Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded Components
Aluminium alloy 6082 is widely used in the automotive and aerospace industries due to its high strength-to-weight ratio. However, its structural integrity can sometimes be affected by an early fatigue failure. This study investigates the fatigue performance of extruded 6082-T6 samples through a seri...
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MDPI AG
2025-07-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/7/247 |
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| author | Viththagan Vivekanandam Shubham Sanjay Joshi Jaime Lazaro-Nebreda Zhongyun Fan |
| author_facet | Viththagan Vivekanandam Shubham Sanjay Joshi Jaime Lazaro-Nebreda Zhongyun Fan |
| author_sort | Viththagan Vivekanandam |
| collection | DOAJ |
| description | Aluminium alloy 6082 is widely used in the automotive and aerospace industries due to its high strength-to-weight ratio. However, its structural integrity can sometimes be affected by an early fatigue failure. This study investigates the fatigue performance of extruded 6082-T6 samples through a series of fatigue tests conducted at varying stress levels. The material showed significant variability under identical fatigue conditions, suggesting the presence of microstructural defects. Scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS) and scanning transmission electron microscopy (S/TEM) were used to identify the nature and location of the defects and evaluate the underlying mechanisms influencing the fatigue performance. Computer tomography (CT) also confirmed the presence of oxide inclusions on the fracture surface and near the edges of the samples. These oxide inclusions are distributed throughout the material heterogeneously and in the form of broken oxide films, suggesting that they might have originated during the material’s early processing stages. These oxides acted as stress concentrators, initiating microcracks that led to catastrophic and unpredictable early failure, ultimately reducing the fatigue life of micro-oxide-containing samples. These results highlight the need for better casting control and improved post-processing techniques to minimise the effect of oxide presence in the final components, thus enhancing their fatigue life. |
| format | Article |
| id | doaj-art-10e3f43b63df4bc4999b5c4302fc3f0d |
| institution | DOAJ |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-10e3f43b63df4bc4999b5c4302fc3f0d2025-08-20T02:45:46ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-07-019724710.3390/jmmp9070247Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded ComponentsViththagan Vivekanandam0Shubham Sanjay Joshi1Jaime Lazaro-Nebreda2Zhongyun Fan3Brunel Centre of Advanced Solidification Technology (BCAST), Brunel University of London, Uxbridge, Middlesex UB8 3PH, UKBrunel Centre of Advanced Solidification Technology (BCAST), Brunel University of London, Uxbridge, Middlesex UB8 3PH, UKBrunel Centre of Advanced Solidification Technology (BCAST), Brunel University of London, Uxbridge, Middlesex UB8 3PH, UKBrunel Centre of Advanced Solidification Technology (BCAST), Brunel University of London, Uxbridge, Middlesex UB8 3PH, UKAluminium alloy 6082 is widely used in the automotive and aerospace industries due to its high strength-to-weight ratio. However, its structural integrity can sometimes be affected by an early fatigue failure. This study investigates the fatigue performance of extruded 6082-T6 samples through a series of fatigue tests conducted at varying stress levels. The material showed significant variability under identical fatigue conditions, suggesting the presence of microstructural defects. Scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS) and scanning transmission electron microscopy (S/TEM) were used to identify the nature and location of the defects and evaluate the underlying mechanisms influencing the fatigue performance. Computer tomography (CT) also confirmed the presence of oxide inclusions on the fracture surface and near the edges of the samples. These oxide inclusions are distributed throughout the material heterogeneously and in the form of broken oxide films, suggesting that they might have originated during the material’s early processing stages. These oxides acted as stress concentrators, initiating microcracks that led to catastrophic and unpredictable early failure, ultimately reducing the fatigue life of micro-oxide-containing samples. These results highlight the need for better casting control and improved post-processing techniques to minimise the effect of oxide presence in the final components, thus enhancing their fatigue life.https://www.mdpi.com/2504-4494/9/7/247aluminium alloy 6082extrusionfatigue lifefractureoxidesmicrostructural characterisation |
| spellingShingle | Viththagan Vivekanandam Shubham Sanjay Joshi Jaime Lazaro-Nebreda Zhongyun Fan Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded Components Journal of Manufacturing and Materials Processing aluminium alloy 6082 extrusion fatigue life fracture oxides microstructural characterisation |
| title | Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded Components |
| title_full | Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded Components |
| title_fullStr | Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded Components |
| title_full_unstemmed | Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded Components |
| title_short | Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded Components |
| title_sort | effect of processing induced oxides on the fatigue life variability of 6082 al mg si alloy extruded components |
| topic | aluminium alloy 6082 extrusion fatigue life fracture oxides microstructural characterisation |
| url | https://www.mdpi.com/2504-4494/9/7/247 |
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