Three different bonding couples assembled by two commonly used aerospace aluminum alloys were bonded within the temperature range of 460–520 °C under 6 MPa for 60 min in vacuum atmosphere. The interface microstructure and alloying elements distribution of the bonded joints were determined by scanning electron microscope (SEM) and Energy Dispersive Spectroscope (EDS); the bond strength was evaluated by tensile-shear strength test. The results show the bond quality improved effectively as the bonding temperature increased. Compared with the 1420-1420 and 7B04-7B04 bonding couples, the 1420-7B04 couples obtained better interface integrity and higher bond strength, the highest shear strength for 1420-7B04 couple can be as high as 188 MPa when bonded at 520 °C. Special attention was focused on the 1420-7B04 couple, the diffusion coefficient of Mg at the original interface under different temperatures were investigated, the results show the diffusion coefficient increased obviously as the bonding temperature increased. A diffusion affected zone (DAZ) without continuous intermetallic phases formed due to the diffusion of alloying elements across the bonding interface. The combined action of temperature and alloying elements gradient resulted in the increase of alloying elements diffusion fluxes, which in turn promote the bonding quality through the accelerated shrinkage of interfacial voids.

Flight feather shafts are outstanding bioinspiration templates due to their unique light weight and their stiff and strong characteristics. As a thin wall of a natural composite beam, the keratinous cortex has evolved anisotropic features to support flight. Here, the anisotropic keratin composition, tensile response, dynamic properties of the cortex, and fracture behaviors of the shafts are clarified. The analysis of Fourier transform infrared (FTIR) spectra indicates that the protein composition of calamus cortex is almost homogeneous. In the middle and distal shafts (rachis), the content of the hydrogen bonds (HBs) and side-chain is the highest within the dorsal cortex and is consistently lower within the lateral wall. The tensile responses, including the properties and dominant damage pattern, are correlated with keratin composition and fiber orientation in the cortex. As for dynamic properties, the storage modulus and damping of the cortex are also anisotropic, corresponding to variation in protein composition and fibrous structure. The fracture behaviors of bent shafts include matrix breakage, fiber dissociation and fiber rupture on compressive dorsal cortex. To clarify, ‘real-time’ damage behaviors, and an integrated analysis between AE signals and fracture morphologies, are performed, indicating that calamus failure results from a straight buckling crack and final fiber rupture. Moreover, in the dorsal and lateral walls of rachis, the matrix breakage initially occurs, and then the propagation of the crack is restrained by ‘ligament-like’ fiber bundles and cross fiber, respectively. Subsequently, the further matrix breakage, interface dissociation and induced fiber rupture in the dorsal cortex result in the final failure.

It is well-known that cell morphology plays a vital role in the mechanical properties of the closed-cell aluminum foam. In this work, a three-dimensional (3D) realistic structure was obtained by using the synchrotron X-ray micro-tomography technique and then translated into a numerical model for a further finite-element simulation. In order to investigate the early compressive deformation in the closed-cell aluminum foam, we chose three different strain levels, namely, 0.2% (initiation of plastic strain), 2.8% (propagation of plastic strain band), and 6% (formation of collapse band) to discuss the evolution forms of plastic strain concentration by simulation. We found that the curvature, anisotropy, and distribution of cell volume of adjacent cells played a vital role in the initiation of plastic strain. Furthermore, the phenomenon that plastic strain band propagated along the direction aligned 45° with respect to the orientation of the compression was also investigated in the propagation of the plastic strain band and formation of the collapse band. Finally, the comparison between experimental results and simulation results was performed to illustrate the early location of these three different levels in the whole compressive deformation.

The effect of traveling magnetic fields (TMFs) on the grain and micro-pore formation in an Al alloy was studied by scanning electron microscope and X-ray microtomography in this work. The results show that with the increasing magnetic flux density, the three-dimensional morphology of the micro-pores transformed from dendrite to a relatively equiaxed structure. Quantified results show that both the micro-pore volume fraction and the average grain size of the primary phase decreased as the TMF density increased. The analyses show that the forced convection induced by TMF can break the dendrites, refine the grain size, and promote the liquid feeding, leading to the decrease in the volume fraction of the porosity and improved mechanical property. The TMF performed at different stages during solidification reveal that the maximum effect of TMF on reducing the micro-pore formation was found when TMF was applied in the stage of nucleation and the early stage of grain growth during solidification.

The fabrication of Ti-aluminide multi-layered composites have attracted great attention for their excellent mechanical properties, such as high specific strength, high specific stiffness, tolerable toughness, and low density. The preparation of the composite produced by a hybrid procedure composed of Vacuum Hot Pressing (VHP) and Hot Isostatic Pressing (HIP) using Ti foils and Al foils has been performed. Further, X-Ray Diffraction (XRD) and Scanning Electron Microscopy (SEM) equipped with Energy Dispersive X-ray Spectrometry (EDXS) were carried out to identify the microstructure and phase formation of the composite. In addition, an in-situ three-point bending test was conducted on the notched specimen to observe the crack propagation behavior carefully. The results indicate that the densified composite was obtained without any apparent voids and pores which could undesirably develop into the source of cracks. Furthermore, all the pure Al foils were totally consumed to form a series of the Ti-Al compounds through the diffusive reaction between the adjacent Ti and Al foils. Moreover, the in-situ observation demonstrates the initiation and propagation of cracks in the intermetallic layers and the role of residual Ti layers to blunt and bridge the cracks by their plastic deformation. This study provides a new strategy for fabricating the Ti-aluminide multi-layered composites.

The effect of high pressure (135 MPa) and the following heat treatment on the microstructure and micro-hardness of the squeezing cast AlSi9CuMg alloy is investigated, using optical microscopy (OM), Vickers tester, scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The results indicate that the application of high pressure can increase under-cooling and the cooling rate during solidification and cause the refinement of the microstructure. The enhanced melt flow resulting from high pressure can also break the dendrite to form the spherical and elliptical primary α (Al) grains during the early stage of solidification. The winter-sweet flower-shaped primary α (Al) phases can also be formed through plastic deformation caused by the flow of the partially solidified melt. The ageing treatment results showed that a maximum (peak) micro-hardness value was obtained for each of the three ageing temperatures at different ageing times, and the highest peak value was achieved at 175 °C for 480 min. The micro-hardness change of the sample under different ageing processes was attributed to the variation of type, density, and size of the precipitates.