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Magnesium and its alloys are promising engineering materials with broad potential applications in the automotive, aerospace, and biomedical fields. These materials are prized for their lightweight properties, impressive specific strength, and biocompatibility. However, their practical use is often hindered by their low wear and corrosion resistance. Despite their excellent mechanical properties, the high strength-to-weight ratio of magnesium alloys necessitates surface protection for many applications. In this particular study, we employed the plasma spraying technique to enhance the low corrosion resistance of the AZ91D magnesium alloy. We conducted a wear analysis on nine coated samples, each with a thickness of 6mm, to assess their tribological performance. To evaluate the surface morphology and microstructure of the dual-phase treated samples, we employed scanning electron microscopy (SEM) and X-ray diffraction (XRD).

Aluminum alloys are employed in agricultural equipment, aerospace sectors, medical instruments, machinery, automobiles, etc. due to their physical and mechanical characteristics. The geometrical shape and size of the parts are modified in turning operation by using a single-point cutting tool. A356 aluminum alloy is widely used in various engineering sectors, hence there is a necessity to produce A-356 components with quality. The inappropriate cutting parameters used in turning operation entail high production costs and reduce tool life. Box–Behnken design (BBD) based on response surface methodology (RSM) was used to design the experiments such that the experiment trials were conducted by varying cutting parameters like N-spindle speed (rpm), f-feed rate (mm/rev), and d-depth of cut (mm). The multi-objective responses, such as surface roughness (SR) and metal removal rate (MRR) were analyzed with the desirability method.

Abstract The hot corrosion studies for the die-casted magnesium (Mg) silver (Ag) alloys are carried out through the steam heating route. The Magnesium Silver (QE22A) alloy is fixed under the top lid of the pressure cooker (2 liters) and filled with water and 5% salt (NaCl) solution. The specimens are treated with different time intervals (10, 20, and 30 minutes), with the steam temperature maintained at 100°C around the specimen. The results showed an increase in the corrosion rate with the increase in the steaming time. Further, after the specimens have cooled down to room temperature, similar experiments are repeated for the second and third cycles. Here the formation of the oxide layers over the specimen has reduced the corrosion rate. The structural, surface study was carried out through scanning electron microscopy (SEM), X-ray diffraction (XRD), and energy-dispersive spectroscopy (EDS) to know the corrosion behavior on the specimen.

Using tolerance stacks ensures that parts fit together properly, reducing scrap and rework, thereby increasing value. This 2-day foundational-level course explains how to use tolerance stacks to analyze product designs and how to use geometric tolerances in stacks.

Additive manufacturing (AM) technology, also known as 3D printing, has transitioned from concepts and prototypes to part-for-part substitution and the creation of unique AM-specific part geometries. These applications are increasingly present in demanding, mission-critical fields such as medicine and aerospace, which require materials with certain thermal, stiffness, corrosion, and static loading properties. To advance in these arenas, metallic, ceramic, and polymer composite AM parts need to be free from discontinuities. The manufacturing processes have to be stable, robust, and repeatable. And the nondestructive testing (NDT) technology and inspection methods will need to be sufficiently capable and reliable to ensure that discontinuities will be detected to prevent the components from being accepted for use. As the second installment of a six-part series of SAE EDGE™ Research Reports on AM, this one discusses the need, challenges, technologies, and opportunities for NDT in AM.