Aluminum alloys are widely used in many industries, including aerospace, automotive, civil, and electrical engineering. When compared to pure aluminum, most aluminum alloys have lower electrical and thermal conductivity, corrosion resistance, and weldability, as well as a low density and specific gravity. At the same time, the properties of aluminum alloys vary significantly depending on the group, which has a significant impact on their machinability. This review article is focused on the study of machining characteristics of aluminum alloys, such as machinability, surface integrity, tool wear and tool life, material removal rate (MRR), and chip morphology. The directions of increasing machinability by controlling cutting parameters, cutting environment, such as dry machining, conventional cooling systems, minimum quantity of lubricant (MQL), cryogenic lubrication (CL), with tool geometry, and textured tools, are also considered; tool materials include coating, vibration, thermally, and hybrid assisted machining. The article discusses the main types of machining, namely, turning, milling, drilling, and grinding. It shows ways to increase the machinability of machining on aluminum alloys, as well as the advantages and disadvantages. From the literature, it can be concluded that tool wear when machining aluminum alloys is 30–40% lower than when machining steel alloys due to their higher ductility and lower strength. Surface integrity, affected by the cutting parameters and cutting temperatures — which can reach between 200 and 400 °C — can vary by up to 15% in hardness and 20% in surface roughness. Cutting tool characteristics can enhance surface finish by up to 25% and extend tool life, reducing edge formation by up to 30%. Chip morphology, influenced by factors such as cutting parameters and tool material, can improve tool life by up to 35%. Vibration techniques can reduce thermal effects and improve surface finish by up to 40%, reducing cutting forces by around 30%.

Natural fibers and polyurethane based composites may present chemical bonding between the components of the polymer and the lignin of the fiber. The incidence of radiation can cause degradation of the polymeric material and alter its mechanical properties. The objective of this study was to obtain and characterize cold pressed composites from polyurethane derived from castor oil and sisal fibers, without coupling agents, through thermogravimetric and mechanical tests, before and after the incidence of 25 kGy dose of gamma radiation. Woven composites that were not irradiated had maximum values of 4.40 GPa for flexural elastic modulus on three point flexural test and dispersed fiber composite that were not irradiated had maximum values of 2.25 GPa. These materials are adequate for use in non-structural applications in radiotherapy and radiodiagnostic rooms.

A multi-scale modeling approach for simulating the tensile behavior of the corroded aluminum alloy 2024 T3 was developed, accounting for both the geometrical features of corrosion damage and the effect of corrosion-induced hydrogen embrittlement (HE). The approach combines two Finite Element (FE) models: a model of a three-dimensional Representative Unit Cell (RUC), representing an exfoliated area and its correspondent hydrogen embrittled zone (HEZ), and a model of the tensile specimen. The models lie at the micro- and macro-scales, respectively. The characteristics of the HEZ are determined from measurements of nanoindentation hardness, conducted on pre-corroded specimens. Using the model of the RUC, the local homogenized mechanical behavior of the corroded material is simulated. Then, the behavior of the exfoliated areas is assigned into different areas (elements) of the tensile specimen and final analyses are performed to simulate the tensile behavior of the corroded material. The approach was applied to model specimens after 8, 16 and 24 h exposure periods of the Exfoliation Corrosion (EXCO) test. For validation of the approach, tensile tests were used. The numerical results show that this approach is suitable for accurately simulating the tensile behavior of pre-corroded experimental specimens, accounting for both geometrical features of corrosion damage and corrosion-induced HE.

Anodizing can generate porous wear-resistant layers, which can act as reservoirs for gradually releasing lubricants. Studies on the formation of zinc dialkyl dithiophosphate (ZDDP) tribofilms in non-ferrous metals are relatively rare. Furthermore, adding nanoparticles can improve wear resistance in various applications. This investigation aims to correlate several anodized surfaces using H₂SO₄ (5 or 10%wt. concentration and 45 or 60 min exposition) to tribological outputs, contributing to understanding the friction behavior of non-metallic layers. Three steps were applied on anodized Alumold 500 alloy. Firstly, the scratching test, to select the layers with higher critical loads. The greatest scratch resistance was obtained with the highest H³/E² value and thickest layer. Secondly, lubricated tests with only poly-alpha-olefin oils (PAO6) were performed in a reciprocating test rig using an alumina ball as the counterpart. From that, only the best AAO condition was selected. Finally, three more lubricant compositions were tested, as follows: adding ZDDP to PAO6, alumina nanoparticles (~100 nm) to PAO6, and ZDDP + nanoparticles. The addition of nano-alumina to the PAO6 resulted in the maintenance of COF values with only PAO6 (~0.1), when the most significant drop in the surface roughness was observed along with the tests.