactured by using two aluminium sheets and a low density polyethylene core under heat and pressure, which shows the outstanding properties of low weight, good rigidity and impact resistance. Experimental tests were performed using drop weight test machine, samples were impacted using steel conical, ogival, hemispherical and flat impactors, all 12 mm in diameter, for different initial impact energies of 29.43 J and 44.15 J and specimen thickness of 4 mm containing three different parts (0.5 + 3.0 + 0.5). A three dimensional non-linear finite element model is developed for simulating the impact behaviour of sandwich composite plate and the ABAQUS/Explicit commercial program was used. The face sheet material aluminium alloy 3003-O of the plate was modelled as isotropic with elastic plastic characteristics. The description of the material characteristic of the attenuator was made by means of the Johnson Cook elastic plastic law. The material constitutive law of the Al 3003 plates has been implemented in a user-defined subroutine UMAT. The foam core was modelled as a crushable foam material. The finite element results showed a good correlation to the experimental data in terms of contact-force histories, energy histories, absorbed energy, and failure of the sandwich composite was observed between the experimental data. (C) 2015 Elsevier Ltd. All rights reserved.