An Al2014–alumina (Al2O3) composite’s characteristics are significantly influenced by the reinforcement particle size variation. Therefore, this study examines the microstructure, mechanical, fractography, and wear performance of an Al2014–Al2O3p composite made using a unique two-stage stir casting method and various alumina weight fractions (9, 12, and 15 wt %). Three categories of alumina particle size are used, i.e., fine particle size (FPS, 8 μm), intermediate particle size (IPS, 53 μm), and coarse particle size (CPS, 88 μm). The shapes of the composites were characterized using scanning electron microscopy. According to scanning electron microscopic analyses of the microstructure, the FPS dispersion was more uniform than IPS and CPS, whereas CPS causes agglomeration. Additionally, the studies show that the FPS composite outperformed CPS and IPS composites in terms of mechanical characteristics and wear performance. The fractography study shows conical and equiaxed dimple failure in the Al2014 matrix and the circular cavities.

Diffusion bonding is a joining process that relies on the inter-diffusion of atoms across the interface as the primary mechanism. Diffusion bonding techniques such as solid state and transient liquid phase (TLP) bonding are currently performed in a vacuum, which is a time-consuming, costly method and also limits the size of the components that can be bonded adequately. The present study aims at achieving the diffusion bonded joints of AA2014 under the bonding temperatures of 440, 460, and 480 0C. Microstructural evaluation is carried out using light optical microscopy (LOM), and scanning electron microscopy (SEM). Energy dispersive spectroscopy (EDS) is used for elemental analysis on the interface of the bonded specimens. Hardness at the interface is evaluated using the Vickers Microhardness test.

Recent advancements in the field of coating have shown that the Ni-Al2O3 electrodeposited coatings are of excellent wear-resistant, corrosion-resistant. In this study, Ni-Al2O3 composite coating is produced by electrodeposition process by using standard watts bath due to the advantage over other coating techniques. Al2O3 nanoparticles are co-deposited on AA6061 with Nickel. There are many parameters that influence the coating characteristics, however, in this study temperature, current density and percentage of nanoparticle loading are considered as significant parameters. Optimization of the coating parameters is examined by using the Taguchi method. The coating morphology and microstructure are studied using Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD). The dry sliding wear behaviour of composite coatings is tested on a pin-on-disc wear test rig.

Solid-state diffusion bonding of AA2219 alloy is carried out under the nonvacuum condition to form AA2219/AA2219 joints. In the currently adopted method, AA2219 alloys are joined under the bonding temperature of 450–500°C, bonding pressure of 10 MPa, and bonding time of 30 min. Chemical cleaning is adopted to protect the joining surfaces from reoxidation before the diffusion bonding process. Microstructure evolution at the bonded joints is characterized using optical microscopy, scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS). The hardness at the bonded joints increased with the increase in the bonding temperature. The parent metal structure is achieved at 500°C bonding temperature with an increase in hardness of 112.14 Hv at the bond interface. There is no evidence of intermetallic found at the interface, as confirmed by X-ray diffraction (XRD).