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Sample records for strength aluminum casting

  1. Metallic Reinforcement of Direct Squeeze Die Casting Aluminum Alloys for Improved Strength and Fracture Resistance

    Energy Technology Data Exchange (ETDEWEB)

    D. Schwam: J.F. Wallace: Y. Zhu: J.W. Ki

    2004-10-01

    obtained with unreinforced 356 aluminum casting. Good strength can be obtained with a sound die casting without any defects produced by squeeze casting. The use of higher pressure to produce the squeeze casting has been shown to increase the strength of a hemispherical dome casting. This dome shape casting has been produced both with and without reinforcement and tested to determine its pressure resistance under internal pressure of water. Only a slight improvement in strength could be determined because of water leaks at the seal between hemispherical dome and its flat supporting side. However, when the ability of the casting was tested under the compressive force of a plunger, the strengthening effect of wire mesh or sheet was evident. Higher loads to failure were obtained because of the reinforcement of the stainless steel wire and punched sheet. Rather than a sudden failure occurring, the reinforcement of the stainless steel wire or the punched hard stainless steel sheet held the material together and prevented any loss of the fractured casting to the surroundings. Unalloyed steel did not have the required strength or mechanical properties to increase the properties of the casting.

  2. Beryllium-aluminum alloys for investment castings

    International Nuclear Information System (INIS)

    Nachtrab, W.T.; Levoy, N.

    1997-01-01

    Beryllium-aluminum alloys containing greater than 60 wt % beryllium are very favorable materials for applications requiring light weight and high stiffness. However, when produced by traditional powder metallurgical methods, these alloys are expensive and have limited applications. To reduce the cost of making beryllium-aluminum components, Nuclear Metals Inc. (NMI) and Lockheed Martin Electronics and Missiles have recently developed a family of patented beryllium-aluminum alloys that can be investment cast. Designated Beralcast, the alloys can achieve substantial weight savings because of their high specific strength and stiffness. In some cases, weight has been reduced by up to 50% over aluminum investment casting. Beralcast is now being used to make thin wall precision investment castings for several advanced aerospace applications, such as the RAH-66 Comanche helicopter and F-22 jet fighter. This article discusses alloy compositions, properties, casting method, and the effects of cobalt additions on strength

  3. Reinforcement of Aluminum Castings with Dissimilar Metals

    Energy Technology Data Exchange (ETDEWEB)

    Han, Q

    2004-01-07

    The project ''Reinforcement of Aluminum Casting with Dissimilar Metal'' was a Cooperative Research and Development Agreements (CRADAs) between Oak Ridge National Laboratory (ORNL) and Cummins Inc. This project, technologies have been developed to reinforce aluminum castings with steel insert. Defect-free bond between the steel insert and the aluminum casting has been consistently obtained. The push-out experiment indicated that the bond strength is higher than that of the Al-Fin method. Two patents have been granted to the project team that is comprised of Cummins Inc. and ORNL. This report contains four sections: the coating of the steel pins, the cast-in method, microstructure characterization, and the bond strength. The section of the coating of the steel pins contains coating material selection, electro-plating technique for plating Cu and Ni on steel, and diffusion bonding of the coatings to the steel. The section of cast-in method deals with factors that affecting the quality of the metallurgical bond between the coated steel and the aluminum castings. The results of microstructure characteristics of the bonding are presented in the microstructure characterization section. A push-out experiment and the results obtained using this method is described in the section of bond strength/mechanical property.

  4. Manufacturing of aluminum composite material using stir casting process

    International Nuclear Information System (INIS)

    Jokhio, M.H.; Panhwar, M.I.; Unar, M.A.

    2011-01-01

    Manufacturing of aluminum alloy based casting composite materials via stir casting is one of the prominent and economical route for development and processing of metal matrix composites materials. Properties of these materials depend upon many processing parameters and selection of matrix and reinforcements. Literature reveals that most of the researchers are using 2, 6 and 7 xxx aluminum matrix reinforced with SiC particles for high strength properties whereas, insufficient information is available on reinforcement of 'AI/sub 2/O/sub 3/' particles in 7 xxx aluminum matrix. The 7 xxx series aluminum matrix usually contains Cu-Zn-Mg; Therefore, the present research was conducted to investigate the effect of elemental metal such as Cu-Zn-Mg in aluminum matrix on mechanical properties of stir casting of aluminum composite materials reinforced with alpha 'AI/sub 2/O/sub 3/' particles using simple foundry melting alloying and casting route. The age hardening treatments were also applied to study the aging response of the aluminum matrix on strength, ductility and hardness. The experimental results indicate that aluminum matrix cast composite can be manufactured via conventional foundry method giving very good responses to the strength and ductility up to 10% 'AI/sub 2/O/sub 3/' particles reinforced in aluminum matrix. (author)

  5. Manufacturing of Aluminum Composite Material Using Stir Casting Process

    Directory of Open Access Journals (Sweden)

    Muhammad Hayat Jokhio

    2011-01-01

    Full Text Available Manufacturing of aluminum alloy based casting composite materials via stir casting is one of the prominent and economical route for development and processing of metal matrix composites materials. Properties of these materials depend upon many processing parameters and selection of matrix and reinforcements. Literature reveals that most of the researchers are using 2, 6 and 7xxx aluminum matrix reinforced with SiC particles for high strength properties whereas, insufficient information is available on reinforcement of \\"Al2O3\\" particles in 7xxx aluminum matrix. The 7xxx series aluminum matrix usually contains Cu-Zn-Mg. Therefore, the present research was conducted to investigate the effect of elemental metal such as Cu-Zn-Mg in aluminum matrix on mechanical properties of stir casting of aluminum composite materials reinforced with alpha \\"Al2O3\\" particles using simple foundry melting alloying and casting route. The age hardening treatments were also applied to study the aging response of the aluminum matrix on strength, ductility and hardness. The experimental results indicate that aluminum matrix cast composite can be manufactured via conventional foundry method giving very good responses to the strength and ductility up to 10% \\"Al2O3\\" particles reinforced in aluminum matrix.

  6. Microstructures and properties of aluminum die casting alloys

    Energy Technology Data Exchange (ETDEWEB)

    M. M. Makhlouf; D. Apelian; L. Wang

    1998-10-01

    This document provides descriptions of the microstructure of different aluminum die casting alloys and to relate the various microstructures to the alloy chemistry. It relates the microstructures of the alloys to their main engineering properties such as ultimate tensile strength, yield strength, elongation, fatigue life, impact resistance, wear resistance, hardness, thermal conductivity and electrical conductivity. Finally, it serves as a reference source for aluminum die casting alloys.

  7. High strength cast aluminum alloy development

    Science.gov (United States)

    Druschitz, Edward A.

    The goal of this research was to understand how chemistry and processing affect the resulting microstructure and mechanical properties of high strength cast aluminum alloys. Two alloy systems were investigated including the Al-Cu-Ag and the Al-Zn-Mg-Cu systems. Processing variables included solidification under pressure (SUP) and heat treatment. This research determined the range in properties that can be achieved in BAC 100(TM) (Al-Cu micro-alloyed with Ag, Mn, Zr, and V) and generated sufficient property data for design purposes. Tensile, stress corrosion cracking, and fatigue testing were performed. CuAl2 and Al-Cu-Fe-Mn intermetallics were identified as the ductility limiting flaws. A solution treatment of 75 hours or longer was needed to dissolve most of the intermetallic CuAl 2. The Al-Cu-Fe-Mn intermetallic was unaffected by heat treatment. These results indicate that faster cooling rates, a reduction in copper concentration and a reduction in iron concentration might increase the ductility of the alloy by decreasing the size and amount of the intermetallics that form during solidification. Six experimental Al-Zn-Mg-Cu series alloys were produced. Zinc concentrations of 8 and 12wt% and Zn/Mg ratios of 1.5 to 5.5 were tested. Copper was held constant at 0.9%. Heat treating of the alloys was optimized for maximum hardness. Al-Zn-Mg-Cu samples were solution treated at 441°C (826°F) for 4 hours before ramping to 460°C (860°F) for 75 hours and then aged at 120°C (248°F) for 75 hours. X-ray diffraction showed that the age hardening precipitates in most of these alloys was the T phase (Mg32Zn 31.9Al17.1). Tensile testing of the alloys showed that the best mechanical properties were obtained in the lowest alloy condition. Chilled Al-8.2Zn-1.4Mg-0.9Cu solidified under pressure resulted in an alloy with a yield strength of 468MPa (68ksi), tensile strength of 525MPa (76ksi) and an elongation of 9%.

  8. Hot forging of roll-cast high aluminum content magnesium alloys

    Science.gov (United States)

    Kishi, Tomohiro; Watari, Hisaki; Suzuki, Mayumi; Haga, Toshio

    2017-10-01

    This paper reports on hot forging of high aluminum content magnesium alloy sheets manufactured using horizontal twin-roll casting. AZ111 and AZ131 were applied for twin-roll casting, and a hot-forging test was performed to manufacture high-strength magnesium alloy components economically. For twin-roll casting, the casting conditions of a thick sheet for hot forging were investigated. It was found that twin-roll casting of a 10mm-thick magnesium alloy sheet was possible at a roll speed of 2.5m/min. The grain size of the cast strip was 50 to 70µm. In the hot-forging test, blank material was obtained from as-cast strip. A servo press machine with a servo die cushion was used to investigate appropriate forging conditions (e.g., temperature, forging load, and back pressure) for twin-roll casts (TRCs) AZ111 and AZ131. It was determined that high aluminum content magnesium alloy sheets manufactured using twin-roll casting could be forged with a forging load of 150t and a back pressure of 3t at 420 to 430°C. Applying back pressure during hot forging effectively forged a pin-shaped product.

  9. Production of A356 aluminum alloy wheels by thixo-forging combined with a low superheat casting process

    Directory of Open Access Journals (Sweden)

    Wang Shuncheng

    2013-09-01

    Full Text Available The A356 aluminum alloy wheels were produced by thixo-forging combined with a low superheat casting process. The as-cast microstructure, microstructure evolution during reheating and the mechanical properties of thixo-forged wheels made from the A356 aluminum alloy were studied. The results show that the A356 aluminum alloy round billet with fine, uniform and non-dendritic grains can be obtained when the melt is cast at 635 篊. When the round billet is reheated at 600 篊 for 60 min, the non-dendritic grains are changed into spherical ones and the round billet can be easily thixo-forged into wheels. The tensile strength, yield strength and elongation of the thixo-forged wheels with T6 heat treatment are 327.6 MPa, 228.3 MPa and 7.8%, respectively, which are higher than those of a cast wheel. It is suggested that the thixo-forging combined with the low superheat casting process is an effective technique to produce aluminum alloy wheels with high mechanical properties.

  10. Lost foam casting of aluminum alloy-SiCp composite material

    International Nuclear Information System (INIS)

    Baalasuburamaniam, R.; Cvetnic, C.; Ravindran, C.

    2002-01-01

    Metal matrix composites are a viable alternative to cast irons in automotive components with possible increase in strength-to-weight ratio. Lost foam casting of aluminum alloy matrix composite containing 20 volume percent SiC was carried out at 690, 730, and 770 o C with a view to determining the effects of cooling rate on microstructure, particle distribution, microporosity and mechanical properties. These results were compared with those for the matrix material cast under similar conditions. The results and the correlations are of particular interest as there is no published literature on lost foam casting of composite materials. (author)

  11. High-Temperature Cast Aluminum for Efficient Engines

    Science.gov (United States)

    Bobel, Andrew C.

    Accurate thermodynamic databases are the foundation of predictive microstructure and property models. An initial assessment of the commercially available Thermo-Calc TCAL2 database and the proprietary aluminum database of QuesTek demonstrated a large degree of deviation with respect to equilibrium precipitate phase prediction in the compositional region of interest when compared to 3-D atom probe tomography (3DAPT) and transmission electron microscopy (TEM) experimental results. New compositional measurements of the Q-phase (Al-Cu-Mg-Si phase) led to a remodeling of the Q-phase thermodynamic description in the CALPHAD databases which has produced significant improvements in the phase prediction capabilities of the thermodynamic model. Due to the unique morphologies of strengthening precipitate phases commonly utilized in high-strength cast aluminum alloys, the development of new microstructural evolution models to describe both rod and plate particle growth was critical for accurate mechanistic strength models which rely heavily on precipitate size and shape. Particle size measurements through both 3DAPT and TEM experiments were used in conjunction with literature results of many alloy compositions to develop a physical growth model for the independent prediction of rod radii and rod length evolution. In addition a machine learning (ML) model was developed for the independent prediction of plate thickness and plate diameter evolution as a function of alloy composition, aging temperature, and aging time. The developed models are then compared with physical growth laws developed for spheres and modified for ellipsoidal morphology effects. Analysis of the effect of particle morphology on strength enhancement has been undertaken by modification of the Orowan-Ashby equation for 〈110〉 alpha-Al oriented finite rods in addition to an appropriate version for similarly oriented plates. A mechanistic strengthening model was developed for cast aluminum alloys containing

  12. Development Program for Natural Aging Aluminum Casting Alloys

    Energy Technology Data Exchange (ETDEWEB)

    Dr. Geoffrey K. Sigworth

    2004-05-14

    A number of 7xx aluminum casting alloys are based on the ternary Al-Zn-Mg system. These alloys age naturally to high strength at room temperature. A high temperature solution and aging treatment is not required. Consequently, these alloys have the potential to deliver properties nearly equivalent to conventional A356-T6 (Al-Si-Mg) castings, with a significant cost saving. An energy savings is also possible. In spite of these advantages, the 7xx casting alloys are seldom used, primarily because of their reputation for poor castibility. This paper describes the results obtained in a DOE-funded research study of these alloys, which is part of the DOE-OIT ''Cast Metals Industries of the Future'' Program. Suggestions for possible commercial use are also given.

  13. Casting Characteristics of High Cerium Content Aluminum Alloys

    Energy Technology Data Exchange (ETDEWEB)

    Weiss, D; Rios, O R; Sims, Z C; McCall, S K; Ott, R T

    2017-09-05

    This paper compares the castability of the near eutectic aluminum-cerium alloy system to the aluminum-silicon and aluminum-copper systems. The alloys are compared based on die filling capability, feeding characteristics and tendency to hot tear in both sand cast and permanent mold applications. The castability ranking of the binary Al–Ce systems is as good as the aluminum-silicon system with some deterioration as additional alloying elements are added. In alloy systems that use cerium in combination with common aluminum alloying elements such as silicon, magnesium and/or copper, the casting characteristics are generally better than the aluminum-copper system. In general, production systems for melting, de-gassing and other processing of aluminum-silicon or aluminum-copper alloys can be used without modification for conventional casting of aluminum-cerium alloys.

  14. Determining casting defects in near-net shape casting aluminum parts by computed tomography

    Science.gov (United States)

    Li, Jiehua; Oberdorfer, Bernd; Habe, Daniel; Schumacher, Peter

    2018-03-01

    Three types of near-net shape casting aluminum parts were investigated by computed tomography to determine casting defects and evaluate quality. The first, second, and third parts were produced by low-pressure die casting (Al-12Si-0.8Cu-0.5Fe-0.9Mg-0.7Ni-0.2Zn alloy), die casting (A356, Al-7Si-0.3Mg), and semi-solid casting (A356, Al-7Si-0.3Mg), respectively. Unlike die casting (second part), low-pressure die casting (first part) significantly reduced the formation of casting defects (i.e., porosity) due to its smooth filling and solidification under pressure. No significant casting defect was observed in the third part, and this absence of defects indicates that semi-solid casting could produce high-quality near-net shape casting aluminum parts. Moreover, casting defects were mostly distributed along the eutectic grain boundaries. This finding reveals that refinement of eutectic grains is necessary to optimize the distribution of casting defects and reduce their size. This investigation demonstrated that computed tomography is an efficient method to determine casting defects in near-net shape casting aluminum parts.

  15. High strength aluminum cast alloy: A Sc modification of a standard Al–Si–Mg cast alloy

    Energy Technology Data Exchange (ETDEWEB)

    Muhammad, Arfan, E-mail: engr.arfan@gmail.com [Key Laboratory of Aerospace Advanced Materials and Performance of Ministry of Education, School of Material Science and Engineering, Beihang University, Beijing 100191 (China); Xu, Cong; Xuejiao, Wang [Key Laboratory of Aerospace Advanced Materials and Performance of Ministry of Education, School of Material Science and Engineering, Beihang University, Beijing 100191 (China); Hanada, Shuji [Institute for Materials Research, Tohoku University, Sendai 980-8577 (Japan); Yamagata, Hiroshi [Center for Advanced Die Engineering and Technology, Gifu University, 1-1 Yanagido, Gifu City, Gifu 501-1193 (Japan); Hao, LiRong [Hebei Sitong New Metal Material Co., Ltd., Baoding 071105 (China); Chaoli, Ma [Key Laboratory of Aerospace Advanced Materials and Performance of Ministry of Education, School of Material Science and Engineering, Beihang University, Beijing 100191 (China)

    2014-05-01

    A standard Aluminum–Silicon–Magnesium cast alloy (A357 foundry alloy without Beryllium) modified with different weight percentages of Scandium (Sc), has been studied to evaluate the effects of Sc contents on microstructure and strength. Study has been conducted under optimized parameters of melting, casting and heat treatment. Characterization techniques like optical microscopy, SEM, TEM and tensile testing were employed to analyze the microstructure and mechanical properties. Results obtained in this research indicate that with the increase of Sc contents up to 0.4 wt%, grain size is decreased by 80% while ultimate tensile strength and hardness are increased by 28% and 19% respectively. Moreover along with the increase in strength, elongation to failure is also increased up to 165%. This is quite interesting behavior because usually strength and ductility have inverse relationship.

  16. 40 CFR 464.10 - Applicability; description of the aluminum casting subcategory.

    Science.gov (United States)

    2010-07-01

    ... aluminum casting subcategory. 464.10 Section 464.10 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Aluminum Casting Subcategory § 464.10 Applicability; description of the aluminum casting subcategory. The...

  17. Strength and Ductility of Forged 1200 Aluminum Alloy Reinforced ...

    African Journals Online (AJOL)

    With 50% reduction and fine-sized steel particles (512μm) in aluminum alloy, tensile strength dropped to 160MPa without significant decrease in ductility (1.7). Microstructure of cast samples show the presence of fine Fe particles at grain boundaries after annealing with most of the particles in solid solution. Al3Fe and AlFeSi ...

  18. Effects of Eutectic Si Particles on Mechanical Properties and Fracture Toughness of Cast A356 Aluminum Alloys

    International Nuclear Information System (INIS)

    Lee, Kyu Hong; Lee, Sung Hak; Kwon, Yong Nam

    2007-01-01

    The present study aims at investigating the effects of eutectic Si particles on mechanical properties and fracture toughness of three A356 aluminum alloys. These A356 alloys were fabricated by casting processes such as rheo-casting, squeeze-casting, and casting-forging, and their mechanical properties and fracture toughness were analyzed in relation with microfracture mechanism study. All the cast A356 alloys contained eutectic Si particles mainly segregated along solidification cells, and the distribution of Si particles was modified by squeeze-casting and casting-forging processes. Microfracture observation results showed that eutectic Si particles segregated along cells were cracked first, but that aluminum matrix played a role in blocking crack propagation. Tensile properties and fracture toughness of the squeeze cast and cast-forged alloys having homogeneous distribution of eutectic Si particles were superior to those of the rheo-cast alloy. In particular, the cast-forged alloy had excellent hardness, strength, ductility, and fracture toughness because of the matrix strengthening and homogeneous distribution of eutectic Si particles due to forging process

  19. Modeling mechanical properties of cast aluminum alloy using artificial neural network

    International Nuclear Information System (INIS)

    Jokhio, M.H.; Panhwar, M.I.

    2009-01-01

    Modeling is widely used to investigate the mechanical properties of engineering materials due to increasing demand of low cost and high strength to weight ratio for many engineering applications. The aluminum casting alloys are cost competitive material and possess the desired properties. The mechanical properties largely depend upon composition of alloys and their processing method. Alloy design involves controlling mechanical properties via optimization of the composition and processing parameters. For optimization the possible root is empirical modeling and its more refined version is the analysis of the wide range of data using ANN (Artificial Neural Networks) modeling. The modeling of mechanical properties of the aluminum alloys are the main objective of present work. For this purpose, some data were collected and experimentally prepared using conventional casting method. A MLP (Multilayer Perceptron) network was developed, which is trained by using the error back propagation algorithm. (author)

  20. Optimization of Casting Design Parameters on Fabrication of Reliable Semi-Solid Aluminum Suspension Control Arm

    Science.gov (United States)

    Ragab, Kh. A.; Bouaicha, A.; Bouazara, M.

    2017-09-01

    The semi-solid casting process has the advantage of providing reliable mechanical aluminum parts that work continuously in dynamic as control arm of the suspension system in automotive vehicles. The quality performance of dynamic control arm is related to casting mold and gating system designs that affect the fluidity of semi-solid metal during filling the mold. Therefore, this study focuses on improvement in mechanical performance, depending on material characterization, and casting design optimization, of suspension control arms made of A357 aluminum semi-solid alloys. Mechanical and design analyses, applied on the suspension arm, showed the occurrence of mechanical failures at unexpected weak points. Metallurgical analysis showed that the main reason lies in the difficult flow of semi-solid paste through the thin thicknesses of a complex geometry. A design modification procedure is applied to the geometry of the suspension arm to avoid this problem and to improve its quality performance. The design modification of parts was carried out by using SolidWorks design software, evaluation of constraints with ABAQUS, and simulation of flow with ProCast software. The proposed designs showed that the modified suspension arm, without ribs and with a central canvas designed as Z, is considered as a perfect casting design showing an increase in the structural strength of the component. In this case, maximum von Mises stress is 199 MPa that is below the yield strength of the material. The modified casting mold design shows a high uniformity and minim turbulence of molten metal flow during semi-solid casting process.

  1. Cast Aluminum Alloys for High Temperature Applications Using Nanoparticles Al2O3 and Al3-X Compounds (X = Ti, V, Zr)

    Science.gov (United States)

    Lee, Jonathan A.

    2009-01-01

    In this paper, the effect of nanoparticles Al2O3 and Al3-X compounds (X = Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their low cost, chemical stability and low diffusions rates in aluminum at high temperatures. The strengthening mechanism at high temperature for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. For Al2O3 nanoparticles, the test samples were prepared from special Al2O3 preforms, which were produced using ceramic injection molding process and then pressure infiltrated by molten aluminum. In another method, Al2O3 nanoparticles can also be homogeneously mixed with fine aluminum powder and consolidated into test samples through hot pressing and sintering. With the Al3-X nanoparticles, the test samples are produced as precipitates from in-situ reactions with molten aluminum using conventional permanent mold or die casting techniques. It is found that cast aluminum alloy using nanoparticles Al3-X is the most cost effective method to produce high strength aluminum alloys for high temperature applications in comparison to nanoparticles Al2O3. Furthermore, significant mechanical properties retention in high temperature environment could be achieved with Al3-X nanoparticles, resulting in tensile strength of nearly 3 times higher than most 300- series conventional cast aluminum alloys tested at 600 F.

  2. Rotary bending fatigue behavior of A356 –T6 aluminum alloys by vacuum pressurizing casting

    Directory of Open Access Journals (Sweden)

    Yong-qin Liu

    2015-09-01

    Full Text Available Vacuum pressurizing casting technique, providing better mould filling and inter-dendritic feeding, can reduce the porosity greatly in cast aluminum alloys, and improve the fatigue properties. The rotary bending fatigue properties of A356-T6 alloys prepared by vacuum pressurizing casting were investigated. The S-N curve and limit strength 90 MPa under fatigue life of 107 cycles were obtained. The analyses on the fatigue fractography and microstructure of specimens showed that the fatigue fracture mainly occurs at the positions with casting defects in the subsurface, especially at porosities regions, which attributed to the crack propagation during the fatigue fracture process. Using the empirical crack propagation law of Pairs-Erdogon, the quantitative relationship among the initial crack size, fatigue life and applied stress was established. The fatigue life decreases with an increase in initial crack size. Two constants in the Pairs-Erdogon equation of aluminum alloy A356-T6 were calculated using the experimental data.

  3. Evaluation and Characterization of In-Line Annealed Continuous Cast Aluminum Sheet

    Energy Technology Data Exchange (ETDEWEB)

    Dr Subodh K. Das

    2006-01-17

    This R&D program will develop optimized, energy-efficient thermo-mechanical processing procedures for in-line annealing of continuously cast hot bands of two 5000 series aluminum alloys (5754 and 5052). The implementation of the R&D will result in the production of sheet with improved formability at high levels of productivity consistency and quality. The proposed R&D involves the following efforts: (1) Design and build continuous in-line annealing equipment for plant-scale trials; (2) Carry out plant-scale trials at Commonwealth Aluminum Corp.'s (CAC) plant in Carson; (3) Optimize the processing variables utilizing a metallurgical model for the kinetics of microstructure and texture evolution during thermo-mechanical processing; (4) Determine the effects of processing variables on the microstructure, texture, mechanical properties, and formability of aluminum sheet; (5) Develop design parameters for commercial implementation; and (6) Conduct techno-economic studies of the recommended process equipment to identify impacts on production costs. The research and development is appropriate for the domestic industry as it will result in improved aluminum processing capabilities and thus lead to greater application of aluminum in various industries including the automotive market. A teaming approach is critical to the success of this effort as no single company alone possesses the breadth of technical and financial resources for successfully carrying out the effort. This program will enable more energy efficient aluminum sheet production technology, produce consistent high quality product, and have The proposal addresses the needs of the aluminum industry as stated in the aluminum industry roadmap by developing new and improved aluminum processes utilizing energy efficient techniques. The effort is primarily related to the subsection on Rolling and Extrusion with the R&D to address energy and environmental efficiencies in aluminum manufacturing and will provide

  4. Standard digital reference images for inspection of aluminum castings

    CERN Document Server

    American Society for Testing and Materials. Philadelphia

    2005-01-01

    1.1 These digital reference images illustrate the types and degrees of discontinuities that may be found in aluminum-alloy castings. The castings illustrated are in thicknesses of 1/ 4 in. [6.35 mm] and 3/4 in. [19.1mm]. 1.2 All areas of this standard may be open to agreement between the cognizant engineering organization and the supplier, or specific direction from the cognizant engineering organization. These items should be addressed in the purchase order or the contract. 1.3 The values stated in inch-pound units are to be regarded as standard. 1.4 These digital reference images are not intended to illustrate the types and degrees of discontinuities found in aluminum-alloy castings when performing film radiography. If performing film radiography of aluminum-alloy castings, refer to Reference Radiographs E 155. This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and he...

  5. Improved design and durability of aluminum die casting horizontal shot sleeves

    Science.gov (United States)

    Birceanu, Sebastian

    The design and performance of shot sleeves is critical in meeting the engineering requirements of aluminum die cast parts. Improvement in shot sleeve materials have a major impact on dimensional stability, reproducibility and quality of the product. This investigation was undertaken in order to improve the life of aluminum die casting horizontal shot sleeves. Preliminary pin tests were run to evaluate the soldering, wash-out and thermal fatigue behavior of commercially available materials and coatings. An experimental rig was designed and constructed for shot sleeve configuration evaluation. Fabrication and testing of experimental shot sleeves was based upon preliminary results and manufacturing costs. Three shot sleeve designs and materials were compared to a reference nitrided H13 sleeve. Nitrided H13 is the preferred material for aluminum die casting shot sleeves because of wear resistance, strength and relative good soldering and wash-out resistance. The study was directed towards damage evaluation on the area under the pouring hole. This area is the most susceptible to damage because of high temperatures and impingement of molten aluminum. The results of this study showed that tungsten and molybdenum had the least amount of soldering and wash-out damage, and the best thermal fatigue resistance. Low solubility in molten aluminum and stability of intermetallic layers are main factors that determine the soldering and wash-out behavior. Thermal conductivity and thermal expansion coefficient directly influence thermal fatigue behavior. TiAlN nanolayered coating was chosen as the material with the best damage resistance among several commercial PVD coatings, because of relatively large thickness and simple deposition conditions. The results show that molybdenum thermal sprayed coating provided the best protection against damage under the pouring hole. Improved bonding is however required for life extension of the coating. TiAlN PVD coating applied on H13 nitrided

  6. Modeling Mechanical Properties of Aluminum Composite Produced Using Stir Casting Method

    Directory of Open Access Journals (Sweden)

    Muhammad Hayat Jokhio

    2011-01-01

    Full Text Available ANN (Artificial Neural Networks modeling methodology was adopted for predicting mechanical properties of aluminum cast composite materials. For this purpose aluminum alloy were developed using conventional foundry method. The composite materials have complex nature which posses the nonlinear relationship among heat treatment, processing parameters, and composition and affects their mechanical properties. These nonlinear relation ships with properties can more efficiently be modeled by ANNs. Neural networks modeling needs sufficient data base consisting of mechanical properties, chemical composition and processing parameters. Such data base is not available for modeling. Therefore, a large range of experimental work was carried out for the development of aluminum composite materials. Alloys containing Cu, Mg and Zn as matrix were reinforced with 1- 15% Al2O3 particles using stir casting method. Alloys composites were cast in a metal mold. More than eighty standard samples were prepared for tensile tests. Sixty samples were given solution treatments at 580oC for half an hour and tempered at 120oC for 24 hours. The samples were characterized to investigate mechanical properties using Scanning Electron Microscope, X-Ray Spectrometer, Optical Metallurgical Microscope, Vickers Hardness, Universal Testing Machine and Abrasive Wear Testing Machine. A MLP (Multilayer Perceptron feedforward was developed and used for modeling purpose. Training, testing and validation of the model were carried out using back propagation learning algorithm. The modeling results show that an architecture of 14 inputs with 9 hidden neurons and 4 outputs which includes the tensile strength, elongation, hardness and abrasive wear resistance gives reasonably accurate results with an error within the range of 2-7 % in training, testing and validation.

  7. Modeling mechanical properties of aluminum composite produced using stir casting method

    International Nuclear Information System (INIS)

    Jokhio, M.H.; Panhwar, M.I.; Unar, M.A.

    2011-01-01

    ANN (Artificial Neural Networks) modeling methodology was adopted for predicting mechanical properties of aluminum cast composite materials. For this purpose aluminum alloy were developed using conventional foundry method. The composite materials have complex nature which posses the nonlinear relationship among heat treatment, processing parameters, and composition and affects their mechanical properties. These nonlinear relation ships with properties can more efficiently be modeled by ANNs. Neural networks modeling needs sufficient data base consisting of mechanical properties, chemical composition and processing parameters. Such data base is not available for modeling. Therefore, a large range of experimental work was carried out for the development of aluminum composite materials. Alloys containing Cu, Mg and Zn as matrix were reinforced with 1- 15% AI/sub 2/O/sub 3/ particles using stir casting method. Alloys composites were cast in a metal mold. More than eighty standard samples were prepared for tensile tests. Sixty samples were given solution treatments at 580 deg. C for half an hour and tempered at 120 deg. C for 24 hours. The samples were characterized to investigate mechanical properties using Scanning Electron Microscope, X-Ray Spectrometer, Optical Metallurgical Microscope, Vickers Hardness, Universal Testing Machine and Abrasive Wear Testing Machine. A MLP (Multilayer Perceptron) feed forward was developed and used for modeling purpose. Training, testing and validation of the model were carried out using back propagation learning algorithm. The modeling results show that an architecture of 14 inputs with 9 hidden neurons and 4 outputs which includes the tensile strength, elongation, hardness and abrasive wear resistance gives reasonably accurate results with an error within the range of 2-7 % in training, testing and validation. (author)

  8. Ultrasonic maps of porosity in aluminum castings

    International Nuclear Information System (INIS)

    Ghaffari, Bita; Potter, Timothy J.; Mozurkewich, George

    2002-01-01

    The use of cast aluminum in the automotive industry has grown dramatically in recent years, leading to increased need for quantitative characterization of microporosity. As previously reported in the literature, the attenuation of ultrasound can be used to measure the porosity volume fraction and the mean pore size. An immersion ultrasound system has been built utilizing this technique to scan castings with high spatial resolution. Maps of attenuation are shown to locate areas of varying porosity readily and reliably

  9. High strength corrosion-resistant zirconium aluminum alloys

    International Nuclear Information System (INIS)

    Schulson, E.M.; Cameron, D.J.

    1976-01-01

    A zirconium-aluminum alloy is described possessing superior corrosion resistance and mechanical properties. This alloy, preferably 7.5-9.5 wt% aluminum, is cast, worked in the Zr(Al)-Zr 2 Al region, and annealed to a substantially continuous matrix of Zr 3 Al. (E.C.B.)

  10. Cast and hipped gamma titanium aluminum alloys modified by chromium, boron, and tantalum

    International Nuclear Information System (INIS)

    Huang, Shyhchin.

    1993-01-01

    A cast body is described of a chromium, boron, and tantalum modified titanium aluminum alloy, said alloy consisting essentially of titanium, aluminum, chromium, boron, and tantalum in the following approximate atomic ratio: Ti-Al 45-50 Cr 1-3 Ta 1-8 B 0.1-0.3 , and said alloy having been prepared by casting the alloy to form said cast body and by HIPping said body

  11. Evaluation of microstructure of A356 aluminum alloy casting ...

    Indian Academy of Sciences (India)

    The objective of this investigation was to evaluate the effect of vibrations (during solidification) on the metallurgical properties of A356 aluminum casting. Mechanical vibrations were applied to A356 aluminum alloy through set up. A356 melt has been subjected to mechanical vibration with the frequency range from 0 to 400 ...

  12. Quality Management and Control of Low Pressure Cast Aluminum Alloy

    Science.gov (United States)

    Zhang, Dianxi; Zhang, Yanbo; Yang, Xiufan; Chen, Zhaosong; Jiang, Zelan

    2018-01-01

    This paper briefly reviews the history of low pressure casting and summarizes the major production processes of low pressure casting. It briefly introduces the quality management and control of low pressure cast aluminum alloy. The main processes include are: preparation of raw materials, Melting, refining, physical and chemical analysis, K-mode inspection, sand core, mold, heat treatment and so on.

  13. 3D scanning based mold correction for planar and cylindrical parts in aluminum die casting

    Directory of Open Access Journals (Sweden)

    Takashi Seno

    2015-04-01

    Full Text Available Aluminum die casting is an important manufacturing process for mechanical components. Die casting is known to be more accurate than other types of casting; however, post-machining is usually necessary to achieve the required accuracy. The goal of this investigation is to develop machining- free aluminum die casting. Improvement of the accuracy of planar and cylindrical parts is expected by correcting metal molds. In the proposed method, the shape of cast aluminum made with the initial metal molds is measured by 3D scanning. The 3D scan data includes information about deformations that occur during casting. Therefore, it is possible to estimate the deformation and correction amounts by comparing 3D scan data with product computer-aided design (CAD data. We corrected planar and cylindrical parts of the CAD data for the mold. In addition, we corrected the planar part of the metal mold using the corrected mold data. The effectiveness of the proposed method is demonstrated by evaluating the accuracy improvement of the cast aluminum made with the corrected mold.

  14. Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Light Metals Permanent Mold Casting

    Energy Technology Data Exchange (ETDEWEB)

    Fasoyinu, Yemi [CanmetMATERIALS

    2014-03-31

    Current vehicles use mostly ferrous components for structural applications. It is possible to reduce the weight of the vehicle by substituting these parts with those made from light metals such as aluminum and magnesium. Many alloys and manufacturing processes can be used to produce these light metal components and casting is known to be most economical. One of the high integrity casting processes is permanent mold casting which is the focus of this research report. Many aluminum alloy castings used in automotive applications are produced by the sand casting process. Also, aluminum-silicon (Al-Si) alloys are the most widely used alloy systems for automotive applications. It is possible that by using high strength aluminum alloys based on an aluminum-copper (Al-Cu) system and permanent mold casting, the performance of these components can be enhanced significantly. This will also help to further reduce the weight. However, many technological obstacles need to be overcome before using these alloys in automotive applications in an economical way. There is very limited information in the open literature on gravity and low-pressure permanent mold casting of high strength aluminum alloys. This report summarizes the results and issues encountered during the casting trials of high strength aluminum alloy 206.0 (Al-Cu alloy) and moderate strength alloy 535.0 (Al-Mg alloy). Five engineering components were cast by gravity tilt-pour or low pressure permanent mold casting processes at CanmetMATERIALS (CMAT) and two production foundries. The results of the casting trials show that high integrity engineering components can be produced successfully from both alloys if specific processing parameters are used. It was shown that a combination of melt processing and mold temperature is necessary for the elimination of hot tears in both alloys.

  15. Multiscale modeling for the prediction of casting defects in investment cast aluminum alloys

    International Nuclear Information System (INIS)

    Hamilton, R.W.; See, D.; Butler, S.; Lee, P.D.

    2003-01-01

    Macroscopic modeling of heat transfer and fluid flow is now routinely used for the prediction of macroscopic defects in castings, while microscopic models are used to investigate the effects of alloy changes on typical microstructures. By combining these two levels of modeling it is possible to simulate the casting process over a wider range of spatial and temporal scales. This paper presents a multiscale model where micromodels for dendrite arm spacing and microporosity are incorporated into a macromodel of heat transfer and in order to predict the as cast microstructure and prevalence of microscopic defects, specifically porosity. The approach is applied to aluminum alloy (L169) investment castings. The models are compared with results obtained by optical image analysis of prepared slices, and X-ray tomography of volume samples from the experiments. Multiscale modeling is shown to provide the designer with a useful tool to improve the properties of the final casting by testing how altering the casting process affects the final microstructure including porosity

  16. Effect of zirconium addition on the ductility and toughness of cast zinc-aluminum alloy5, zamak5, grain refined by titanium plus boron

    International Nuclear Information System (INIS)

    Adnan, I.O.

    2007-01-01

    Zinc-aluminum casting alloys are frequently employed in design. They are inexpensive and have mechanical properties in many respects superior to aluminum and copper alloys. Common applications of zinc-aluminum alloys are in the automobile industry for manufacturing carburetors bodies, fuel pump bodies, driving wheels and door handles. They are mainly used for die casting due to their low melting points which ranges from 375 to 487 degree C, good fluidity, pollution free melting in addition to their high corrosion resistance. Against these advantages there exists the deficiency as these alloys solidify in a coarse dentititic structure which tends to deteriorate the mechanical properties and impact strength. It was found that addition of some rare earth materials e.g. titanium or titanium plus boron results in modifying its structure into a petal-like or nodular type. The available literature reveals that most of the published work is directed towards the metallurgical aspects and little or no work is published on the effect of those elements on its mechanical strength, ductility, toughness and impact strength. In this paper, the effect of addition of Zirconium on the microstructure, mechanical behavior, hardness, ductility and impact strength of zinc-aluminum alloy5, Zamak5, is investigated. It was found that addition of Ti+B or Zr or Ti+B+Zr resulted in modifying the coarse dentritic structure of the Zamak5 alloy into a fine nodular one. Further more, addition of any of these elements alone or together resulted in enhancement of the mechanical strength, hardness, ductility, toughness and impact strength of this alloy, for example an increase of 11% in hardness was achieved in case of Zr addition and 100% increase of ductility and 12.5% increase in impact strength were achieved in case of Ti+B addition. (author)

  17. The influence of flame hardening process to aluminum 7075 series on the mechanical strength and micro structure

    Science.gov (United States)

    Koin, Sudibtia Titio; Triyono, Teguh; Surojo, Eko

    2018-02-01

    The 7075 series alloys are heat treatable wrought aluminum alloys based on the Al-Zn-Mg(-Cu) system. They are widely used in high-performance structural aerospace and transportation applications. Apart from compositional, casting and thermo-mechanical processing effects, the balance of properties is also significantly influenced by the way in which the materials are heat-treated. This paper describes the effect of flame hardening process to aluminum 7075 series on the increasing hardness, tensile strength, and evolution of microstructure. A test specimen had made by machining process and flame heating. Temperature of solution heat treatment is varied on 350 °C, 400 °C, 450 °C and 500 °C. After that process a test specimen would be quenched at nitrate-nitrite liquid during 45 minutes and artificial aging at 120°C until two days. The testing specimen consist of hardness and tensile strength according to ASTM. The result showed that specimen had precipitation on microstructure lead to an increase in aluminum properties. On the temperature 450°C solution heat treatment, the aluminum properties reached the highest value, namely, hardness of 129 HVN and tensile strength 570 MPa.

  18. Electroerosion formation and technology of cast iron coatings on aluminum alloys

    Directory of Open Access Journals (Sweden)

    Smolentsev Vladislav P.

    2017-01-01

    Full Text Available At present in the course of designing basic production parts and industrial equipment designers pay more and more attention to aluminum alloys having a number of properties compared favorably with other materials. In particular, technological aluminum tool electrodes without coating in the presence of products of processing with alkali in the composition of operation environment are being destroyed at the expense of intensified material dissolution. It is shown in the paper that the method offered by the authors and covered by the patents on cast iron coating of products made of aluminum alloys, allows obtaining on a product surface the layers with high adhesion durability ensuring a high protection against destruction in the friction units including operation in hostile environment. Thereupon, aluminum, as compared with iron-based alloys used at manufacturing technological equipment for electrical methods of processing, has a high electrical and thermal conduction, its application will allow achieving considerable energy-saving in the course of parts production. A procedure for the design of a technological process of qualitative cast iron coatings upon aluminum tool electrodes and parts of basic production used in different branches of mechanical engineering is developed.

  19. New Approaches to Aluminum Integral Foam Production with Casting Methods

    Directory of Open Access Journals (Sweden)

    Ahmet Güner

    2015-08-01

    Full Text Available Integral foam has been used in the production of polymer materials for a long time. Metal integral foam casting systems are obtained by transferring and adapting polymer injection technology. Metal integral foam produced by casting has a solid skin at the surface and a foam core. Producing near-net shape reduces production expenses. Insurance companies nowadays want the automotive industry to use metallic foam parts because of their higher impact energy absorption properties. In this paper, manufacturing processes of aluminum integral foam with casting methods will be discussed.

  20. Effects of low frequency electromagnetic field on the as-cast microstructures and mechanical properties of superhigh strength aluminum alloy

    International Nuclear Information System (INIS)

    Zuo Yubo; Cui Jianzhong; Dong Jie; Yu Fuxiao

    2005-01-01

    A new superhigh strength Al-Zn-Mg-Cu alloy was made by low frequency electromagnetic casting (LFEC) and conventional direct chill (DC) casting, respectively. The effects of low frequency electromagnetic field on the as-cast microstructures and mechanical properties were investigated. The results show that under the low frequency electromagnetic field (25 Hz, 32 mT), the microstructures of LFEC ingot from the border to the center on the cross section are all fine equiaxed or nearly equiaxed grains. The grains are much finer and more uniform than that of DC ingot. It was found that magnetic flux density plays an important role on the microstructure formation of LFEC ingots. With increasing the magnetic flux density, grains become finer and more uniform. In the range of experimental parameters, the optimum magnetic flux density for LFEC process is found to be 32 mT. The mechanical tests show that for this new superhigh strength Al-Zn-Mg-Cu alloy, the as-cast mechanical properties of LFEC ingot are much higher than that of DC ingot

  1. Die Casting Mold Design for Aluminum Alloy Shell of Instrument

    Directory of Open Access Journals (Sweden)

    Li Yuanyuan

    2015-01-01

    Full Text Available This paper is about die casting mold design for aluminum alloy shell of instrument. Three-dimensional model of the casting and mold are designed by using Pro/Engineer and AutoCad which can analyze forming quality. Digital design and theoretical calculation can greatly shorten product development cycle and mold design cycle, improve the accuracy of product design and mold design, and reduce the cost of mold design.

  2. PRODUCTION OF ROTARY ENGINES’ PARTS FROM ALUMINUM ALLOYS USING LOST FOAM CASTING PROCESS

    Directory of Open Access Journals (Sweden)

    E. I. Marukovich

    2018-01-01

    Full Text Available The production technology of casting details for rotary engine from the aluminum alloy АК12М2 is developed. The bulk density of expanded polystyrene to ensure the best quality of the surface of castings has been experimentally established. The lost foam casting shop was organized in the experimental department of the Institute.

  3. Energy-Saving Melting and Revert Reduction Technology (E-SMARRT): Lost Foam Thin Wall - Feasibility of Producing Lost Foam Castings in Aluminum and Magnesium Based Alloys

    Energy Technology Data Exchange (ETDEWEB)

    Fasoyinu, Yemi [CanmetMATERIALS; Griffin, John A. [University of Alabama - Birmingham

    2014-03-31

    With the increased emphasis on vehicle weight reduction, production of near-net shape components by lost foam casting will make significant inroad into the next-generation of engineering component designs. The lost foam casting process is a cost effective method for producing complex castings using an expandable polystyrene pattern and un-bonded sand. The use of un-bonded molding media in the lost foam process will impose less constraint on the solidifying casting, making hot tearing less prevalent. This is especially true in Al-Mg and Al-Cu alloy systems that are prone to hot tearing when poured in rigid molds partially due to their long freezing range. Some of the unique advantages of using the lost foam casting process are closer dimensional tolerance, higher casting yield, and the elimination of sand cores and binders. Most of the aluminum alloys poured using the lost foam process are based on the Al-Si system. Very limited research work has been performed with Al-Mg and Al-Cu type alloys. With the increased emphasis on vehicle weight reduction, and given the high-strength-to-weight-ratio of magnesium, significant weight savings can be achieved by casting thin-wall (≤ 3 mm) engineering components from both aluminum- and magnesium-base alloys.

  4. Development of a New Ferrous Aluminosilicate Refractory Material for Investment Casting of Aluminum Alloys

    Science.gov (United States)

    Yuan, Chen; Jones, Sam; Blackburn, Stuart

    2012-12-01

    Investment casting is a time-consuming, labour intensive process, which produces complex, high value-added components for a variety of specialised industries. Current environmental and economic pressures have resulted in a need for the industry to improve current casting quality, reduce manufacturing costs and explore new markets for the process. Alumino-silicate based refractories are commonly used as both filler and stucco materials for ceramic shell production. A new ceramic material, norite, is now being produced based on ferrous aluminosilicate chemistry, having many potential advantages when used for the production of shell molds for casting aluminum alloy. This paper details the results of a direct comparison made between the properties of a ceramic shell system produced with norite refractories and a typical standard refractory shell system commonly used in casting industry. A range of mechanical and physical properties of the systems was measured, and a full-scale industrial casting trial was also carried out. The unique properties of the norite shell system make it a promising alternative for casting aluminum based alloys in the investment foundry.

  5. Impact Toughness and Heat Treatment for Cast Aluminum

    Science.gov (United States)

    Lee, Jonathan A (Inventor)

    2016-01-01

    A method for transforming a cast component made of modified aluminum alloy by increasing the impact toughness coefficient using minimal heat and energy. The aluminum alloy is modified to contain 0.55%-0.60% magnesium, 0.10%-0.15% titanium or zirconium, less than 0.07% iron, a silicon-tomagnesium product ratio of 4.0, and less than 0.15% total impurities. The shortened heat treatment requires an initial heating at 1,000deg F. for up to I hour followed by a water quench and a second heating at 350deg F. to 390deg F. for up to I hour. An optional short bake paint cycle or powder coating process further increase.

  6. Demonstration of the Impact of Thermomagnetic Processing on Cast Aluminum Alloys

    Energy Technology Data Exchange (ETDEWEB)

    Ludtka, Gerard Michael [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Murphy, Bart L. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Rios, Orlando [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Kesler, Michael S. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Henderson, Hunter B. [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

    2017-10-01

    This project builds on an earlier Manufacturing Demonstration Facility Technical Collaboration phase 1 project to investigate application of high magnetic fields during solution heat treating and aging of three different cast aluminum alloys.

  7. Friction Stir Processing Parameters and Property Distributions in Cast Nickel Aluminum Bronze

    National Research Council Canada - National Science Library

    Rosemark, Brian P

    2006-01-01

    Cast nickel-aluminum bronze (NAB) alloy is specified for many marine applications, including ship propellers, due to its excellent corrosion-resistance combined with acceptable mechanical properties...

  8. High-strength laser welding of aluminum-lithium scandium-doped alloys

    Science.gov (United States)

    Malikov, A. G.; Ivanova, M. Yu.

    2016-11-01

    The work presents the experimental investigation of laser welding of an aluminum alloy (system Al-Mg-Li) and aluminum alloy (system Al-Cu-Li) doped with Sc. The influence of nano-structuring of the surface layer welded joint by cold plastic deformation on the strength properties of the welded joint is determined. It is founded that, regarding the deformation degree over the thickness, the varying value of the welded joint strength is different for these aluminum alloys. The strength of the plastically deformed welded joint, aluminum alloys of the Al-Mg-Li and Al-Cu-Li systems reached 0.95 and 0.6 of the base alloy strength, respectively.

  9. Fatigue behavior in rheocast aluminum 357 suspension arms using the SEED process

    Science.gov (United States)

    Samuel, Ehab; Zheng, Chang-Qing; Bouaicha, Amine; Bouazara, Mohamed

    Extensive studies have been devoted to the use of aluminum alloys in the automotive industry, by virtue of the favourable mechanical properties that can be attained. Moreover, the aluminum casting method employed has also been the subject of scrutiny, given the multitude of casting options available. The present work serves to illustrate the advancements made in the area of rheocasting, using the SEED method, as carried out at the National Research Council Canada — Aluminum Technology Centre. The SEED (Swirled Enthalpy Equilibration Device) process, which relies on heat extraction of the liquid aluminum alloy via mechanical agitation in a confined cylinder to form the semi-solid billet, has already proven successful in producing sound aluminum castings having an excellent combination of strength and ductility. Moreover, fatigue testing on the cast alloy parts has shown enormous potential for this emerging technology.

  10. Interfacial characteristics of diamond/aluminum composites with high thermal conductivity fabricated by squeeze-casting method

    International Nuclear Information System (INIS)

    Jiang, Longtao; Wang, Pingping; Xiu, Ziyang; Chen, Guoqin; Lin, Xiu; Dai, Chen; Wu, Gaohui

    2015-01-01

    In this work, aluminum matrix composites reinforced with diamond particles (diamond/aluminum composites) were fabricated by squeeze casting method. The material exhibited a thermal conductivity as high as 613 W / (m · K). The obtained composites were investigated by scanning electron microscope and transmission electron microscope in terms of the (100) and (111) facets of diamond particles. The diamond particles were observed to be homogeneously distributed in the aluminum matrix. The diamond (111) /Al interface was found to be devoid of reaction products. While at the diamond (100) /Al interface, large-sized aluminum carbides (Al 4 C 3 ) with twin-crystal structure were identified. The interfacial characteristics were believed to be responsible for the excellent thermal conductivity of the material. - Graphical abstract: Display Omitted - Highlights: • Squeeze casting method was introduced to fabricate diamond/Al composite. • Sound interfacial bonding with excellent thermal conductivity was produced. • Diamond (111) / aluminum interface was firstly characterized by TEM/HRTEM. • Physical combination was the controlling bonding for diamond (111) /aluminum. • The growth mechanism of Al 4 C 3 was analyzed by crystallography theory

  11. Effects of aluminum and copper chill on mechanical properties and microstructures of Cu-Zn-Al alloys with sand casting

    Science.gov (United States)

    Ardhyananta, Hosta; Wibisono, Alvian Toto; Ramadhani, Mavindra; Widyastuti, Farid, Muhammad; Gumilang, Muhammad Shena

    2018-04-01

    Cu-Zn-Al alloy is one type of brass, which has high strength and high corrosion resistant. It has been applied on ship propellers and marine equipment. In this research, the addition of aluminum (Al) with variation of 1, 2, 3, 4% aluminum to know the effect on mechanical properties and micro structure at casting process using a copper chill and without copper chill. This alloy is melted using furnace in 1100°C without holding. Then, the molten metal is poured into the mold with copper chill and without copper chill. The speciment of Cu-Zn-Al alloy were chracterized by using Optical Emission Spectroscopy (OES), Metallography Test, X-Ray Diffraction (XRD), Hardness Test of Rockwell B and Charpy Impact Test. The result is the addition of aluminum and the use of copper chill on the molds can reduce the grain size, increases the value of hardness and impact.

  12. Numerical simulation of low pressure die-casting aluminum wheel

    Directory of Open Access Journals (Sweden)

    Mi Guofa

    2009-02-01

    Full Text Available The FDM numerical simulation software, ViewCast system, was employed to simulate the low pressure die casting (LPDC of an aluminum wheel. By analyzing the mold-fi lling and solidifi cation stage of the LPDC process, the distribution of liquid fraction, temperature field and solidification pattern of castings were studied. The potential shrinkage defects were predicted to be formed at the rim/spoke junctions, which is in consistence with the X-ray detection result. The distribution pattern of the defects has also been studied. A solution towards reducing such defects has been presented. The cooling capacity of the mold was improved by installing water pipes both in the side mold and the top mold. Analysis on the shrinkage defects under forced cooling mode proved that adding the cooling system in the mold is an effective method for reduction of shrinkage defects.

  13. Modeling and simulation of phase-transitions in multicomponent aluminum alloy casting

    NARCIS (Netherlands)

    Cate, ten A.; Geurts, B.J.; Muskulus, M.; Köster, D.; Muntean, A.; Opheusden, van J.; Peschansky, A.; Vreman, A.W.; Zegeling, P.A.; Bokhove, O.; et al., xx

    2008-01-01

    The casting process of aluminum products involves the spatial distribution of alloying elements. It is essential that these elements are uniformly distributed in order to guarantee reliable and consistent products. This requires a good understanding of the main physical mechanisms that affect the

  14. The effect of zinc on the microstructure and phase transformations of casting Al-Cu alloys

    OpenAIRE

    Manasijević Ivana I.; Štrbac Nada D.; Živković Dragana T.; Balanović Ljubiša T.; Minić Duško M.; Manasijević Dragan M.

    2016-01-01

    Copper is one of the main alloying elements for aluminum casting alloys. As an alloying element, copper significantly increases the tensile strength and toughness of alloys based on aluminum. The copper content in the industrial casting aluminum alloys ranges from 3,5 to 11 wt.%. However, despite the positive effect on the mechanical properties, copper has a negative influence on the corrosion resistance of aluminum and its alloys. In order to further improve the properties of Al-Cu alloys th...

  15. Production and characterization of cast aluminum sponges

    International Nuclear Information System (INIS)

    Rivarola, M.E; Marmo Lupano, J.M; Malachevsky, M.T

    2004-01-01

    Cellular materials have unique physical features that make them particularly appropriate for applications that require high mechanical resistance and low weight. They can be produced in different ways: by powder metallurgy, by infiltration over plastic foams, adding a releasing agent of gas to a fused metal or simply injecting gas into it. Cellular structures can also be formed by casting onto a pore forming material. This work proposes a method that is basically similar to the last one mentioned but that allows the resulting material's porosity and topology to be controlled. Thus, the mechanical or thermal features of the material that is being manufactured can be predicted and/or designed. First the three dimensional print of a mold is made in a 3D printer, which is the negative of the piece that will be produced. Then a vacuum assisted aluminum cast is made. A preliminary study is presented for the applicability of this method and the mechanical properties of the resulting sponges (CW)

  16. Effect of heat treatment on the properties of laser-beam welded rheo-cast F357 aluminum

    CSIR Research Space (South Africa)

    Theron, M

    2012-02-01

    Full Text Available Semi-solid metal rheo-cast F357 aluminum plates were joined by autogenous Nd:YAG laser welding and were welded in either the as-cast (F) condition, T4 temper or T6 temper condition. The weldability of this age-hardenable Al–7%Si–0.6%Mg casting alloy...

  17. White cast iron with a nano-eutectic microstructure and high tensile strength and considerable ductility prepared by an aluminothermic reaction casting

    International Nuclear Information System (INIS)

    La, Peiqing; Wei, Fuan; Hu, Sulei; Li, Cuiling; Wei, Yupeng

    2013-01-01

    A white cast iron with nano-eutectic microstructure was prepared by an aluminothermic reaction casting. Microstructures of the cast iron were investigated by optical microscope (OM), electron probe micro-analyzer (EPMA), scanning electron microscope (SEM) and X-ray diffraction (XRD). Mechanical properties of the cast iron were tested. The results showed that the cast iron consisted of pearlite and cementite phases. Lamellar spacing of the pearlite phase was in a range of 110–275 nm and much smaller than that of the Ni-Hard 2 cast iron. Hardness of the cast iron was 552 Hv, tensile strength was 383 MPa, total elongation was 3% and compressive strength was 2224 MPa. Tensile strength and hardness of the cast iron was same to Ni-Hard 2 cast iron, besides the ductility was much better than that of the Ni-Hard 2 cast iron which is much expensive than the cast iron.

  18. Interfacial characteristics of diamond/aluminum composites with high thermal conductivity fabricated by squeeze-casting method

    Energy Technology Data Exchange (ETDEWEB)

    Jiang, Longtao, E-mail: longtaojiang@163.com [Department of Material Science and Engineering, Harbin Institute of Technology, Harbin 150001 (China); Wang, Pingping [Department of Material Science and Engineering, Harbin Institute of Technology, Harbin 150001 (China); Xiu, Ziyang [Skate Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001 (China); Chen, Guoqin [Department of Material Science and Engineering, Harbin Institute of Technology, Harbin 150001 (China); Lin, Xiu [Heilongjiang Academy of Industrial Technology, Harbin 150001 (China); Dai, Chen; Wu, Gaohui [Department of Material Science and Engineering, Harbin Institute of Technology, Harbin 150001 (China)

    2015-08-15

    In this work, aluminum matrix composites reinforced with diamond particles (diamond/aluminum composites) were fabricated by squeeze casting method. The material exhibited a thermal conductivity as high as 613 W / (m · K). The obtained composites were investigated by scanning electron microscope and transmission electron microscope in terms of the (100) and (111) facets of diamond particles. The diamond particles were observed to be homogeneously distributed in the aluminum matrix. The diamond{sub (111)}/Al interface was found to be devoid of reaction products. While at the diamond{sub (100)}/Al interface, large-sized aluminum carbides (Al{sub 4}C{sub 3}) with twin-crystal structure were identified. The interfacial characteristics were believed to be responsible for the excellent thermal conductivity of the material. - Graphical abstract: Display Omitted - Highlights: • Squeeze casting method was introduced to fabricate diamond/Al composite. • Sound interfacial bonding with excellent thermal conductivity was produced. • Diamond{sub (111)}/ aluminum interface was firstly characterized by TEM/HRTEM. • Physical combination was the controlling bonding for diamond{sub (111)}/aluminum. • The growth mechanism of Al{sub 4}C{sub 3} was analyzed by crystallography theory.

  19. Characteristics of copper-clad aluminum rods prepared by horizontal continuous casting

    Science.gov (United States)

    Zhang, Yubo; Fu, Ying; Jie, Jinchuan; Wu, Li; Svynarenko, Kateryna; Guo, Qingtao; Li, Tingju; Wang, Tongmin

    2017-11-01

    An innovative horizontal continuous casting method was developed and successfully used to prepare copper-clad aluminum (CCA) rods with a diameter of 85 mm and a sheath thickness of 16 mm. The solidification structure and element distribution near the interface of the CCA ingots were investigated by means of a scanning electron microscope, an energy dispersive spectrometer, and an electron probe X-ray microanalyzer. The results showed that the proposed process can lead to a good metallurgical bond between Cu and Al. The interface between Cu and Al was a multilayered structure with a thickness of 200 μm, consisting of Cu9Al4, CuAl2, α-Al/CuAl2 eutectic, and α-Al + α-Al/CuAl2 eutectic layers from the Cu side to the Al side. The mean tensile-shear strength of the CCA sample was 45 MPa, which fulfills the requirements for the further extrusion process. The bonding and diffusion mechanisms are also discussed in this paper.

  20. Hot Roll Bonding of Aluminum to Twin-Roll Cast (TRC) Magnesium and Its Subsequent Deformation Behavior

    Science.gov (United States)

    Saleh, H.; Schmidtchen, M.; Kawalla, R.

    2018-02-01

    In an experiment in which twin-roll cast AZ31 magnesium alloy and commercial purity aluminum (AA 1050) sheets were bonded by hot rolling as Al/Mg/Al laminate composites, it was found that increasing the preheating temperatures up to 400 °C enhances the bonding strength of composites. Further increases in the preheating temperatures accelerate the magnesium oxide growth and thus reduce the bonding strength. The influence of the reduction ratio on the bonding properties was also studied, whereby it was observed that increasing the rolling reduction led to an increase in the bonding strength. The experimental results show that the optimum bonding strength can be obtained at rolling temperatures of 375-400 °C with a 50-60% reduction in thickness. On the other hand, the subsequent deformation behavior of composite was assessed using plane strain compression and deep drawing tests. We demonstrate that the composites produced using the optimum roll bonding conditions exhibited sufficient bonding during subsequent deformation and did not reveal any debonding at the bonding interface.

  1. Thin wall ductile iron casting as a substitute for aluminum alloy casting in automotive industry

    Directory of Open Access Journals (Sweden)

    M. Górny

    2009-01-01

    Full Text Available In paper it is presented thin wall ductile iron casting (TWDI as a substitute of aluminium alloy casting. Upper control arm made of ductile iron with wall thickness ranging from 2 – 3.7 mm was produced by inmold process. Structure, mechanical properties and computer simulations were investigated. Structural analysis of TWDI shows pearlitic-ferritic matrix free from chills and porosity. Mechanical testing disclose superior ultimate tensile strength (Rm, yield strength (Rp0,2 and slightly lower elongation (E of TWDI in comparison with forged control arm made of aluminium alloy (6061-T6. Moreover results of computer simulation of static loading for tested control arms are presented. Analysis show that the light-weight ductile iron casting can be loaded to similar working conditions as the forged Al alloy without any potential failures.

  2. Microstructure and Mechanical Properties of MWCNTs Reinforced A356 Aluminum Alloys Cast Nanocomposites Fabricated by Using a Combination of Rheocasting and Squeeze Casting Techniques

    Directory of Open Access Journals (Sweden)

    Abou Bakr Elshalakany

    2014-01-01

    Full Text Available A356 hypoeutectic aluminum-silicon alloys matrix composites reinforced by different contents of multiwalled carbon nanotubes (MWCNTs were fabricated using a combination of rheocasting and squeeze casting techniques. A novel approach by adding MWCNTs into A356 aluminum alloy matrix with CNTs has been performed. This method is significant in debundling and preventing flotation of the CNTs within the molten alloy. The microstructures of nanocomposites and the interface between the aluminum alloy matrix and the MWCNTs were examined by using an optical microscopy (OM and scanning electron microscopy (SEM equipped with an energy dispersive X-ray analysis (EDX. This method remarkably facilitated a uniform dispersion of nanotubes within A356 aluminum alloy matrix as well as a refinement of grain size. In addition, the effects of weight fraction (0.5, 1.0, 1.5, 2.0, and 2.5 wt% of the CNT-blended matrix on mechanical properties were evaluated. The results have indicated that a significant improvement in ultimate tensile strength and elongation percentage of nanocomposite occurred at the optimal amount of 1.5 wt% MWCNTs which represents an increase in their values by a ratio of about 50% and 280%, respectively, compared to their corresponding values of monolithic alloy. Hardness of the samples was also significantly increased by the addition of CNTs.

  3. Gating system optimization of low pressure casting A356 aluminum alloy intake manifold based on numerical simulation

    Directory of Open Access Journals (Sweden)

    Jiang Wenming

    2014-03-01

    Full Text Available To eliminate the shrinkage porosity in low pressure casting of an A356 aluminum alloy intake manifold casting, numerical simulation on filling and solidification processes of the casting was carried out using the ProCAST software. The gating system of the casting is optimized according to the simulation results. Results show that when the gating system consists of only one sprue, the filling of the molten metal is not stable; and the casting does not follow the sequence solidification, and many shrinkage porosities are observed through the casting. After the gating system is improved by adding one runner and two in-gates, the filling time is prolonged from 4.0 s to 4.5 s, the filling of molten metal becomes stable, but this casting does not follow the sequence solidification either. Some shrinkage porosity is also observed in the hot spots of the casting. When the gating system was further improved by adding risers and chill to the hot spots of the casting, the shrinkage porosity defects were eliminated completely. Finally, by using the optimized gating system the A356 aluminum alloy intake manifold casting with integrated shape and smooth surface as well as dense microstructure was successfully produced.

  4. Processing and Characterization of Functionally Graded Aluminum (A319)—SiCp Metallic Composites by Centrifugal Casting Technique

    Science.gov (United States)

    Jayakumar, E.; Jacob, Jibin C.; Rajan, T. P. D.; Joseph, M. A.; Pai, B. C.

    2016-08-01

    Functionally graded materials (FGM) are successfully adopted for the design and fabrication of engineering components with location-specific properties. The present study describes the processing and characterization of A319 Aluminum functionally graded metal matrix composites (FGMMC) with 10 and 15 wt pct SiCp reinforcements. The liquid stir casting method is used for composite melt preparation followed by FGMMC formation by vertical centrifugal casting method. The process parameters used are the mold preheating temperature of 523 K (250 °C), melt pouring temperature of 1013 K (740 °C), and mold rotation speed of 1300 rpm. The study analyzes the distribution and concentration of reinforcement particles in the radial direction of the FGMMC disk along with the effects of gradation on density, hardness, mechanical strength, the variation in coefficient of thermal expansion and the wear resistance properties at different zones. Microstructures of FGMMC reveal an outward radial gradient distribution of reinforcements forming different zones. Namely, matrix-rich inner, transition, particles-rich outer, and chill zone of a few millimeters thick at the outer most periphery of the casting are formed. From 10-FGM, a radial shift in the position of SiCp maxima is observed in 15-FGM casting. The mechanical characterization depicts enhanced properties for the particle-rich zone. The hardness shows a graded nature in correlation with particle concentration and a maximum of 94.4 HRB has been obtained at the particle-rich region of 15-FGM. In the particle-rich zone, the lowest CTE value of 20.1 µm/mK is also observed with a compressive strength of 650 MPa and an ultimate tensile strength of 279 MPa. The wear resistance is higher at the particle-rich zone of the FGMMC.

  5. Effects of heat pipe cooling on permanent mold castings of aluminum alloys

    International Nuclear Information System (INIS)

    Zhang, C.; Mucciardi, F.; Gruzleski, J.E.

    2002-01-01

    The temperature distribution within molds is a critical parameter in determining the ultimate casting quality in permanent mold casting processes, so there is a considerable incentive to develop a more effective method of mold cooling. Based on this consideration, a novel, effective and controllable heat pipe has been successfully developed and used as a new method of permanent mold cooling. Symmetric step casting of A356 alloy have been produced in an experimental permanent mold made of H13 tool steel, which is cooled by such heat pipes. The experimental results show that heat pipes can provide extremely high cooling rates in permanent mold castings of aluminum. The dendrite arm spacing of A356 alloy is refined considerably, and porosity and shrinkage of the castings are redistributed by the heat pipe cooling. Moreover, the heat pipe can be used to determine the time when the air gap forms at the interface between the mold and the casting. The effect of heat pipe cooling on solidification time of castings of A356 alloy with different coating types is also discussed in this paper. (author)

  6. Investigation of Bond Strength in Centrifugal Lining of Babbitt on Cast Iron

    Science.gov (United States)

    Diouf, Papa; Jones, Alan

    2010-03-01

    The quality of the bond between Babbitt metal and a cast iron substrate was evaluated for centrifugal casting and static casting using the Chalmers bond strength method and scanning electron microscopy (SEM). The effect of three different centrifugal casting parameters, the speed of revolution, the pouring rate, and the cooling rate, was investigated. The bond strength and the microstructure at the bond interface were predominantly affected by the cooling rate, with a fast cooling rate resulting in better properties. The speed of revolution and the pouring rate only had a small effect on the bond strength, with faster revolution and faster pouring rate resulting in slightly better bonds.

  7. NASA-427: A New Aluminum Alloy

    Science.gov (United States)

    Nabors, Sammy A.

    2015-01-01

    NASA's Marshall Space Flight Center researchers have developed a new, stronger aluminum alloy, ideal for cast aluminum products that have powder or paint-baked thermal coatings. With advanced mechanical properties, the NASA-427 alloy shows greater tensile strength and increased ductility, providing substantial improvement in impact toughness. In addition, this alloy improves the thermal coating process by decreasing the time required for heat treatment. With improvements in both strength and processing time, use of the alloy provides reduced materials and production costs, lower product weight, and better product performance. The superior properties of NASA-427 can benefit many industries, including automotive, where it is particularly well-suited for use in aluminum wheels.

  8. Preliminary study on tensile properties and fractography of the recycled aluminum cast product

    International Nuclear Information System (INIS)

    Hishamuddin Hussain; Mohd Harun; Hafizal Yazid; Shaiful Rizam Shamsudin; Zaiton Selamat; Mohd Shariff Sattar

    2004-01-01

    Among many mechanical properties of materials, tensile properties are probably the most frequently considered, evaluated, and referred by the industry. This paper presents the result of preliminary study regarding the tensile properties and fractography of the recycled aluminum cast product. For this purpose, three sets of specimen were prepared for tensile testing by using permanent mold casting technique. The cast products are in durable shaped tensile specimens with the gauge length of 50mm. The tensile testing was conducted in accordance with BS EN 10002-1 and ISO 6892 standards. Fracture surface analysis was also conducted to understand materials behaviour. (Author)

  9. Centrifugal Casting Features/Metallurgical Characterization of Aluminum Alloys

    International Nuclear Information System (INIS)

    Chirita, G.; Soares, D.; Cruz, D.; Silva, F. S.; Stefanescu, I.

    2008-01-01

    This paper deals with the study of centrifugal effects on aluminium castings under high G values. Most of the studies in this domain (FGMs obtained by centrifugal casting) deal with functionally graded composites reinforced with a solid phase such as silicon particles or others. However, in this study it will be shown that unreinforced aluminium alloys may be significantly influenced by the centrifugal effect and that functionally graded castings are also obtained. It has been observed that the centrifugal effect may increase in some alloys, depending on the relative position in the castings, the rupture strength by approx. 50%, and rupture strain by about 300%, as compared to the gravity casting technique. The Young's modulus may also increase by about 20%. It has also been reported that in vertical centrifugal castings there are mainly three aspects that affect the components thus obtained, namely: fluid dynamics; vibration (inherent to the system); and centrifugal force. These features have a different effect on the castings depending on the aluminium alloy. In this paper, an analysis of the most important effects of the centrifugal casting process on metallurgical features is conducted. A solidification characterization at several points along the mould will be made in order to have an accurate idea of both the fluid dynamics inside the mould during the casting and the solidification behavior in different parts of the component. These two analyses will be related to the metallurgical properties (phase distribution; SDAS; eutectic silicon content and shape, pores density and shape) along the component and mainly along the direction of the centrifugal pressure. A comparison between castings obtained by both centrifugal casting technique and gravity casting technique is made for reference (gravity casting)

  10. Influence of core-finishing intervals on tensile strength of cast posts-and-cores luted with zinc phosphate cement

    Directory of Open Access Journals (Sweden)

    Michele Andrea Lopes Iglesias

    2012-08-01

    Full Text Available The core finishing of cast posts-and-cores after luting is routine in dental practice. However, the effects of the vibrations produced by the rotary cutting instruments over the luting cements are not well-documented. This study evaluated the influence of the time intervals that elapsed between the cementation and the core-finishing procedures on the tensile strength of cast posts-and-cores luted with zinc phosphate cement. Forty-eight bovine incisor roots were selected, endodontically treated, and divided into four groups (n = 12: GA, control (without finishing; GB, GC, and GD, subjected to finishing at 20 minutes, 60 minutes, and 24 hours after cementation, respectively. Root canals were molded, and the resin patterns were cast in copper-aluminum alloy. Cast posts-and-cores were luted with zinc phosphate cement, and the core-finishing procedures were applied according to the groups. The tensile tests were performed at a crosshead speed of 0.5 mm/min for all groups, 24 hours after the core-finishing procedures. The data were subjected to one-way analysis of variance (ANOVA and Tukey's test (α = 0.05. No significant differences were observed in the tensile strengths between the control and experimental groups, regardless of the time interval that elapsed between the luting and finishing steps. Within the limitations of the present study, it was demonstrated that the core-finishing procedures and time intervals that elapsed after luting did not appear to affect the retention of cast posts-and-cores when zinc phosphate cement was used.

  11. Energy-Saving Melting and Revert Reduction Technology (E-SMARRT): Development of Elevated Temperature Aluminum Metal Matrix Composite (MMC) Alloy and Its Processing Technology

    Energy Technology Data Exchange (ETDEWEB)

    Weiss, David C. [Eck Industreis, Inc.; Gegal, Gerald A.

    2014-04-15

    The objective of this project was to provide a production capable cast aluminum metal matrix composite (MMC) alloy with an operating temperature capability of 250-300°C. Important industrial sectors as well as the military now seek lightweight aluminum alloy castings that can operate in temperature ranges of 250-300°C. Current needs in this temperature range are being satisfied by the use of titanium alloy castings. These have the desired strength properties but the end components are heavier and significantly more costly. Also, the energy requirements for production of titanium alloy castings are significantly higher than those required for production of aluminum alloys and aluminum alloy castings.

  12. Low Cost Al-Si Casting Alloy As In-Situ Composite for High Temperature Applications

    Science.gov (United States)

    Lee, Jonathan A.

    2000-01-01

    A new aluminum-silicon (Al-Si) alloy has been successfully developed at NASA- Marshall Space Flight Center (MSFC) that has significant improvement in tensile and fatigue strength at elevated temperatures (500 F-700 F). The alloy offers a number of benefits such as light weight, high hardness, low thermal expansion and high surface wear resistance. In hypereutectic form, this alloy is considered as an in-situ Al-Si composite with tensile strength of about 90% higher than the auto industry 390 alloy at 600 F. This composite is very economically produced by using either conventional permanent steel molds or die casting. The projected material cost is less than $0.90 per pound, and automotive components such as pistons can be cast for high production rate using conventional casting techniques with a low and fully accounted cost. Key Words: Metal matrix composites, In-situ composite, aluminum-silicon alloy, hypereutectic alloy, permanent mold casting, die casting.

  13. Microstructure, Friction and Wear of Aluminum Matrix Composites

    Science.gov (United States)

    Florea, R. M.

    2018-06-01

    MMCs are made by dispersing a reinforcing material into a metal matrix. They are prepared by casting, although several technical challenges exist with casting technology. Achieving a homogeneous distribution of reinforcement within the matrix is one such challenge, and this affects directly on the properties and quality of composite. The aluminum alloy composite materials consist of high strength, high stiffness, more thermal stability, more corrosion and wear resistance, and more fatigue life. Aluminum alloy materials found to be the best alternative with its unique capacity of designing the materials to give required properties. In this work a composite is developed by adding silicon carbide in Aluminum metal matrix by mass ratio 5%, 10% and 15%. Mechanical tests such as hardness test and microstructure test are conducted.

  14. Differential ion beam sputtering of segregated phases in aluminum casting alloys

    International Nuclear Information System (INIS)

    Nguyen, Chuong L.; Wirtz, Tom; Fleming, Yves; Metson, James B.

    2013-01-01

    Highlights: ► Novel combination of SIMS and SPM for accurate 3D chemical mapping. ► Different removal rates of metallurgical phases by ion beam. ► Faster oxidation rate of silicon vs. aluminum at room temperature in vacuum. - Abstract: Differential sputtering of materials is an important phenomenon in materials science with many implications. One of the practical applications of this phenomenon is the modification of the interface between a substrate and coating during sputter coating of materials. Aluminum casting alloys, as common materials in many applications, are suitable candidates to investigate this phenomenon due to their phase separated microstructures. Changes at the sample surface under ion bombardment can be characterized by a range of complimentary techniques. The novel SIMS–SPM instrument used here enables a thorough investigation into the evolution of topography and composition caused by ion beam sputtering. For the alloy examined in this work, the aluminum regions are removed faster than the silicon particles. The faster oxidation rate of silicon compared to aluminum in the exposed surface can also be deduced from this study.

  15. The application of cast SiC/Al to rotary engine components

    Science.gov (United States)

    Stoller, H. M.; Carluccio, J. R.; Norman, J. P.

    1986-01-01

    A silicon carbide reinforced aluminum (SiC/Al) material fabricated by Dural Aluminum Composites Corporation was tested for various components of rotary engines. Properties investigated included hardness, high temperature strength, wear resistance, fatigue resistance, thermal conductivity, and expansion. SiC/Al appears to be a viable candidate for cast rotors, and may be applicable to other components, primarily housings.

  16. Stress corrosion in high-strength aluminum alloys

    Science.gov (United States)

    Dorward, R. C.; Hasse, K. R.

    1980-01-01

    Report describes results of stress-corrosion tests on aluminum alloys 7075, 7475, 7050, and 7049. Tests compare performance of original stress-corrosion-resistant (SCR) aluminum, 7075, with newer, higher-strength SCR alloys. Alloys 7050 and 7049 are found superior in short-transverse cross-corrosion resistance to older 7075 alloy; all alloys are subject to self-loading effect caused by wedging of corrosion products in cracks. Effect causes cracks to continue to grow, even at very-low externally applied loads.

  17. Bainitic high-strength cast iron with globular graphite

    Science.gov (United States)

    Silman, G. I.; Makarenko, K. V.; Kamynin, V. V.; Zentsova, E. A.

    2013-07-01

    Special features of formation of bainitic structures in grayed cast irons are considered. The influence of the graphite phase and of the special features of chemical composition of the iron on the intermediate transformation in high-carbon alloys is allowed for. The range of application of high-strength cast irons with bainitic structure is determined. The paper is the last and unfinished work of G. I. Silman completed by his disciples as a tribute to their teacher.

  18. The effect of microstructure of low-alloy spheroidal cast iron on impact strength

    Directory of Open Access Journals (Sweden)

    T. Szykowny

    2010-01-01

    Full Text Available The study presents an evaluation of the effect of microstructure of low-alloy spheroidal cast iron on impact strength within the temperature range from –60 to 100°C. Analyses were conducted on one type of cast iron containing 0.51% Cu and 0.72% Ni. Cast iron was austempered or normalized. Values of KCV and static mechanical properties were determined. Structural and fractographic analyses were based on light and scanning microscopy as well as X-ray diffraction. It was found that thermal processing considerably improves impact strength in relation to cast iron after casting. At the same time static mechanical properties are enhanced.

  19. Annealing of chromium oxycarbide coatings deposited by plasma immersion ion processing (PIIP) for aluminum die casting

    International Nuclear Information System (INIS)

    Peters, A.M.; He, X.M.; Trkula, M.; Nastasi, M.

    2001-01-01

    Chromium oxycarbide coatings have been investigated for use as non-wetting coatings for aluminum die casting. This paper examines Cr-C-O coating stability and non-wetability at elevated temperatures for extended periods. Coatings were deposited onto 304 stainless steel from chromium carbonyl [Cr(CO) 6 ] by plasma immersion ion processing. The coatings were annealed in air at an aluminum die casting temperature of 700 deg. C up to 8 h. Coatings were analyzed using resonant ion backscattering spectroscopy, nanoindentation and pin-on-disk tribometry. Molten aluminum was used to determine coating wetting and contact angle. Results indicate that the surface oxide layer reaches a maximum thickness of 900 nm. Oxygen concentrations in the coatings increased from 24% to 34%, while the surface concentration rose to almost 45%. Hardness values ranged from 22.1 to 6.7 GPa, wear coefficients ranged from 21 to 8x10 -6 mm 3 /Nm and contact angles ranged from 156 deg. to 127 deg

  20. Fatigue Strength Estimation Based on Local Mechanical Properties for Aluminum Alloy FSW Joints

    Directory of Open Access Journals (Sweden)

    Kittima Sillapasa

    2017-02-01

    Full Text Available Overall fatigue strengths and hardness distributions of the aluminum alloy similar and dissimilar friction stir welding (FSW joints were determined. The local fatigue strengths as well as local tensile strengths were also obtained by using small round bar specimens extracted from specific locations, such as the stir zone, heat affected zone, and base metal. It was found from the results that fatigue fracture of the FSW joint plate specimen occurred at the location of the lowest local fatigue strength as well as the lowest hardness, regardless of microstructural evolution. To estimate the fatigue strengths of aluminum alloy FSW joints from the hardness measurements, the relationship between fatigue strength and hardness for aluminum alloys was investigated based on the present experimental results and the available wide range of data from the references. It was found as: σa (R = −1 = 1.68 HV (σa is in MPa and HV has no unit. It was also confirmed that the estimated fatigue strengths were in good agreement with the experimental results for aluminum alloy FSW joints.

  1. Microstructured metal molds fabricated via investment casting

    International Nuclear Information System (INIS)

    Cannon, Andrew H; King, William P

    2010-01-01

    This paper describes an investment casting process to produce aluminum molds having integrated microstructures. Unlike conventional micromolding tools, the aluminum mold was large and had complex curved surfaces. The aluminum was cast from curved microstructured ceramic molds which were themselves cast from curved microstructured rubber. The aluminum microstructures had an aspect ratio of 1:1 and sizes ranging from 25 to 50 µm. Many structures were successfully cast into the aluminum with excellent replication fidelity, including circular, square and triangular holes. We demonstrate molding of large, curved surfaces having surface microstructures using the aluminum mold.

  2. Study of strength of Dsub(y)150 gate valve case, manufactured by centrifugal casting

    International Nuclear Information System (INIS)

    Umanskaya, L.G.; Semenov, P.V.; Tinyakov, V.G.; Babkina, R.I.; Khatuntsev, Eh.V.

    1982-01-01

    A process for manufacturing centrifugal-cast gate valve body is developed. Structural strength of such items, homogeneity, ductile and strength properties over the cross section as well as the metal susceptibility to embrittlement have been investigated. Three cast gate valve bodies have been taken: one - of 20GSL steel - for hydraulic testing, and two - of 15Kh1MFL steel - for investigation into the metal properties across the valve thickness. The strength properties of the centrifugal-cast gate valve body of 15Kh1M1FL steel are stated to meet the specifications. The gate valve metal ductility (delta and PSI) is twice as high as that of a sand-cast valve. The microstructure, strength and ductility are uniform both over wall thickness and over different body cross sections

  3. Microstructural and mechanical evolutions during the forging step of the COBAPRESS, a casting/forging process

    Science.gov (United States)

    Perrier, Frédéric; Desrayaud, Christophe; Bouvier, Véronique

    Aluminum casting/forging processes are used to produce parts for the automotive industry. In this study, we examined the influence of the forging step on the microstructure and the mechanical properties of an A356 aluminum alloy modified with strontium. Firstly, a design of samples which allows us to test mechanically the alloy before and after forging was created. A finite element analysis with the ABAQUS software predicts a maximum of strain in the core of the specimens. Observations with the EBSD technique confirm a more intense sub-structuration of the dendrite cells in this zone. Yield strength, ultimate tensile strength, elongation and fatigue lives were then improved for the casting/forging samples compared to the only cast specimens. The closure of the porosities and the improvement of the surface quality during the forging step enhance also the fatigue resistance of the samples.

  4. Influence of Composition on the Environmental Impact of a Cast Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    Patricia Gómez

    2016-05-01

    Full Text Available The influence of alloy composition on the environmental impact of the production of six aluminum casting alloys (Al Si12Cu1(Fe, Al Si5Mg, Al Si9Cu3Zn3Fe, Al Si10Mg(Fe, Al Si9Cu3(Fe(Zn and Al Si9 has been analyzed. In order to perform a more precise environmental impact calculation, Life Cycle Assessment (LCA with ReCiPe Endpoint methodology has been used, with the EcoInvent v3 AlMg3 aluminum alloy dataset as a reference. This dataset has been updated with the material composition ranges of the mentioned alloys. The balanced, maximum and minimum environmental impact values have been obtained. In general, the overall impact of the studied aluminum alloys varies from 5.98 × 10−1 pts to 1.09 pts per kg, depending on the alloy composition. In the analysis of maximum and minimum environmental impact, the alloy that has the highest uncertainty is AlSi9Cu3(Fe(Zn, with a range of ±9%. The elements that contribute the most to increase its impact are Copper and Tin. The environmental impact of a specific case, an LED luminaire housing made out of an Al Si12Cu1(Fe cast alloy, has been studied, showing the importance of considering the composition. Significant differences with the standard datasets that are currently available in EcoInvent v3 have been found.

  5. Influence of Composition on the Environmental Impact of a Cast Aluminum Alloy.

    Science.gov (United States)

    Gómez, Patricia; Elduque, Daniel; Sarasa, Judith; Pina, Carmelo; Javierre, Carlos

    2016-05-25

    The influence of alloy composition on the environmental impact of the production of six aluminum casting alloys (Al Si12Cu1(Fe), Al Si5Mg, Al Si9Cu3Zn3Fe, Al Si10Mg(Fe), Al Si9Cu3(Fe)(Zn) and Al Si9) has been analyzed. In order to perform a more precise environmental impact calculation, Life Cycle Assessment (LCA) with ReCiPe Endpoint methodology has been used, with the EcoInvent v3 AlMg3 aluminum alloy dataset as a reference. This dataset has been updated with the material composition ranges of the mentioned alloys. The balanced, maximum and minimum environmental impact values have been obtained. In general, the overall impact of the studied aluminum alloys varies from 5.98 × 10 -1 pts to 1.09 pts per kg, depending on the alloy composition. In the analysis of maximum and minimum environmental impact, the alloy that has the highest uncertainty is AlSi9Cu3(Fe)(Zn), with a range of ±9%. The elements that contribute the most to increase its impact are Copper and Tin. The environmental impact of a specific case, an LED luminaire housing made out of an Al Si12Cu1(Fe) cast alloy, has been studied, showing the importance of considering the composition. Significant differences with the standard datasets that are currently available in EcoInvent v3 have been found.

  6. Microstructure, Tensile Strength and Probabilistic Fatigue Life Evaluation of Gray Cast Iron

    Energy Technology Data Exchange (ETDEWEB)

    Sung, Yong Hyeon; Han, Seung-Wook; Choi, Nak-Sam [Hanyang Univ., Seoul (Korea, Republic of)

    2017-08-15

    High-grade gray cast iron (HCI350) was prepared by adding Cr, Mo and Cu to the gray cast iron (GC300). Their microstructure, mechanical properties and fatigue strength were studied. Cast iron was made from round bar and plate-type castings, and was cut and polished to measure the percentage of each microstructure. The size of flake graphite decreased due to additives, while the structure of high density pearlite increased in volume percentage improving the tensile strength and fatigue strength. Based on the fatigue life data obtained from the fatigue test results, the probability - stress - life (P-S-N) curve was calculated using the 2-parameter Weibull distribution to which the maximum likelihood method was applied. The P-S-N curve showed that the fatigue strength of HCI350 was significantly improved and the dispersion of life data was lower than that of GC300. However, the fatigue life according to fatigue stress alleviation increased further. Data for reliability life design was presented by quantitatively showing the allowable stress value for the required life cycle number using the calculated P-S-N curve.

  7. Tribological and Wear Performance of Nanocomposite PVD Hard Coatings Deposited on Aluminum Die Casting Tool

    Directory of Open Access Journals (Sweden)

    Jose Mario Paiva

    2018-02-01

    Full Text Available In the aluminum die casting process, erosion, corrosion, soldering, and die sticking have a significant influence on tool life and product quality. A number of coatings such as TiN, CrN, and (Cr,AlN deposited by physical vapor deposition (PVD have been employed to act as protective coatings due to their high hardness and chemical stability. In this study, the wear performance of two nanocomposite AlTiN and AlCrN coatings with different structures were evaluated. These coatings were deposited on aluminum die casting mold tool substrates (AISI H13 hot work steel by PVD using pulsed cathodic arc evaporation, equipped with three lateral arc-rotating cathodes (LARC and one central rotating cathode (CERC. The research was performed in two stages: in the first stage, the outlined coatings were characterized regarding their chemical composition, morphology, and structure using glow discharge optical emission spectroscopy (GDOES, scanning electron microscopy (SEM, and X-ray diffraction (XRD, respectively. Surface morphology and mechanical properties were evaluated by atomic force microscopy (AFM and nanoindentation. The coating adhesion was studied using Mersedes test and scratch testing. During the second stage, industrial tests were carried out for coated die casting molds. In parallel, tribological tests were also performed in order to determine if a correlation between laboratory and industrial tests can be drawn. All of the results were compared with a benchmark monolayer AlCrN coating. The data obtained show that the best performance was achieved for the AlCrN/Si3N4 nanocomposite coating that displays an optimum combination of hardness, adhesion, soldering behavior, oxidation resistance, and stress state. These characteristics are essential for improving the die mold service life. Therefore, this coating emerges as a novelty to be used to protect aluminum die casting molds.

  8. Tribological and Wear Performance of Nanocomposite PVD Hard Coatings Deposited on Aluminum Die Casting Tool.

    Science.gov (United States)

    Paiva, Jose Mario; Fox-Rabinovich, German; Locks Junior, Edinei; Stolf, Pietro; Seid Ahmed, Yassmin; Matos Martins, Marcelo; Bork, Carlos; Veldhuis, Stephen

    2018-02-28

    In the aluminum die casting process, erosion, corrosion, soldering, and die sticking have a significant influence on tool life and product quality. A number of coatings such as TiN, CrN, and (Cr,Al)N deposited by physical vapor deposition (PVD) have been employed to act as protective coatings due to their high hardness and chemical stability. In this study, the wear performance of two nanocomposite AlTiN and AlCrN coatings with different structures were evaluated. These coatings were deposited on aluminum die casting mold tool substrates (AISI H13 hot work steel) by PVD using pulsed cathodic arc evaporation, equipped with three lateral arc-rotating cathodes (LARC) and one central rotating cathode (CERC). The research was performed in two stages: in the first stage, the outlined coatings were characterized regarding their chemical composition, morphology, and structure using glow discharge optical emission spectroscopy (GDOES), scanning electron microscopy (SEM), and X-ray diffraction (XRD), respectively. Surface morphology and mechanical properties were evaluated by atomic force microscopy (AFM) and nanoindentation. The coating adhesion was studied using Mersedes test and scratch testing. During the second stage, industrial tests were carried out for coated die casting molds. In parallel, tribological tests were also performed in order to determine if a correlation between laboratory and industrial tests can be drawn. All of the results were compared with a benchmark monolayer AlCrN coating. The data obtained show that the best performance was achieved for the AlCrN/Si₃N₄ nanocomposite coating that displays an optimum combination of hardness, adhesion, soldering behavior, oxidation resistance, and stress state. These characteristics are essential for improving the die mold service life. Therefore, this coating emerges as a novelty to be used to protect aluminum die casting molds.

  9. Generating material strength standards of aluminum alloys for research reactors. Pt. 1. Yield strength values Sy and tensile strength values Su

    International Nuclear Information System (INIS)

    Tsuji, H.; Miya, K.

    1995-01-01

    Aluminum alloys are frequently used as structural materials for research reactors. The material strength standards, however, such as the yield strength values (S y ), the tensile strength values (S u ) and the design fatigue curve -which are needed to use aluminum alloys as structural materials in ''design by analysis'' - for those materials have not been determined yet. Hence, a series of material tests was performed and the results were statistically analyzed with the aim of generating these material strength standards. This paper, the first in a series on material strength standards of aluminum alloys, describes the aspects of the tensile properties of the standards. The draft standards were compared with MITI no. 501 as well as with the ASME codes, and the trend of the available data also was examined. It was revealed that the draft proposal could be adopted as the material strength standards, and that the values of the draft standards at and above 150 C for A6061-T6 and A6063-T6 could be applied only to the reactor operating conditions III and IV. Also the draft standards have already been adopted in the Science and Technology Agency regulatory guide (standards for structural design of nuclear research plants). (orig.)

  10. Effect of hot-humid exposure on static strength of adhesive-bonded aluminum alloys

    Directory of Open Access Journals (Sweden)

    Rui Zheng

    2015-09-01

    Full Text Available The effect of hot-humid exposure (i.e., 40 °C and 98% R.H. on the quasi-static strength of the adhesive-bonded aluminum alloys was studied. Test results show that the hot-humid exposure leads to the significant decrease in the joint strength and the change of the failure mode from a mixed cohesive and adhesive failure with cohesive failure being dominant to adhesive failure being dominant. Careful analyses of the results reveal that the physical bond is likely responsible for the bond adhesion between L adhesive and aluminum substrates. The reduction in joint strength and the change of the failure mode resulted from the degradation in bond adhesion, which was primarily attributed to the corrosion of aluminum substrate. In addition, the elevated temperature exposure significantly accelerated the corrosion reaction of aluminum, which accelerated the degradation in joint strength.

  11. Prediction of as-cast grain size of inoculated aluminum alloys melt solidified under non-isothermal conditions

    International Nuclear Information System (INIS)

    Du, Qiang; Li, Yanjun

    2015-01-01

    In this paper, a multi-scale as-cast grain size prediction model is proposed to predict as-cast grain size of inoculated aluminum alloys melt solidified under non-isothermal condition, i.e., the existence of temperature gradient. Given melt composition, inoculation and heat extraction boundary conditions, the model is able to predict maximum nucleation undercooling, cooling curve, primary phase solidification path and final as-cast grain size of binary alloys. The proposed model has been applied to two Al-Mg alloys, and comparison with laboratory and industrial solidification experimental results have been carried out. The preliminary conclusion is that the proposed model is a promising suitable microscopic model used within the multi-scale casting simulation modelling framework. (paper)

  12. The Cryogenic Properties of Several Aluminum-Beryllium Alloys and a Beryllium Oxide Material

    Science.gov (United States)

    Gamwell, Wayne R.; McGill, Preston B.

    2003-01-01

    Performance related mechanical properties for two aluminum-beryllium (Al-Be) alloys and one beryllium-oxide (BeO) material were developed at cryogenic temperatures. Basic mechanical properties (Le., ultimate tensile strength, yield strength, percent elongation, and elastic modulus were obtained for the aluminum-beryllium alloy, AlBeMetl62 at cryogenic [-195.5"C (-320 F) and -252.8"C (-423"F)I temperatures. Basic mechanical properties for the Be0 material were obtained at cyrogenic [- 252.8"C (-423"F)] temperatures. Fracture properties were obtained for the investment cast alloy Beralcast 363 at cryogenic [-252.8"C (-423"F)] temperatures. The AlBeMetl62 material was extruded, the Be0 material was hot isostatic pressing (HIP) consolidated, and the Beralcast 363 material was investment cast.

  13. Characterization and Mechanical Properties of 2014 Aluminum Alloy Reinforced with Al2O3p Composite Produced by Two-Stage Stir Casting Route

    Science.gov (United States)

    Bharath, V.; Ajawan, Santhrusht S.; Nagaral, Madev; Auradi, Virupaxi; Kori, Shivaputrappa Amarappa

    2018-02-01

    Metal matrix composites (MMC's) form appropriate choice of materials where there is a demand for stiffness, strength combined with low weight for different applications. The applications of Aluminum based MMC's as engineering materials has been exceedingly increased in almost all industrial sectors. Aluminum strengthened with Al2O3p gives excellent physical and mechanical properties like high hardness, low density, high electrical conductivity etc., which are generally used in the field of aerospace, automobile and industrial applications. In present work, an attempt is being made to integrate 2014 Al alloy with Al2O3p by two stage stir casting with addition level of reinforcement maintained at 9 and 12 wt%. Microstructural characterization carried out using scanning electron microscopy showed fairly uniform distribution of Al2O3p with grain refinement of the matrix. These prepared composites are mechanically characterized as per the ASTM standards using computerized universal testing machine. Improvements in tensile strength, density and hardness of the prepared composites were observed with increase in the reinforcement wt%. Percentage improvements of 5.09% (9 wt%), 17.65% (12 wt%) in terms of tensile strength and 29.18% (9 wt%), 43.69% (12 wt%) in terms of hardness were obtained respectively.

  14. Evaluation of the Characteristics of the Aluminum Alloy Casting Material by Heat Treatment

    International Nuclear Information System (INIS)

    Lee, Syung Yul; Park, Dong Hyun; Won, Jong Pil; Kim, Yun Hae; Lee, Myung Hoon; Moon, Kyung Man; Jeong, Jae Hyun

    2012-01-01

    Aluminum is on active metal, but it is well known that its oxide film plays a role as protective barrier which is comparatively stable in air and neutral aqueous solution. Thus, aluminum alloys have been widely applied in architectural trim, cold and hot-water storage vessels and piping etc., furthermore, the aluminum alloy of AC8A have been widely used in mold casting material of engine piston because of its properties of temperature and wear resistance. In recent years, the oil price is getting higher and higher, thus the using of low quality oil has been significantly increased in engines of ship and vehicle. Therefore it is considered that evaluation of corrosion resistance as well as wear resistance of AC8A material is also important to improve its property and prolong its lifetime. In this study, the effect of solution and tempering heat treatment to corrosion and wear resistance is investigated with electrochemical method and measurement of hardness. The hardness decreased with solution heat treatment compared to mold casting condition, but its value increased with tempering heat treatment and exhibited the highest value of hardness with tempering heat treatment temperature at 190 .deg. C for 24hrs. Furthermore, corrosion resistance increased with decreasing of the hardness, and decreased with increasing of the hardness reversely. As a result, it is suggested that the optimum heat treatment to improve both corrosion and wear resistance is tempering heat treatment temperature at 190 .deg. C for 16hrs

  15. Strength Estimation of Die Cast Beams Considering Equivalent Porous Defects

    Energy Technology Data Exchange (ETDEWEB)

    Park, Moon Shik [Hannam Univ., Daejeon (Korea, Republic of)

    2017-05-15

    As a shop practice, a strength estimation method for die cast parts is suggested, in which various defects such as pores can be allowed. The equivalent porosity is evaluated by combining the stiffness data from a simple elastic test at the part level during the shop practice and the theoretical stiffness data, which are defect free. A porosity equation is derived from Eshelby's inclusion theory. Then, using the Mori-Tanaka method, the porosity value is used to draw a stress-strain curve for the porous material. In this paper, the Hollomon equation is used to capture the strain hardening effect. This stress-strain curve can be used to estimate the strength of a die cast part with porous defects. An elastoplastic theoretical solution is derived for the three-point bending of a die cast beam by using the plastic hinge method as a reference solution for a part with porous defects.

  16. Permanent Mold Casting of JIS-AC4C Aluminum Alloy Using a Low-Temperature Mold

    International Nuclear Information System (INIS)

    Yamagata, Hiroshi; Nikawa, Makoto

    2011-01-01

    Permanent mold casting using mold temperatures below 200 deg. C was conducted to obtain a high-strength, thin-walled casting. Al-7.36 mass% Si -0.18 Cu- 0.27Mg-0.34Fe alloy JIS-AC4C was cast using a bottom pouring cast plan. The product had a rectangular tube shape (70 mm W x 68 mm D x 180 mm H) with wall thicknesses of 1, 3 and 5 mm. The effect of heat insulation at the melt path was compared when using a sand runner insert and when using a steel runner insert as well as a powder mold release agent. Fine microstructures were observed in the casting. The smaller the thickness, the higher the hardness with smaller secondary dendrite arm spacing (SDAS). However, the hardness and the SDAS were unaffected by the mold temperature. It was proposed that the avoidance of the formation of primary α dendrite at the melt path generates a higher strength casting with adequate mold filling.

  17. Squeeze casting of aluminum alloy A380: Microstructure and tensile behavior

    Directory of Open Access Journals (Sweden)

    Li Fang

    2015-09-01

    Full Text Available A380 alloy with a relatively thick cross-section of 25 mm was squeeze cast using a hydraulic press with an applied pressure of 90 MPa. Microstructure and tensile properties of the squeeze cast A380 were characterized and evaluated in comparison with the die cast counterpart. Results show that the squeeze cast A380 possesses a porosity level much lower than the die cast alloy, which is disclosed by both optical microscopy and the density measurement technique. The results of tensile testing indicate the improved tensile properties, specifically ultimate tensile strength (UTS: 215.9 MPa and elongation (Ef: 5.4%, for the squeeze cast samples over those of the conventional high-pressure die cast part (UTS: 173.7 MPa, Ef: 1.0%. The analysis of tensile behavior shows that the squeeze cast A380 exhibits a high tensile toughness (8.5 MJ·m-3 and resilience (179.3 kJ·m-3 compared with the die cast alloy (toughness: 1.4 MJ·m-3, resilience: 140.6 kJ·m-3, despite that, during the onset of plastic deformation, the strain-hardening rate of the die cast specimen is higher than that of the squeeze cast specimens. The microstructure analyzed by the scanning electron microscopy (SEM shows that both the squeeze and die cast specimens contain the primary α-Al, Al2Cu, Al5FeSi phase and the eutectic Si phase. But, the Al2Cu phase present in the squeeze cast alloy is relatively large in size and quantity. The SEM fractography evidently reveals the ductile fracture features of the squeeze cast A380 alloy.

  18. Numerical Simulation of Steady State Conduction Heat Transfer During the Solidification of Aluminum Casting in Green Sand Mould

    Directory of Open Access Journals (Sweden)

    Victor ANJO

    2012-08-01

    Full Text Available The solidification of molten metal during the casting process involves heat transfer from the molten metal to the mould, then to the atmosphere. The mechanical properties and grain size of metals are determined by the heat transfer process during solidification. The aim of this study is to numerically stimulate the steady conduction heat transfer during the solidification of aluminum in green sand mould using finite difference analysis 2D. The properties of materials used are industrial AI 50/60 AFS green sand mould, pure aluminum and MATLAB 7.0.1. for the numerical simulation. The method includes; the finite difference analysis of the heat conduction equation in steady (Laplace’s and transient states and using MATLAB to numerically stimulate the thermal flow and cooling curve. The results obtained are: the steady state thermal flow in 2D and transient state cooling curve of casting. The results obtain were consider relevant in the control of the grain size and mechanical properties of the casting.

  19. Comparative Evaluation of Cast Aluminum Alloys for Automotive Cylinder Heads: Part II—Mechanical and Thermal Properties

    Science.gov (United States)

    Roy, Shibayan; Allard, Lawrence F.; Rodriguez, Andres; Porter, Wallace D.; Shyam, Amit

    2017-05-01

    The first part of this study documented the as-aged microstructure of five cast aluminum alloys namely, 206, 319, 356, A356, and A356+0.5Cu, that are used for manufacturing automotive cylinder heads (Roy et al. in Metall Mater Trans A, 2016). In the present part, we report the mechanical response of these alloys after they have been subjected to various levels of thermal exposure. In addition, the thermophysical properties of these alloys are also reported over a wide temperature range. The hardness variation due to extended thermal exposure is related to the evolution of the nano-scale strengthening precipitates for different alloy systems (Al-Cu, Al-Si-Cu, and Al-Si). The effect of strengthening precipitates (size and number density) on the mechanical response is most obvious in the as-aged condition, which is quantitatively demonstrated by implementing a strength model. Significant coarsening of precipitates from long-term heat treatment removes the strengthening efficiency of the nano-scale precipitates for all these alloys systems. Thermal conductivity of the alloys evolve in an inverse manner with precipitate coarsening compared to the strength, and the implications of the same for the durability of cylinder heads are noted.

  20. synthesis and characterization of al/sic composite made by stir casting method

    International Nuclear Information System (INIS)

    Ghauri, K.M.; Ahmad, A.; Ahmad, R.; Din, K.M.; Chaudhry, J.A.

    2013-01-01

    Ceramics contain a distinctive property of completely absence of slip planes and have least probability of deforming by the application of force. Among these ceramics, the silicon carbide occupies a competent place to be used as a reinforcing agent for aluminum or its alloys. It has the density close to aluminum and is best for making composite having good strength and good heat conductivity. Stir casting has been used to synthesize Al/SiC MMCs by reinforcing silicon carbide particles into aluminum matrix. The reason for using stir casting is to develop technology for the development of MMCs at affordable cost. The selection of SiC as reinforcement and Al as matrix is because of their easy availability. The practical data acquired, analyzed and optimized will be interpreted in the light of information available in the literature and be shared with the relevant industries. The present work was mainly carried out to characterize the SiC/Al composite which was produced by reinforcing the various proportions of SiC (5, 10, 15, 25 and 30%) in aluminum matrix using stir casting technique. Mechanical properties of test specimens made from stir-casted Aluminum-Silicon Carbide composites have been studied using metallographic and mechanical testing techniques. It was observed that as the volume fraction of SiC in the composite is gradually increased, the hardness and toughness increase. However, beyond a level of 25-30 percent SiC, the results are not very consistent, and depend largely on the uniformity of distribution of SiC in the aluminum matrix. (author)

  1. Connection between hot tearing and cold cracking in DC-casting of AA7050 : Experiments and computer simulations

    NARCIS (Netherlands)

    Sosro Subroto, T.A.

    2014-01-01

    Direct-chill (DC) casting is one of the most common methods to produce ingots of high-strength aluminum alloys such as an AA7050. Despite of its superior mechanical properties, this alloy is prone to both hot tearing (HT) and cold cracking (CC) during DC casting. HT form above the solidus while CC

  2. USE OF HIGH-STRENGTH BAINITIC CAST IRON FOR PRODUCING GEAR WHEELS

    Directory of Open Access Journals (Sweden)

    A. I. Pokrovskiy

    2015-01-01

    Full Text Available The advantages and drawbacks of high-strength cast irons with bainitic structure are reviewed basing on the authors’ own experience in the production of critical partsfrom this material and on the analysis of world trends. A possibility of the replacement of alloy steels by bainitic cast iron in manufacturing critical machine parts is discussed.

  3. High-strength and high-RRR Al-Ni alloy for aluminum-stabilized superconductor

    CERN Document Server

    Wada, K; Sakamoto, H; Yamamoto, A; Makida, Y

    2000-01-01

    The precipitation type aluminum alloys have excellent performance as the increasing rate in electric resistivity with additives in the precipitation state is considerably low, compared to that of the aluminum alloy with additives in the solid-solution state. It is possible to enhance the mechanical strength without remarkable degradation in residual resistivity ratio (RRR) by increasing content of selected additive elements. Nickel is the suitable additive element because it has very low solubility in aluminum and low increasing rate in electric resistivity, and furthermore, nickel and aluminum form intermetallic compounds which effectively resist the motion of dislocations. First, Al-0.1wt%Ni alloy was developed for the ATLAS thin superconducting solenoid. This alloy achieved high yield strength of 79 MPa (R.T.) and 117 MPa (4.2 K) with high RRR of 490 after cold working of 21% in area reduction. These highly balanced properties could not be achieved with previously developed solid-solution aluminum alloys. ...

  4. A process chain for integrating piezoelectric transducers into aluminum die castings to generate smart lightweight structures

    Directory of Open Access Journals (Sweden)

    Stefan Stein

    Full Text Available The application of piezoelectric transducers to structural body parts of machines or vehicles enables the combination of passive mechanical components with sensor and actuator functions in one single structure. According to Herold et al. [1] and Staeves [2] this approach indicates significant potential regarding smart lightweight construction. To obtain the highest yield, the piezoelectric transducers need to be integrated into the flux of forces (load path of load bearing structures. Application in a downstream process reduces yield and process efficiency during manufacturing and operation, due to the necessity of a subsequent process step of sensor/actuator application. The die casting process offers the possibility for integration of piezoelectric transducers into metal structures. Aluminum castings are particularly favorable due to their high quality and feasibility for high unit production at low cost (Brunhuber [3], Nogowizin [4]. Such molded aluminum parts with integrated piezoelectric transducers enable functions like active vibration damping, structural health monitoring or energy harvesting resulting in significant possibilities of weight reduction, which is an increasingly important driving force of automotive and aerospace industry (Klein [5], Siebenpfeiffer [6] due to increasingly stringent environmental protection laws. In the scope of those developments, this paper focuses on the entire process chain enabling the generation of lightweight metal structures with sensor and actuator function, starting from the manufacturing of piezoelectric modules over electrical and mechanical bonding to the integration of such modules into aluminum (Al matrices by die casting. To achieve this challenging goal, piezoceramic sensors/actuator modules, so-called LTCC/PZT modules (LPM were developed, since ceramic based piezoelectric modules are more likely to withstand the thermal stress of about 700 °C introduced by the casting process (Flössel et

  5. A process chain for integrating piezoelectric transducers into aluminum die castings to generate smart lightweight structures

    Science.gov (United States)

    Stein, Stefan; Wedler, Jonathan; Rhein, Sebastian; Schmidt, Michael; Körner, Carolin; Michaelis, Alexander; Gebhardt, Sylvia

    The application of piezoelectric transducers to structural body parts of machines or vehicles enables the combination of passive mechanical components with sensor and actuator functions in one single structure. According to Herold et al. [1] and Staeves [2] this approach indicates significant potential regarding smart lightweight construction. To obtain the highest yield, the piezoelectric transducers need to be integrated into the flux of forces (load path) of load bearing structures. Application in a downstream process reduces yield and process efficiency during manufacturing and operation, due to the necessity of a subsequent process step of sensor/actuator application. The die casting process offers the possibility for integration of piezoelectric transducers into metal structures. Aluminum castings are particularly favorable due to their high quality and feasibility for high unit production at low cost (Brunhuber [3], Nogowizin [4]). Such molded aluminum parts with integrated piezoelectric transducers enable functions like active vibration damping, structural health monitoring or energy harvesting resulting in significant possibilities of weight reduction, which is an increasingly important driving force of automotive and aerospace industry (Klein [5], Siebenpfeiffer [6]) due to increasingly stringent environmental protection laws. In the scope of those developments, this paper focuses on the entire process chain enabling the generation of lightweight metal structures with sensor and actuator function, starting from the manufacturing of piezoelectric modules over electrical and mechanical bonding to the integration of such modules into aluminum (Al) matrices by die casting. To achieve this challenging goal, piezoceramic sensors/actuator modules, so-called LTCC/PZT modules (LPM) were developed, since ceramic based piezoelectric modules are more likely to withstand the thermal stress of about 700 °C introduced by the casting process (Flössel et al., [7]). The

  6. Improving the casting properties of high-strength aluminium alloys:

    OpenAIRE

    Ekrt, Ondřej; Šerák, Jan; Vojtěch, Dalibor

    2004-01-01

    Al-Zn-Mg-Cu alloys are examples of high-strength alloys. After age-hardening they often possess tensile strengths of more than 500 MPa. However, their casting properties are relatively poor as a result of solidification intervals that are too wide. Therefore, they often require an extrusion, rolling, or forging treatment, and the production of small series of special parts can, as a consequence, be very expensive. In this study, an improvement in the castability and a reduction of the hot-tea...

  7. Tensile strength and fatigue strength of 6061 aluminum alloy friction welded joints

    Energy Technology Data Exchange (ETDEWEB)

    Ochi, H.; Tsujino, R. [Osaka Inst. of Tech., Asahi-ku Osaka (Japan); Sawai, T. [Osaka Sangyo Univ., Daito (Japan); Yamamoto, Y. [Setsunan Univ., Neyagawa (Japan); Ogawa, K. [Osaka Prefecture Univ., Sakai (Japan); Suga, Y. [Keio Univ., Kohoku-ku, Yokohama (Japan)

    2002-07-01

    Friction welding of 6061 aluminum alloy was carried out in order to examine the relationship between deformation heat input in the upset stage and joint performance. The joint performance was evaluated by tensile testing and fatigue testing. Stabilized tensile strength was obtained when the deformation heat input in the upset stage exceeded 200 J/s. Weld condition at the weld interface and the width of softened area affected fatigue strength more than tensile strength. That is, when the weld condition at the weld interface is good and the softened area is wide, fatigue strength increases. On the other hand, when the weld condition at the weld interface is good and the softened area is narrow, and when the weld condition at the weld interface is somewhat poor in spite of the wide softened area, fatigue strength decreases. The fatigue limit obtained by the fatigue testing revealed that, when the deformation heat input in the upset stage exceeded a certain value, sound joints could be produced. (orig.)

  8. Mechanical properties and microstructure of stir casted Al/B{sub 4}C/garnet composites

    Energy Technology Data Exchange (ETDEWEB)

    Kumar, Rathinam Ashok [Chendhuran College of Engineering and Technology, Tamil Nadu (India). Mechanical Engineering Dept.; Sait, Abdullah Naveen [Chendhuran College of Engineering and Technology, Tamil Nadu (India); Subramanian, Karuppazhi [Government College of Engineering, Tamil Nadu (India). Dept. of Mechanical Engineering

    2017-05-01

    Aluminum based metal matrix composites are one of the advanced engineering materials that have been developed for low weight and high strength applications in automotive industries due to high specific strength and good wear resistance. In this context, aluminum alloy boron carbide and garnet composites were fabricated by the stir casting process. The microstructural examination was done by using a scanning electron microscope to assess the distribution of particulates in the aluminum matrix. The composites were characterized by hardness and tensile tests. The wear behavior of the composites was analyzed with the help of a pin-on-disc wear test. By increasing the amount of garnet in the composite, it has been observed that the tensile strength and hardness increase. The wear test analysis proved that the addition of reinforcements reduces the wear rate behavior of composite.

  9. Aerospace Patented High-Strength Aluminum Alloy Used in Commercial Industries

    Science.gov (United States)

    2004-01-01

    NASA structural materials engineers at Marshall Space Flight Center (MSFC) in Huntsville, Alabama developed a high-strength aluminum alloy for aerospace applications with higher strength and wear-resistance at elevated temperatures. The alloy is a solution to reduce costs of aluminum engine pistons and lower engine emissions for the automobile industry. The Boats and Outboard Engines Division at Bombardier Recreational Products of Sturtevant, Wisconsin is using the alloy for pistons in its Evinrude E-Tec outboard, 40-90 horsepower, engine line. The alloy pistons make the outboard motor quieter and cleaner, while improving fuel mileage and increasing engine durability. The engines comply with California Air resources Board emissions standards, some of the most stringent in the United States. (photo credit: Bombardiier Recreational Products)

  10. Flow Strength of Shocked Aluminum in the Solid-Liquid Mixed Phase Region

    Science.gov (United States)

    Reinhart, William

    2011-06-01

    Shock waves have been used to determine material properties under high shock stresses and very-high loading rates. The determination of mechanical properties such as compressive strength under shock compression has proven to be difficult and estimates of strength have been limited to approximately 100 GPa or less in aluminum. The term ``strength'' has been used in different ways. For a Von-Mises solid, the yield strength is equal to twice the shear strength of the material and represents the maximum shear stress that can be supported before yield. Many of these concepts have been applied to materials that undergo high strain-rate dynamic deformation, as in uni-axial strain shock experiments. In shock experiments, it has been observed that the shear stress in the shocked state is not equal to the shear strength, as evidenced by elastic recompressions in reshock experiments. This has led to an assumption that there is a yield surface with maximum (loading)and minimum (unloading), shear strength yet the actual shear stress lies somewhere between these values. This work provides the first simultaneous measurements of unloading velocity and flow strength for transition of solid aluminum to the liquid phase. The investigation describes the flow strength observed in 1100 (pure), 6061-T6, and 2024 aluminum in the solid-liquid mixed phase region. Reloading and unloading techniques were utilized to provide independent data on the two unknowns (τc and τo) , so that the actual critical shear strength and the shear stress at the shock state could be estimated. Three different observations indicate a change in material response for stresses of 100 to 160 GPa; 1) release wave speed (reloading where applicable) measurements, 2) yield strength measurements, and 3) estimates of Poisson's ratio, all of which provide information on the melt process including internal consistency and/or non-equilibrium and rate-dependent melt behavior. The study investigates the strength properties

  11. Strength and deformation behaviour of magnesium die casting alloys

    International Nuclear Information System (INIS)

    Regener, D.; Schick, E.; Wagner, I.; Heyse, H.

    1999-01-01

    Modern magnesium die casting alloys are used for the manufacturing of automotive parts due to their low density, fortunate mechanical and physical properties as well as good castability and machinability. However, in comparison to other materials the automotive application of these alloys is still low. The reasons for this are among other things the shortage of relevant materials values, insufficient knowledge concerning the correlation between the microstructure and the mechanical properties as well as deficits in relation to the die cast technology. This paper investigates the influence of the microstructure and manufacture-induced defects like micro-shrinkage and gas pores on the strength and deformability of the alloys AZ91, AM50 and AE42 under tensile and bend loading. To characterise the microstructure in the dependence on the wall thickness, the investigations are mainly carried out using in situ specimens obtained from die castings. (orig.)

  12. The Impact of Ceramic Shell Strength on Hot Tearing during Investment Casting

    International Nuclear Information System (INIS)

    Norouzi, Saeid; Farhangi, Hassan

    2011-01-01

    The effect of ceramic shell strength on hot tearing susceptibility during solidification was inspected practicing investment casting of the cobalt-base superalloy samples with the same casting conditions, but different ceramic shell systems. Results showed that the lower the ceramic shell strength upon using polymer additives, the lower the hindered contraction rate, and the lower the hindered contraction rate, the smaller the hot tearing tendency. Optical microscopy and electron microscopy scanning revealed that the hot tear propagated along the last solidified interdendritic phase, and that the hot tear surface had two major modes: 1) the ductile region in the outer layer; and 2) the inner region of liquid embrittlement.

  13. Microstructure of Friction Stir Welded AlSi9Mg Cast with 5083 and 2017A Wrought Aluminum Alloys

    Science.gov (United States)

    Hamilton, C.; Kopyściański, M.; Dymek, S.; Węglowska, A.; Pietras, A.

    2018-03-01

    Wrought aluminum alloys 5083 and 2017A were each joined with cast aluminum alloy AlSi9Mg through friction stir welding in butt weld configurations. For each material system, the wrought and cast alloy positions, i.e., the advancing side or the retreating side, were exchanged between welding trials. The produced weldments were free from cracks and discontinuities. For each alloy configuration, a well-defined nugget comprised of alternating bands of the welded alloys characterized the microstructure. The degree of mixing, however, strongly depended on which wrought alloy was present and on its position during processing. In all cases, the cast AlSi9Mg alloy dominated the weld center regardless of its position during welding. Electron backscattered diffraction analysis showed that the grain size in both alloys (bands) constituting the nugget was similar and that the majority of grain boundaries exhibited a high angle character (20°-60°). Regardless of the alloy, however, all grains were elongated along the direction of the material plastic flow during welding. A numerical simulation of the joining process visualized the material flow patterns and temperature distribution and helped to rationalize the microstructural observations. The hardness profiles across the weld reflected the microstructure formed during welding and correlated well with the temperature changes predicted by the numerical model. Tensile specimens consistently fractured in the cast alloy near the weld nugget.

  14. [Effects of laser welding on bond of porcelain fused cast pure titanium].

    Science.gov (United States)

    Zhu, Juan-fang; He, Hui-ming; Gao, Bo; Wang, Zhong-yi

    2006-04-01

    To investigate the influence of the laser welding on bond of porcelain fused to cast pure titanium. Twenty cast titanium plates were divided into two groups: laser welded group and control group. The low-fusing porcelain was fused to the laser welded cast pure titanium plates at fusion zone. The bond strength of the porcelain to laser welded cast pure titanium was measured by the three-point bending test. The interface of titanium and porcelain was investigated by scanning electron microscopy (SEM) and energy depressive X-ray detector (EDX). The non-welded titanium plates were used as comparison. No significant difference of the bond strength was found between laser-welded samples [(46.85 +/- 0.76) MPa] and the controls [(41.71 +/- 0.55) MPa] (P > 0.05). The SEM displayed the interface presented similar irregularities with a predominance. The titanium diffused to low-fusing porcelain, while silicon and aluminum diffused to titanium basement. Laser welding does not affect low-fusing porcelain fused to pure titanium.

  15. Filtration of aluminum alloys and its influence on mechanical properties and shape of eutectical silicium

    Directory of Open Access Journals (Sweden)

    M. Brůna

    2008-07-01

    Full Text Available Filtration during casting of high quality aluminum alloys belongs to main refining methods. Even when there are many years of experiences and experimental works on this subject, there are still some specific anomalies. While using ceramic filtration media during casting of aluminum alloys, almost in all experiments occurred increase of strength limit and atypical increase of extension. This anomaly was not explained with classical metallurgical methods, black-white contrast after surface etching neither with color surface etching. For that reason was used deep etching on REM. By using pressed ceramic filters, by studying morphology eutectical silicon was observed modification morphology of eutectical silicon, this explains increase extension after filtration. Pressed ceramic filters were used on experimental works. Casting was executed on hardenable alloy AlSi10MgMn.

  16. Microstructure And Mechanical Properties Of An Al-Zn-Mg-Cu Alloy Produced By Gravity Casting Process

    Directory of Open Access Journals (Sweden)

    Saikawa S.

    2015-06-01

    Full Text Available High-strength aluminum alloy are widely used for structural components in aerospace, transportation and racing car applications. The objective of this study is to enhance the strength of the Al-Zn-Mg-Cu alloy used for gravity casting process. All alloys cast into stepped-form sand mold (Sand-mold Casting; SC and Y-block shaped metal mold(Permanent mold Casting; PC C and then two –step aged at 398-423 K after solution treated at 743 K for 36 ks. The tensile strength and total elongation of the two-step aged SC alloys were 353-387 MPa and about 0.4% respectively. This low tensile properties of the SC alloys might be caused by remaining of undissolved crystallized phase such as Al2CuM, MgZn2 and Al-Fe-Cu system compounds. However, good tensile properties were obtained from PC alloys, tensile strength and 0.2% proof stress and elongation were 503-537 MPa, 474-519 MPa and 1.3-3.3%.

  17. Decontamination and reuse of ORGDP aluminum scrap

    International Nuclear Information System (INIS)

    Compere, A.L.; Griffith, W.L.; Hayden, H.W.; Wilson, D.F.

    1996-12-01

    The Gaseous Diffusion Plants, or GDPs, have significant amounts of a number of metals, including nickel, aluminum, copper, and steel. Aluminum was used extensively throughout the GDPs because of its excellent strength to weight ratios and good resistance to corrosion by UF 6 . This report is concerned with the recycle of aluminum stator and rotor blades from axial compressors. Most of the stator and rotor blades were made from 214-X aluminum casting alloy. Used compressor blades were contaminated with uranium both as a result of surface contamination and as an accumulation held in surface-connected voids inside of the blades. A variety of GDP studies were performed to evaluate the amounts of uranium retained in the blades; the volume, area, and location of voids in the blades; and connections between surface defects and voids. Based on experimental data on deposition, uranium content of the blades is 0.3%, or roughly 200 times the value expected from blade surface area. However, this value does correlate with estimated internal surface area and with lengthy deposition times. Based on a literature search, it appears that gaseous decontamination or melt refining using fluxes specific for uranium removal have the potential for removing internal contamination from aluminum blades. A melt refining process was used to recycle blades during the 1950s and 1960s. The process removed roughly one-third of the uranium from the blades. Blade cast from recycled aluminum appeared to perform as well as blades from virgin material. New melt refining and gaseous decontamination processes have been shown to provide substantially better decontamination of pure aluminum. If these techniques can be successfully adapted to treat aluminum 214-X alloy, internal and, possibly, external reuse of aluminum alloys may be possible

  18. Microstructural evolution and wear characteristics of equal channel angular pressing processed semi-solid-cast hypoeutectic aluminum alloys

    International Nuclear Information System (INIS)

    Thuong, Nguyen Van; Zuhailawati, Hussain; Seman, Anasyida Abu; Huy, Tran Duc; Dhindaw, Brij Kumar

    2015-01-01

    Highlights: • We produced aluminum feedstock for ECAP by two casting techniques: conventional and with cooling slope. • Globular α-Al phase was found in cooling slope sample compared to dendritic in the conventional. • After ECAP uniform Si particles distribution and fine α-Al were observed for cooling slope. • We observed significant improvement in wear resistance of ECAPed sample produced by cooling slope. - Abstract: This work investigated the microstructural evolution of Al–7Si–Mg alloy cast semi-solid using a cooling slope as well as conventional casting followed by equal channel angular pressing (ECAP) in a 120° die. Feed materials were prepared for ECAP by cooling slope casting and by conventional casting. The microstructure of the processed alloys extruded was observed by optical microscope and by transmission electron microscope, and their hardness and wear resistance were evaluated. After ECAP processing, the primary α-Al phase tended to be elongated while the Si particles became fragmented and more nearly globular in shape and uniform in size than in the as-cast sample. The microstructure of the cooling slope-cast ECAPed samples was more homogenous than that of the conventionally cast ECAPed sample. The α-Al phase sub-grains were refined to sub-micrometer sizes for samples cast by both methods after ECAP. The hardness of the cooling slope-cast ECAPed sample was also higher than that of the conventionally cast ECAPed sample. The wear resistance of the alloy improved after cooling slope casting and ECAP processing

  19. Study on Pot Forming of Induction Heater Type Rice Cookers by Forging Cast Process

    Science.gov (United States)

    Ohnishi, Masayuki; Yamaguchi, Mitsugi; Ohashi, Osamu

    This paper describes a study result on pot fabrication by the forging cast process of stainless steel with aluminum. Rice cooked with the new bowl-shaped pot for the induction heater type rice cookers is better tasting than rice cooked with the conventional cylindrical one, due to the achievement of better heat conduction and convection. The conventional pot is made of the clad sheet, consisting of stainless steel and aluminum. However, it is rather difficult to form a bowl shape from the clad sheet, primarily due to the problem of a material spring back. The fabrication of a new type of a pot was made possible by means of the adoption of a forging cast process instead of the clad sheet. In this process, iron powder is inserted between stainless steel and aluminum in order to alleviate the large difference on the coefficient of expansion between each material. It was made clear that the application of two kinds of iron particle, namely 10 μm size powder on the stainless steel side and 44 μm on the aluminum side, enables the joints to become strong enough. The joint strength of the new pot by this fabrication process was confirmed by the tests of the shear strength and the fatigue tests together with the stress analysis.

  20. Anodization of cast aluminium alloys produced by different casting methods

    Directory of Open Access Journals (Sweden)

    K. Labisz

    2008-08-01

    Full Text Available In this paper the usability of two casting methods, of sand and high pressure cast for the anodization of AlSi12 and AlSi9Cu3 aluminium cast alloys was investigated. With defined anodization parameters like electrolyte composition and temperature, current type and value a anodic alumina surface layer was produced. The quality, size and properties of the anodic layer was investigated after the anodization of the chosen aluminium cast alloys. The Alumina layer was observed used light microscope, also the mechanical properties were measured as well the abrasive wear test was made with using ABR-8251 equipment. The researches included analyze of the influence of chemical composition, geometry and roughness of anodic layer obtained on aluminum casts. Conducted investigations shows the areas of later researches, especially in the direction of the possible, next optimization anodization process of aluminum casting alloys, for example in the range of raising resistance on corrosion to achieve a suitable anodic surface layer on elements for increasing applications in the aggressive environment for example as materials on working building constructions, elements in electronics and construction parts in air and automotive industry.

  1. The effect of hot isostatic pressing on the microstructure and tensile properties of an unmodified A356-T6 cast aluminum alloy

    International Nuclear Information System (INIS)

    Ran Guang; Zhou Jingen; Wang, Q.G.

    2006-01-01

    In this paper, the effect of HIPping process on the microstructure and tensile properties of an unmodified sand cast A356-T6 aluminum alloy was studied. The microstructure and tensile fracture surfaces of the alloy were examined by transmission electron microscope (TEM), scanning electron microscope (SEM) and optical microscope. The results show that sub-grain boundaries are formed by HIPping process, and some silicon precipitates are formed at the sub-grain boundaries during aging hardening. The needle-shape precipitates are Mg 2 Si particles according to SED pattern analysis. The lattice misfit between Mg 2 Si and aluminum matrix is about 0.256% for [111] Al //[410] Mg 2 Si HIPping process significantly reduces porosity volume fraction and pore sizes and thus improves ductility. However, the tensile strength is improved very marginally due to the brittle nature of the unmodified coarse microstructure. The sub-grain boundary formed in the HIPping process has not shown significant influence on the tensile properties. For the studied alloy with large secondary dendrite arm spacing (SDAS) (above 80μm), the tensile fracture exhibits a transgranular mode (along the cell boundaries) with quasi-cleavage feature

  2. Residual Stresses in DC cast Aluminum Billet: Neutron Diffraction Measurements and Thermomechanical Modeling

    International Nuclear Information System (INIS)

    Drezet, J.-M.; Evans, A.; Pirling, T.

    2011-01-01

    Thermally-induced residual stresses, generated during the industrial Direct Chill casting process of aluminum alloys, can cause both significant safety concerns as well as the formation of defects during down-stream processing. Although these thermally induced strains can be partially relieved by permanent deformation, cracks will be generated either during solidification (hot tears) or post-solidification cooling (cold cracks) when stresses exceed the deformation limit of the alloy. Furthermore, the thermally induced strains result in the presence of large internal stresses within the billet before further processing steps. Although numerical models have been previously developed to compute these residual stresses, most of the computations have been validated only against measured surface distortions. In the present work, the variation in residual elastic strains and stresses in the steady state regime of casting has been measured as a function of radial position using neutron diffraction in an AA6063 grain-refined cylindrical billet. These measurements have been carried out on the same billet section at Poldi at PSI-Villigen and at Salsa at ILL-Grenoble and compare favorably. The results are used to validate a thermo-mechanical finite element casting model and to assess the level of stored elastic energy within the billet.

  3. The effect of zinc on the microstructure and phase transformations of casting Al-Cu alloys

    Directory of Open Access Journals (Sweden)

    Manasijević Ivana I.

    2016-01-01

    Full Text Available Copper is one of the main alloying elements for aluminum casting alloys. As an alloying element, copper significantly increases the tensile strength and toughness of alloys based on aluminum. The copper content in the industrial casting aluminum alloys ranges from 3,5 to 11 wt.%. However, despite the positive effect on the mechanical properties, copper has a negative influence on the corrosion resistance of aluminum and its alloys. In order to further improve the properties of Al-Cu alloys they are additional alloyed with elements such as zinc, magnesium and others. In this work experimental and analytical examination of the impact of zinc on the microstructure and phase transformations of Al-Cu alloys was carried out. In order to determine the effect of the addition of zinc to the structure and phase transformations of Al-Cu alloys two alloys of Al-Cu-Zn system with selected compositions were prepared and then examined using scanning electron microscopy with energy-dispersive spectroscopy (SEM-EDX. The experimental results were compared with the results of thermodynamic calculations of phase equilibria.

  4. Experimental Investigation and FE Analysis on Constitutive Relationship of High Strength Aluminum Alloy under Cyclic Loading

    Directory of Open Access Journals (Sweden)

    Yuanqing Wang

    2016-01-01

    Full Text Available Experiments of 17 high strength aluminum alloy (7A04 specimens were conducted to investigate the constitutive relationship under cyclic loading. The monotonic behavior and hysteretic behavior were focused on and the fracture surface was observed by scanning electron microscope (SEM to investigate the microfailure modes. Based on Ramberg-Osgood model, stress-strain skeleton curves under cyclic loading were fitted. Parameters of combined hardening model including isotropic hardening and kinematic hardening were calibrated from test data according to Chaboche model. The cyclic tests were simulated in finite element software ABAQUS. The test results show that 7A04 aluminum alloy has obvious nonlinearity and ultra-high strength which is over 600 MPa, however, with relatively poor ductility. In the cyclic loading tests, 7A04 aluminum alloy showed cyclic hardening behavior and when the compressive strain was larger than 1%, the stiffness degradation and strength degradation occurred. The simulated curves derived by FE model fitted well with experimental curves which indicates that the parameters of this combined model can be used in accurate calculation of 7A04 high strength aluminum structures under cyclic loading.

  5. Influence of casting defects on fatigue strength of an investment cast Ti-6Al-4V alloy

    Directory of Open Access Journals (Sweden)

    Léopold Gaëlle

    2014-06-01

    Full Text Available The influence of casting defects on fatigue strength of an investment cast Ti-6Al-4V alloy is investigated. The most common of these defects are: pinhole, linear defect and inclusion. Each of them is currently defined by its size, morphology and position from the surface but is different from each other for a same type. An experimental campaign is defined with different types of defect. The first part of the campaign is focused on the influence of an artificial and spherical defect, considering two different surface conditions. It is shown that fatigue behaviour of this alloy is very sensitive to the surface condition of this artificial defect despite stress concentrations at the tip of the defect. The second part of the campaign is focused on casting defects: reduction of fatigue life is quantified and it is shown that an electro-discharge machined defect cannot be representative of pinhole.

  6. Precision forging technology for aluminum alloy

    Science.gov (United States)

    Deng, Lei; Wang, Xinyun; Jin, Junsong; Xia, Juchen

    2018-03-01

    Aluminum alloy is a preferred metal material for lightweight part manufacturing in aerospace, automobile, and weapon industries due to its good physical properties, such as low density, high specific strength, and good corrosion resistance. However, during forging processes, underfilling, folding, broken streamline, crack, coarse grain, and other macro- or microdefects are easily generated because of the deformation characteristics of aluminum alloys, including narrow forgeable temperature region, fast heat dissipation to dies, strong adhesion, high strain rate sensitivity, and large flow resistance. Thus, it is seriously restricted for the forged part to obtain precision shape and enhanced property. In this paper, progresses in precision forging technologies of aluminum alloy parts were reviewed. Several advanced precision forging technologies have been developed, including closed die forging, isothermal die forging, local loading forging, metal flow forging with relief cavity, auxiliary force or vibration loading, casting-forging hybrid forming, and stamping-forging hybrid forming. High-precision aluminum alloy parts can be realized by controlling the forging processes and parameters or combining precision forging technologies with other forming technologies. The development of these technologies is beneficial to promote the application of aluminum alloys in manufacturing of lightweight parts.

  7. The influence of the parameters of lost foam process on the quality of aluminum alloys castings

    Directory of Open Access Journals (Sweden)

    Aćimović-Pavlović Zagorka

    2010-01-01

    Full Text Available This paper presents the research results of application of Lost foam process for aluminum alloys castings of a simple geometry. The process characteristic is that patterns and gating of moulds, made of polymers, stay in the mould till the liquid metal inflow. In contact with the liquid metal, pattern intensely and in relatively short time decomposes and evaporates, which is accompanied by casting crystallization. As a consequence of polymer pattern decomposition and evaporation a great quantity of liquid and gaseous products are produced, which is often the cause of different types of casting errors. This paper presents the results of a research with a special consideration given to detecting and analyzing the errors of castings. In most cases the cause of these errors are defects of polymer materials used for evaporable patterns production, as well as defects of materials for refractory coatings production for polymer patterns. The researches have shown that different types of coatings determine properties of the obtained castings. Also, the critical processing parameters (polymer pattern density, casting temperature, permeability of refractory coating and sand, construction of patterns and gating of moulds significantly affect on castings quality. During the research a special consideration was given to control and optimization of these parameters with the goal of achieving applicable castings properties. The study of surface and internal error of castings was performed systematically in order to carry out preventive measures to avoid errors and minimize production costs. In order to achieve qualitative and profitable castings production by the method of Lost foam it is necessary to reach the balance in the system: evaporable polymer pattern - liquid metal - refractory coating - sandy cast in the phase of metal inflow, decomposition and evaporation of polymer pattern, formation and solidification of castings. By optimizing the processing

  8. Precise Analysis of Microstructural Effects on Mechanical Properties of Cast ADC12 Aluminum Alloy

    Science.gov (United States)

    Okayasu, Mitsuhiro; Takeuchi, Shuhei; Yamamoto, Masaki; Ohfuji, Hiroaki; Ochi, Toshihiro

    2015-04-01

    The effects of microstructural characteristics (secondary dendrite arm spacing, SDAS) and Si- and Fe-based eutectic structures on the mechanical properties and failure behavior of an Al-Si-Cu alloy are investigated. Cast Al alloy samples are produced using a special continuous-casting technique with which it is easy to control both the sizes of microstructures and the direction of crystal orientation. Dendrite cells appear to grow in the casting direction. There are linear correlations between SDAS and tensile properties (ultimate tensile strength σ UTS, 0.2 pct proof strength σ 0.2, and fracture strain ɛ f). These linear correlations, however, break down, especially for σ UTS vs SDAS and ɛ f vs SDAS, as the eutectic structures become more than 3 μm in diameter, when the strength and ductility ( σ UTS and ɛ f) decrease significantly. For eutectic structures larger than 3 μm, failure is dominated by the brittle eutectic phases, for which SDAS is no longer strongly correlated with σ UTS and ɛ f. In contrast, a linear correlation is obtained between σ 0.2 and SDAS, even for eutectic structures larger than 3 μm, and the eutectic structure does not have a strong effect on yield behavior. This is because failure in the eutectic phases occurs just before final fracture. In situ failure observation during tensile testing is performed using microstructural and lattice characteristics. From the experimental results obtained, models of failure during tensile loading are proposed.

  9. Design of Helical Self-Piercing Rivet for Joining Aluminum Alloy and High-Strength Steel Sheets

    International Nuclear Information System (INIS)

    Kim, W. Y.; Kim, D. B.; Park, J. G; Kim, D. H.; Kim, K. H.; Lee, I. H.; Cho, H. Y.

    2014-01-01

    A self-piercing rivet (SPR) is a mechanical component for joining dissimilar material sheets such as those of aluminum alloy and steel. Unlike conventional rivets, the SPR directly pierces sheets without the need for drilling them beforehand. However, the regular SPR can undergo buckling when it pierces a high-strength steel sheet, warranting the design of a helical SPR. In this study, the joining and forging processes using the helical SPR were simulated using the commercial FEM code, DEFORM-3D. High-tensile-strength steel sheets of different strengths were joined with aluminum alloy sheets using the designed helical SPR. The simulation results were found to agree with the experimental results, validating the optimal design of a helical SPR that can pierce high-strength steel sheets

  10. Design of Helical Self-Piercing Rivet for Joining Aluminum Alloy and High-Strength Steel Sheets

    Energy Technology Data Exchange (ETDEWEB)

    Kim, W. Y.; Kim, D. B.; Park, J. G; Kim, D. H.; Kim, K. H.; Lee, I. H.; Cho, H. Y. [Chungbuk National University, Cheongju (Korea, Republic of)

    2014-07-15

    A self-piercing rivet (SPR) is a mechanical component for joining dissimilar material sheets such as those of aluminum alloy and steel. Unlike conventional rivets, the SPR directly pierces sheets without the need for drilling them beforehand. However, the regular SPR can undergo buckling when it pierces a high-strength steel sheet, warranting the design of a helical SPR. In this study, the joining and forging processes using the helical SPR were simulated using the commercial FEM code, DEFORM-3D. High-tensile-strength steel sheets of different strengths were joined with aluminum alloy sheets using the designed helical SPR. The simulation results were found to agree with the experimental results, validating the optimal design of a helical SPR that can pierce high-strength steel sheets.

  11. The effect of casting conditions on the biaxial flexural strength of glass-ceramic materials.

    Science.gov (United States)

    Johnson, A; Shareef, M Y; Walsh, J M; Hatton, P V; van Noort, R; Hill, R G

    1998-11-01

    To assess the effect of mould and glass casting temperatures on the biaxial flexural strength (BFS) of two different types of castable glass-ceramic, using existing laboratory equipment and techniques. Two castable glass-ceramic materials were evaluated. One glass (LG3) is based on SiO2-Al2O3-P2O5-CaO-CaF2, and is similar in composition to glasses used in the manufacture of glass-ionomer cements. The other glass (SG3) is based on SiO2-K2O-Na2O-CaO-CaF2, and is a canasite-based material. Both materials were used to produce discs of 12 mm diameter and 2 mm thickness using the same lost-wax casting process as used for metal castings. Mould temperatures of between 500 degrees C and 1000 degrees C and glass casting temperatures of between 1100 degrees C and 1450 degrees C were evaluated. The cast discs were cerammed and the biaxial flexural strength determined with a Lloyd 2000 R tester. A significant difference was found for the BFS in the range of mould temperatures evaluated, with the optimum investment mould temperature being 590 degrees C for LG3 and 610 degrees C for SG3 (p = 0.0002 and p = 0.019, respectively). No significant differences were seen between any of the glass casting temperatures evaluated. The mould temperature for castable glass-ceramic materials produced using the lost-wax casting process can have a significant effect on BFS. The optimum mould temperature may differ slightly depending on the type of material being used. The glass casting temperature of these materials does not appear to have a significant effect on BFS.

  12. Influence of Post Weld Heat Treatment on Strength of Three Aluminum Alloys Used in Light Poles

    Directory of Open Access Journals (Sweden)

    Craig C. Menzemer

    2016-03-01

    Full Text Available The conjoint influence of welding and artificial aging on mechanical properties were investigated for extrusions of aluminum alloy 6063, 6061, and 6005A. Uniaxial tensile tests were conducted on the aluminum alloys 6063-T4, 6061-T4, and 6005A-T1 in both the as-received (AR and as-welded (AW conditions. Tensile tests were also conducted on the AR and AW alloys, subsequent to artificial aging. The welding process used was gas metal arc (GMAW with spray transfer using 120–220 A of current at 22 V. The artificial aging used was a precipitation heat treatment for 6 h at 182 °C (360 °F. Tensile tests revealed the welded aluminum alloys to have lower strength, both for yield and ultimate tensile strength, when compared to the as-received un-welded counterpart. The beneficial influence of post weld heat treatment (PWHT on strength and ductility is presented and discussed in terms of current design provisions for welded aluminum light pole structures.

  13. Mechanical Performance of Cold-Sprayed A357 Aluminum Alloy Coatings for Repair and Additive Manufacturing

    Science.gov (United States)

    Petráčková, K.; Kondás, J.; Guagliano, M.

    2017-12-01

    Cold-sprayed coatings made of A357 aluminum alloy, a casting alloy widely used in aerospace, underwent set of standard tests as well as newly developed fatigue test to gain an information about potential of cold spray for repair and additive manufacturing of loaded parts. With optimal spray parameters, coating deposition on substrate with smooth surface resulted in relatively good bonding, which can be further improved by application of grit blasting on substrate's surface. However, no enhancement of adhesion was obtained for shot-peened surface. Process temperature, which was set either to 450 or 550 °C, was shown to have an effect on adhesion and cohesion strength, but it does not influence residual stress in the coating. To assess cold spray perspectives for additive manufacturing, flat tensile specimens were machined from coating and tested in as-sprayed and heat-treated (solution treatment and aging) condition. Tensile properties of the coating after the treatment correspond to properties of the cast A357-T61 aluminum alloy. Finally, fatigue specimen was proposed to test overall performance of the coating and coating's fatigue limit is compared to the results obtained on cast A357-T61 aluminum alloy.

  14. Microcapillary Features in Silicon Alloyed High-Strength Cast Iron

    Directory of Open Access Journals (Sweden)

    R.K. Hasanli

    2017-04-01

    Full Text Available Present study explores features of silicon micro capillary in alloyed high-strength cast iron with nodular graphite (ductile iron produced in metal molds. It identified the nature and mechanism of micro liquation of silicon in a ductile iron alloyed with Nickel and copper, and demonstrated significant change of structural-quality characteristics. It was concluded that the matrix of alloyed ductile iron has a heterogeneous structure with cross reinforcement and high-silicon excrement areas.

  15. Comparison of the bond strength of ceramics to Co-Cr alloys made by casting and selective laser melting.

    Science.gov (United States)

    Lawaf, Shirin; Nasermostofi, Shahbaz; Afradeh, Mahtasadat; Azizi, Arash

    2017-02-01

    Considering the importance of metal-ceramic bond, the present study aimed to compare the bond strength of ceramics to cobalt-chrome (Co-Cr) alloys made by casting and selective laser melting (SLM). In this in-vitro experimental study, two sample groups were prepared, with one group comprising of 10 Co-Cr metal frameworks fabricated by SLM method and the other of 10 Co-Cr metal frameworks fabricated by lost wax cast method with the dimensions of 0.5 × 3 × 25 mm (following ISO standard 9693). Porcelain with the thickness of 1.1 mm was applied on a 3 × 8-mm central rectangular area of each sample. Afterwards, bond strengths of the samples were assessed with a Universal Testing Machine. Statistical analysis was performed with Kolmogorov-Smirnov test and T-test. Bond strength in the conventionally cast group equaled 74.94 ± 16.06 MPa, while in SLM group, it equaled 69.02 ± 5.77 MPa. The difference was not statistically significant ( P ≤ .05). The results indicated that the bond strengths between ceramic and Co-Cr alloys made by casting and SLM methods were not statistically different.

  16. Bioinspired, Graphene/Al2O3 Doubly Reinforced Aluminum Composites with High Strength and Toughness.

    Science.gov (United States)

    Zhang, Yunya; Li, Xiaodong

    2017-11-08

    Nacre, commonly referred to as nature's armor, has served as a blueprint for engineering stronger and tougher bioinspired materials. Nature organizes a brick-and-mortar-like architecture in nacre, with hard bricks of aragonite sandwiched with soft biopolymer layers. However, cloning nacre's entire reinforcing mechanisms in engineered materials remains a challenge. In this study, we employed hybrid graphene/Al 2 O 3 platelets with surface nanointerlocks as hard bricks for primary load bearer and mechanical interlocking, along with aluminum laminates as soft mortar for load distribution and energy dissipation, to replicate nacre's architecture and reinforcing effects in aluminum composites. Compared with aluminum, the bioinspired, graphene/Al 2 O 3 doubly reinforced aluminum composite demonstrated an exceptional, joint improvement in hardness (210%), strength (223%), stiffness (78%), and toughness (30%), which are even superior over nacre. This design strategy and model material system should guide the synthesis of bioinspired materials to achieve exceptionally high strength and toughness.

  17. Development of high-strength aluminum alloys for basket in transport and storage cask for high burn-up spent fuel

    International Nuclear Information System (INIS)

    Maeguchi, T.; Sakaguchi, Y.; Kamiwaki, Y.; Ishii, M.; Yamamoto, T.

    2004-01-01

    Mitsubishi Heavy Industries, Ltd. (MHI) has developed high-strength borated aluminum alloys (high-strength B-Al alloys), suitable for application to baskets in transport and storage casks for high burn-up spent fuels. Aluminum is a suitable base material for the baskets due to its low density and high thermal conductivity. The aluminum basket would reduce weight of the cask, and effectively release heat generated by spent fuels. MHI had already developed borated aluminum alloys (high-toughness B-Al alloy), and registered them as ASME Code Case ''N-673''. However, there has been a strong demand for basket materials with higher strength in the case of MSF (Mitsubishi Spent Fuel) casks for high-burn up spent fuels, since the basket is required to stand up to higher stress at higher temperature. The high-strength basket material enables the design of a compact cask under a limitation of total size and weight. MHI has developed novel high-strength B-Al alloys which meet these requirements, based on a new manufacturing process. The outline of mechanical and metallurgical characteristics of the high-strength B-Al alloys is described in this paper

  18. Models for Strength Prediction of High-Porosity Cast-In-Situ Foamed Concrete

    Directory of Open Access Journals (Sweden)

    Wenhui Zhao

    2018-01-01

    Full Text Available A study was undertaken to develop a prediction model of compressive strength for three types of high-porosity cast-in-situ foamed concrete (cement mix, cement-fly ash mix, and cement-sand mix with dry densities of less than 700 kg/m3. The model is an extension of Balshin’s model and takes into account the hydration ratio of the raw materials, in which the water/cement ratio was a constant for the entire construction period for a certain casting density. The results show that the measured porosity is slightly lower than the theoretical porosity due to few inaccessible pores. The compressive strength increases exponentially with the increase in the ratio of the dry density to the solid density and increases with the curing time following the composite function A2ln⁡tB2 for all three types of foamed concrete. Based on the results that the compressive strength changes with the porosity and the curing time, a prediction model taking into account the mix constitution, curing time, and porosity is developed. A simple prediction model is put forward when no experimental data are available.

  19. Microstructure and mechanical properties of friction stir welded Al/Mg2Si metal matrix cast composite

    International Nuclear Information System (INIS)

    Nami, H.; Adgi, H.; Sharifitabar, M.; Shamabadi, H.

    2011-01-01

    In this research, friction stir weldability of 15 wt.% Mg 2 Si particulate aluminum matrix cast composite and effects of tool rotation speed and number of welding passes on microstructure and mechanical properties of the joints were investigated. Microstructural observations were carried out by employing optical and scanning electron microscopy of the cross sections perpendicular to the tool traverse direction. Mechanical properties including microhardness and tensile strength were evaluated in detail. The results showed fragmentation of Mg 2 Si particles and Mg 2 Si needles existing in eutectic structure in stir zone. Also, homogeneous distribution of Mg 2 Si particles was observed in the stir zone as a result of stirring with high plastic strains. Tension test results indicated that tensile strength of the joint had an optimum at 1120 rpm tool rotation speed and decreased with increasing of the number of welding passes. Hardness of the joint increased due to modification of solidification microstructure of the base composite. This research indicates that friction stir welding is a good candidate for joining of 15 wt.% Mg 2 Si aluminum matrix composite castings.

  20. Precipitation behavior of aluminum alloy 2139 fabricated using additive manufacturing

    Energy Technology Data Exchange (ETDEWEB)

    Brice, Craig, E-mail: craig.a.brice@lmco.com [NASA Langley Research Center, Hampton, VA 23681 (United States); Shenoy, Ravi [Northrop Grumman Corporation Technical Services, Hampton, VA 23681 (United States); Kral, Milo; Buchannan, Karl [University of Canterbury, Christchurch (New Zealand)

    2015-11-11

    Additive manufacturing (AM) is an emerging technology capable of producing near net shape structures in a variety of materials directly from a computer model. Standard metallic alloys that were developed for cast or wrought processing have largely been adopted for AM feedstock. In many applications, these legacy alloys are quite acceptable. In the aluminum alloy family, however, there is a significant performance gap between the casting alloys currently being used in AM processes and the high strength/toughness capability available in certain wrought alloys. The precipitation hardenable alloys, most often used in high performance structures, present challenges for processing by AM. The near net shape nature of AM processes does not allow for mechanical work prior to the heat treatment that is often necessary to develop a uniform distribution of precipitates and give peak mechanical performance. This paper examines the aluminum (Al) alloy 2139, a composition that is strengthened by homogeneous precipitation of Ω (Al{sub 2}Cu) plates and thus ideally suited for near net shape processes like AM. Transmission electron microscopy, microhardness, and tensile testing determined that, with proper processing conditions, Al 2139 can be additively manufactured and subsequently heat treated to strength levels comparable to those of peak aged wrought Al 2139.

  1. Precipitation behavior of aluminum alloy 2139 fabricated using additive manufacturing

    International Nuclear Information System (INIS)

    Brice, Craig; Shenoy, Ravi; Kral, Milo; Buchannan, Karl

    2015-01-01

    Additive manufacturing (AM) is an emerging technology capable of producing near net shape structures in a variety of materials directly from a computer model. Standard metallic alloys that were developed for cast or wrought processing have largely been adopted for AM feedstock. In many applications, these legacy alloys are quite acceptable. In the aluminum alloy family, however, there is a significant performance gap between the casting alloys currently being used in AM processes and the high strength/toughness capability available in certain wrought alloys. The precipitation hardenable alloys, most often used in high performance structures, present challenges for processing by AM. The near net shape nature of AM processes does not allow for mechanical work prior to the heat treatment that is often necessary to develop a uniform distribution of precipitates and give peak mechanical performance. This paper examines the aluminum (Al) alloy 2139, a composition that is strengthened by homogeneous precipitation of Ω (Al_2Cu) plates and thus ideally suited for near net shape processes like AM. Transmission electron microscopy, microhardness, and tensile testing determined that, with proper processing conditions, Al 2139 can be additively manufactured and subsequently heat treated to strength levels comparable to those of peak aged wrought Al 2139.

  2. Production and characterization of AA6061-B4C stir cast composite

    International Nuclear Information System (INIS)

    Kalaiselvan, K.; Murugan, N.; Parameswaran, Siva

    2011-01-01

    Highlights: → Stir casting of AA6061-B 4 C Composite. Color metallographic of composites → Enhanced wetting of B 4 C particles by K 2 TiF 6 flux. → Effect of B 4 C particles on mechanical properties of AA6061. -- Abstract: This work focuses on the fabrication of aluminum (6061-T6) matrix composites (AMCs) reinforced with various weight percentage of B 4 C particulates by modified stir casting route. The wettability of B 4 C particles in the matrix has been improved by adding K 2 TiF 6 flux into the melt. The microstructure and mechanical properties of the fabricated AMCs are analyzed. The optical microstructure and scanning electron microscope (SEM) images reveal the homogeneous dispersion of B 4 C particles in the matrix. The reinforcement dispersion has also been identified with X-ray diffraction (XRD). The mechanical properties like hardness and tensile strength have improved with the increase in weight percentage of B 4 C particulates in the aluminum matrix.

  3. TiB2 reinforced aluminum based in situ composites fabricated by stir casting

    International Nuclear Information System (INIS)

    Chen, Fei; Chen, Zongning; Mao, Feng; Wang, Tongmin; Cao, Zhiqiang

    2015-01-01

    In this study, a new technique involving mechanical stirring at the salts/aluminum interface was developed to fabricate TiB 2 particulate reinforced aluminum based in situ composites with improved particle distribution. Processing parameters in terms of stirring intensity, stirring duration and stirring start time were optimized according to the microstructure and mechanical properties evaluation. The results show that, the first and last 15 min of the entire 60 min holding are of prime importance to the particle distribution of the final composites. When applying 180 rpm (revolutions per minute) stirring at the salts/aluminum interface in these two intervals, a more uniform microstructure can be achieved and the Al-4 wt% TiB 2 composite thus produced exhibits superior mechanical performance. Synchrotron radiation X-ray computed tomography (SR-CT) was used to give a full-scale imaging of the particle distribution. From the SR-CT results, the in situ Al–xTiB 2 composites (x=1, 4 and 7, all in wt%) fabricated by the present technique are characterized by fine and clean TiB 2 particles distributed uniformly throughout the Al matrix. These composites not only have higher yield strength (σ 0.2 ) and ultimate tensile strength (UTS), but also exhibit superior ductility, with respect to the Al–TiB 2 composites fabricated by the conventional process. The σ 0.2 and UTS of the Al–7TiB 2 composite in the present work, are 260% and 180% higher than those of the matrix. A combined mechanism was also presented to interpret the improvements in yield strength of the composites as influenced by their microstructures and processing history. The predicted values are in good agreement with the experimental results, strongly supporting the strengthening mechanism we proposed. Fractography reveals that the composites thus fabricated, follow ductile fracture mechanism in spite of the presence of stiff reinforcements

  4. Mechanical strength parameters of cast iron with lamellar graphite and their significance for the design of pressure-carrying reactor components

    International Nuclear Information System (INIS)

    Janakiev, N.

    1977-01-01

    The tensile strength of thick-walled components in cast iron with lamellar graphite is lower by about 50 to 65% than that stated in DIN 1691. The usable compressive strength of this material under uni-axial load is about twice as high as its tensile strength. The graphite lamellae are not bonded into the metallic matrix. The width of the gaps between the graphite lamellae and the matrix increases with increasing wall thickness of the casting. In stress calculations for design purposes it is advisable to rely only on the permissible tensile stresses. It is shown that cast iron can be used as structural material for shieldings but is unsuitable for thick-walled reactor components carrying compressive and tensile stresses because its mechanical strength parameters decrease rapidly with increasing wall thickness. (orig.) [de

  5. Influence of scandium on the microstructure and strength properties of the welded joint at the laser welding of aluminum-lithium alloys

    Science.gov (United States)

    Malikov, A. G.; Golyshev, A. A.; Ivanova, M. Yu.

    2017-10-01

    Today, aeronautical equipment manufacture involves up-to-date high-strength aluminum alloys of decreased density resulting from lithium admixture. Various technologies of fusible welding of these alloys are being developed. Serious demands are imposed to the welded joints of aluminum alloys in respect to their strength characteristics. The paper presents experimental investigations of the optimization of the laser welding of aluminum alloys with the scandium-modified welded joint. The effect of scandium on the micro-and macro-structure has been studied as well as the strength characteristics of the welded joint. It has been found that scandium under in the laser welding process increases the welded joint elasticity for the system Al-Mg-Li, aluminum alloy 1420 by 20 %, and almost doubles the same for the system Al-Cu-Li, aluminum alloy 1441.

  6. Compressive Strength of EN AC-44200 Based Composite Materials Strengthened with α-Al2O3 Particles

    OpenAIRE

    Kurzawa A.; Kaczmar J. W.

    2017-01-01

    The paper presents results of compressive strength investigations of EN AC-44200 based aluminum alloy composite materials reinforced with aluminum oxide particles at ambient and at temperatures of 100, 200 and 250°C. They were manufactured by squeeze casting of the porous preforms made of α-Al2O3 particles with liquid aluminum alloy EN AC-44200. The composite materials were reinforced with preforms characterized by the porosities of 90, 80, 70 and 60 vol. %, thus the alumina content in the co...

  7. Melting and casting of FeAl-based cast alloy

    Energy Technology Data Exchange (ETDEWEB)

    Sikka, V.K. [Oak Ridge National Lab., TN (United States); Wilkening, D. [Columbia Falls Aluminum Co., Columbia Falls, MT (United States); Liebetrau, J.; Mackey, B. [AFFCO, L.L.C., Anaconda, MT (United States)

    1998-11-01

    The FeAl-based intermetallic alloys are of great interest because of their low density, low raw material cost, and excellent resistance to high-temperature oxidation, sulfidation, carburization, and molten salts. The applications based on these unique properties of FeAl require methods to melt and cast these alloys into complex-shaped castings and centrifugal cast tubes. This paper addresses the melting-related issues and the effect of chemistry on the microstructure and hardness of castings. It is concluded that the use of the Exo-Melt{trademark} process for melting and the proper selection of the aluminum melt stock can result in porosity-free castings. The FeAl alloys can be melted and cast from the virgin and revert stock. A large variation in carbon content of the alloys is possible before the precipitation of graphite flakes occurs. Titanium is a very potent addition to refine the grain size of castings. A range of complex sand castings and two different sizes of centrifugal cast tubes of the alloy have already been cast.

  8. Microstructures and constituents of super-high strength aluminum alloy ingots made through LFEC process

    Directory of Open Access Journals (Sweden)

    WANG Shuang

    2007-11-01

    Full Text Available Ingots of a new super-high strength Al-Zn-Mg-Cu-Zr alloy were produced respectively by low frequency electromagnetic casting (LFEC and by conventional direct chill (DC casting process. Microstructure and constituents of the ingots were studied. The results indicated that the LFEC process significantly refines microstructure and constituents of the alloy, and to some extent, decreases the area (or volume fraction of constituents and eutectic structure precipitated at grain boundaries. But, no difference in the type of constituents was observed between LFEC and DC ingots. The results also showed LFEC process can improve the as-cast mechanical properties.

  9. Comparison of microstructure and mechanical properties of A356 aluminum alloy/Al2O3 composites fabricated by stir and compo-casting processes

    International Nuclear Information System (INIS)

    Sajjadi, S.A.; Ezatpour, H.R.; Torabi Parizi, M.

    2012-01-01

    Highlights: → Nano and micro-composites (A356/Al 2 O 3 ) were fabricated by stir-casting and compo-casting. → Uniform distribution, grain refinement and low porosity in the composites were attained. → Addition of alumina led to the improvement in yield, ultimate tensile and compression strength. → Nano-alumina particles and compo-casting process obtained the best mechanical properties. -- Abstract: Metal-matrix composites (MMCs), as light and strong materials, are very attractive for application in different industries. In the present work, nano and micro-composites (A356/Al 2 O 3 ) with different weight percent of particles were fabricated by two melt techniques such as stir-casting and compo-casting. Microstructural characterization was investigated by optical (OP) and scanning electron microscopy (SEM). Tensile, hardness and compression tests were carried out in order to identify mechanical properties of the composites. The results of microstructural study revealed uniform distribution, grain refinement and low porosity in micro and nano-composite specimens. The mechanical results showed that the addition of alumina (micro and nano) led to the improvement in yield strength, ultimate tensile strength, compression strength and hardness. It was indicated that type of fabrication process and particle size were the effective factors influencing on the mechanical properties. Decreasing alumina particle size and using compo-casting process obtained the best mechanical properties.

  10. Graphene-aluminum nanocomposites

    International Nuclear Information System (INIS)

    Bartolucci, Stephen F.; Paras, Joseph; Rafiee, Mohammad A.; Rafiee, Javad; Lee, Sabrina; Kapoor, Deepak; Koratkar, Nikhil

    2011-01-01

    Highlights: → We investigated the mechanical properties of aluminum and aluminum nanocomposites. → Graphene composite had lower strength and hardness compared to nanotube reinforcement. → Processing causes aluminum carbide formation at graphene defects. → The carbides in between grains is a source of weakness and lowers tensile strength. - Abstract: Composites of graphene platelets and powdered aluminum were made using ball milling, hot isostatic pressing and extrusion. The mechanical properties and microstructure were studied using hardness and tensile tests, as well as electron microscopy, X-ray diffraction and differential scanning calorimetry. Compared to the pure aluminum and multi-walled carbon nanotube composites, the graphene-aluminum composite showed decreased strength and hardness. This is explained in the context of enhanced aluminum carbide formation with the graphene filler.

  11. Characterization of B4C-composite-reinforced aluminum alloy composites

    Science.gov (United States)

    Singh, Ram; Rai, R. N.

    2018-04-01

    Dry sliding wear tests conducted on Pin-on-disk wear test machine. The rotational speed of disc is ranging from (400-600rpm) and under loads ranging from (30-70 N) the contact time between the disc and pin is constant for each pin specimen of composites is 15 minute. In all manufacturing industries the uses of composite materials has been increasing globally, In the present study, an aluminum 5083 alloy is used as the matrix and 5% of weight percentage of Boron Carbide (B4C) as the reinforcing material. The composite is produced using stir casting technique. This is cost effective method. The aluminum 5083 matrix can be strengthened by reinforcing with hard ceramic particles like silicon carbide and boron carbide. In this experiment, aluminum 5083 alloy is selected as one of main material for making parts of the ship it has good mechanical properties, good corrosion resistance and it is can welded very easily and does have good strength. The samples are tested for hardness and tensile strength. The mechanical properties like Hardness can be increased by reinforcing aluminum 5083alloy 5% boron carbide (B4C) particles and tensile strength. Finally the Scanning Electron Microscope (SEM) analysis and EDS is done, which helps to study topography of composites and it produces images of a sample by scanning it with a focused beam of electrons and the presence of composition found in the matrix.

  12. Effect of electrical pulse on the precipitates and material strength of 2024 aluminum alloy

    Energy Technology Data Exchange (ETDEWEB)

    Wu, Weichao, E-mail: weichao127@gmail.com; Wang, Yongjun, E-mail: t.s.wu@163.com; Wang, Junbiao, E-mail: wangjunb@nwpu.edu.cn; Wei, Shengmin, E-mail: weism@nwpu.edu.cn

    2014-07-01

    The effect of electrical pulse on the metastable precipitates and material strength of Al–Cu–Mg based 2024 aluminum alloy was investigated by means of tensile tests, hardness measurement, transmission electron microscopy and differential scanning calorimetry. The experimental results show that the electrical pulse passing through the naturally aged 2024 alloy can cause an electrical pulse retrogression effect which is characterized by the decrease of material strength and the appearance of Portevin–Le Chatelier (PLC) effect. More electrical pulses under higher current densities are more efficient in causing the electrical pulse retrogression effect. TEM and DSC experimental results reveal that, the electrical pulse retrogression effect is owing to the dissolution of the metastable precipitates in naturally aged 2024 alloy. Compared with the traditional retrogression heat treatment that heats the aluminum alloys through bulk heating in furnace for short time to reduce their material strength, the electrical pulse retrogression effect occurs at a much lower temperature and the pulse treated alloy can nearly restore to its original strength at a faster speed at room temperature.

  13. Casting of microstructured shark skin surfaces and possible applications on aluminum casting parts

    Directory of Open Access Journals (Sweden)

    Todor Ivanov

    2011-02-01

    Full Text Available Within the project Functional Surfaces via Micro- and Nanoscaled Structures?which is part of the Cluster of Excellence 揑ntegrative Production Technology?established and financed by the German Research Foundation (DFG, an investment casting process to produce 3-dimensional functional surfaces down to a structural size of 1 μm on near-net-shape-casting parts has been developed. The common way to realize functional microstructures on metallic surfaces is to use laser ablation, electro discharge machining or micro milling. The handicap of these processes is their limited productivity. The approach of this project to raise the efficiency is to use the investment casting process to replicate microstructured surfaces by moulding from a laser-microstructured grand master pattern. The main research objective deals with the investigation of the single process steps of the investment casting process with regard to the moulding accuracy. Actual results concerning making of the wax pattern, suitability of ceramic mould and core materials for casting of an AlSi7Mg0.3 alloy as well as the knock-out behavior of the shells are presented. By using of the example of an intake manifold of a gasoline race car engine, a technical shark skin surface has been realized to reduce the drag of the intake air. The intake manifold consists of an air-restrictor with a defined inner diameter which is microstructured with technical shark skin riblets. For this reason the inner diameter cannot be drilled after casting and demands a very high accuracy of the casting part. A technology for the fabrication and demoulding of accurate microstructured castings are shown. Shrinkage factors of different moulding steps of the macroscopic casting part as well as the microscopic riblet structure have been examined as well.

  14. Experimental Observation and Analytical Modeling of Melting and Solidification during Aluminum Alloy Repair by Turbulence Flow Casting

    Directory of Open Access Journals (Sweden)

    Muki Satya Permana

    2015-10-01

    Full Text Available This paper presents an overview on the state of the art of applicable casting technology for applications in the field of repairing aluminum alloy components. Repair process on the Al alloy sample using similar metal has been carried out to investigate the micro-structural effect. Joining occurs as a result of convection heat transfer of molten flow into the sand mold which melts the existing base metal inside the mold and subsequent solidification. The analytical model has been developed to describe aluminum alloy component repair by turbulence flow casting. The model is designed based on heat transfer principle that can handle the phenomena of heat flow. The experimental result and analytical model analyses pointed out that joint quality are greatly affected by parameters of preheating temperature and duration of molten metal flow in the mold. To obtain a desired metallurgical sound at the joint, the optimum temperature and time were adjusted in order to obtain a similarity of microstructure between filler and base metal. This model is aimed to predict the use of the process parameter ranges in order to have the optimum parameters when it is applied to the experiment. The fixed parameters are flow rate, sand ratio, and pouring temperature. The process parameters are preheating temperature and pouring time. It is concluded that analytical modeling has good agreement with the experimental result.

  15. On the Effect of Natural Aging Prior to Low Temperature ECAP of a High-Strength Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    Sebastian Fritsch

    2018-01-01

    Full Text Available Severe plastic deformation (SPD can be used to generate ultra-fine grained microstructures and thus to increase the strength of many materials. Unfortunately, high strength aluminum alloys are generally hard to deform, which puts severe limits on the feasibility of conventional SPD methods. In this study, we use low temperature equal-channel angular pressing (ECAP to deform an AA7075 alloy. We perform ECAP in a custom-built, cooled ECAP-tool with an internal angle of 90° at −60 °C and with an applied backpressure. In previous studies, high-strength age hardening aluminum alloys were deformed in a solid solution heat treated condition to improve the mechanical properties in combination with subsequent (post-ECAP aging. In the present study, we systematically vary the initial microstructure—i.e., the material condition prior to low temperature ECAP—by (pre-ECAP natural aging. The key result of the present study is that precipitates introduced prior to ECAP speed up grain refinement during ECAP. Longer aging times lead to accelerated microstructural evolution, to increasing strength, and to a transition in fracture behavior after a single pass of low temperature ECAP. These results demonstrate the potential of these thermo-mechanical treatments to produce improved properties of high-strength aluminum alloys.

  16. The analysis of composite properties reinforced with particles from palm oil industry waste produced by casting methods

    Science.gov (United States)

    Tugiman; Ariani, F.; Taher, F.; Hasibuan, M. S.; Suprianto

    2017-12-01

    Palm oil processing industries are very attractive because they offer plenty products with high economic value. The CPO factory processes not only produces crude palm oil but also generates fly ash (FA) particles waste in its final process. The purpose of this investigation to analyze and increase the benefits of particles as reinforcement materials for fabricating aluminum matrix composites (AMC’s) by different casting route. Stirring, centrifugal and squeeze casting method was conducted in this study. Further, the chemical composition of FA particles, densities and mechanical properties have been analyzed. The characteristics of composite material were investigated using an Optical microscope, scanning electron microscope (SEM), hardness (Brinell), impact strength (Charpy). The pin on disc method was used to measure the wear rate. The results show that SiO2, Fe2O3, and Al2O3 are the main compounds of fly ash particles. These particles enhanced the hardness and reduce wear resistance of aluminum matrix composites. The squeeze method gives better results than stir and centrifugal casting.

  17. Cast thermally stable high temperature nickel-base alloys and casting made therefrom

    International Nuclear Information System (INIS)

    Acuncius, D.A.; Herchenroeder, R.B.; Kirchner, R.W.; Silence, W.L.

    1977-01-01

    A cast thermally stable high temperature nickel-base alloy characterized by superior oxidation resistance, sustainable hot strength and retention of ductility on aging is provided by maintaining the alloy chemistry within the composition molybdenum 13.7% to 15.5%; chromium 14.7% to 16.5%; carbon up to 0.1%, lanthanum in an effective amount to provide oxidation resistance up to 0.08%; boron up to 0.015%; manganese 0.3% to 1.0%; silicon 0.2% to 0.8%; cobalt up to 2.0%; iron up to 3.0%; tungsten up to 1.0%; copper up to 0.4%; phosphorous up to 0.02%; sulfur up to 0.015%; aluminum 0.1% to 0.5% and the balance nickel while maintaining the Nv number less than 2.31

  18. Consolidation of mechanically milled powder mixture of aluminum and quasicrystalline particle; Mechanical milling shita junkessho ryushi / aluminium gokin funmatsu no koka seikeisei

    Energy Technology Data Exchange (ETDEWEB)

    Yuasa, E.; Kawamura, C.; Sugiyama, T. [Musashi Institute of Technology, Tokyo (Japan)

    1998-10-15

    A quasi-crystalline Al65Cu20Fe15 powder prepared from alloy cast rapidly solidified by metal-mold casting, and then it was mixed to aluminum powder with various volume fractions by mechanical milling. The powder milled for above 50ks made homogeneous dispersion of quasi-crystalline phase with particle size less than 1{mu}m. The powder was hot-pressed under various conditions and then its features of consolidation were examined by the observation of microstructure and fracture strength in 3-point-bending of the compacts. When the milled powder was hot-pressed at higher compacting temperature than 673K for 3.6ks under pressure of 600MPa, the compact became to dense. Hardness of the obtained compact increases and its fracture strength decreases with increasing volume fraction of quasi-crystalline particles. Intermetallic compound Al7Cu2Fe forms in the interface of aluminum matrix and quasi-crystalline particle. 11 refs., 10 figs.

  19. Developing high strength and ductility in biomedical Co-Cr cast alloys by simultaneous doping with nitrogen and carbon.

    Science.gov (United States)

    Yamanaka, Kenta; Mori, Manami; Chiba, Akihiko

    2016-02-01

    There is a strong demand for biomedical Co-Cr-based cast alloys with enhanced mechanical properties for use in dental applications. We present a design strategy for development of Co-Cr-based cast alloys with very high strength, comparable to that of wrought Co-Cr alloys, without loss of ductility. The strategy consists of simultaneous doping of nitrogen and carbon, accompanied by increasing of the Cr content to increase the nitrogen solubility. The strategy was verified by preparing Co-33Cr-9W-0.35N-(0.01-0.31)C (mass%) alloys. We determined the carbon concentration dependence of the microstructures and their mechanical properties. Metal ion release of the alloys in an aqueous solution of 0.6% sodium chloride (NaCl) and 1% lactic acid was also evaluated to ensure their corrosion resistance. As a result of the nitrogen doping, the formation of a brittle σ-phase, a chromium-rich intermetallic compound, was significantly suppressed. Adding carbon to the alloys resulted in finer-grained microstructures and carbide precipitation; accordingly, the strength increased with increasing carbon concentration. The tensile ductility, on the other hand, increased with increasing carbon concentration only up to a point, reaching a maximum at a carbon concentration of ∼0.1mass% and decreasing with further carbon doping. However, the alloy with 0.31mass% of carbon exhibited 14% elongation and also possessed very high strength (725MPa in 0.2% proof stress). The addition of carbon did not significantly degrade the corrosion resistance. The results show that our strategy realizes a novel high-strength Co-Cr-based cast alloy that can be produced for advanced dental applications using a conventional casting procedure. The present study suggested a novel alloy design concept for realizing high-strength Co-Cr-based cast alloys. The proposed strategy is beneficial from the practical point of view because it uses conventional casting approach-a simpler, more cost-effective, industrially

  20. Simultaneous increase in strength and ductility by decreasing interface energy between Zn and Al phases in cast Al-Zn-Cu alloy.

    Science.gov (United States)

    Han, Seung Zeon; Choi, Eun-Ae; Park, Hyun Woong; Lim, Sung Hwan; Lee, Jehyun; Ahn, Jee Hyuk; Hwang, Nong-Moon; Kim, Kwangho

    2017-09-22

    Cast-Al alloys that include a high amount of the second element in their matrix have comparatively high strength but low ductility because of the high volume fraction of strengthening phases or undesirable inclusions. Al-Zn alloys that have more than 30 wt% Zn have a tensile strength below 300 MPa, with elongation under 5% in the as-cast state. However, we found that after substitution of 2% Zn by Cu, the tensile strength of as-cast Al-Zn-Cu alloys was 25% higher and ductility was four times higher than for the corresponding Al-35% Zn alloy. Additionally, for the Al-43% Zn alloy with 2% Cu after 1 h solution treatment at 400 °C and water quenching, the tensile strength unexpectedly reached values close to 600 MPa. For the Al-33% Zn alloy with 2% Cu, the tensile strength was 500 MPa with 8% ductility. The unusual trends of the mechanical properties of Al-Zn alloys with Cu addition observed during processing from casting to the subsequent solution treatment were attributed to the precipitation of Zn in the Al matrix. The interface energy between the Zn particles and the Al matrix decreased when using a solution of Cu in Zn.

  1. Application of a Pore Fraction Hot Tearing Model to Directionally Solidified and Direct Chill Cast Aluminum Alloys

    Science.gov (United States)

    Dou, Ruifeng; Phillion, A. B.

    2016-08-01

    Hot tearing susceptibility is commonly assessed using a pressure drop equation in the mushy zone that includes the effects of both tensile deformation perpendicular to the thermal gradient as well as shrinkage feeding. In this study, a Pore Fraction hot tearing model, recently developed by Monroe and Beckermann (JOM 66:1439-1445, 2014), is extended to additionally include the effect of strain rate parallel to the thermal gradient. The deformation and shrinkage pore fractions are obtained on the basis of the dimensionless Niyama criterion and a scaling variable method. First, the model is applied to the binary Al-Cu system under conditions of directional solidification. It is shown that for the same Niyama criterion, a decrease in the cooling rate increases both the deformation and shrinkage pore fractions because of an increase in the time spent in the brittle temperature region. Second, the model is applied to the industrial aluminum alloy AA5182 as part of a finite element simulation of the Direct Chill (DC) casting process. It is shown that an increase in the casting speed during DC casting increases the deformation and shrinkage pore fractions, causing the maximum point of pore fraction to move towards the base of the casting. These results demonstrate that including the strain rate parallel to the thermal gradient significantly improves the predictive quality of hot tearing criteria based on the pressure drop equation.

  2. Shaping the Strength of Cast Rocker Arm for Special Purpose Vehicle

    OpenAIRE

    Żuczek R.; Pysz S.; Maj M.; Piekło J.

    2015-01-01

    The article discusses the weldment to casting conversion process of rocker arm designed for operation in a special purpose vehicle to obtain a consistency of objective functions, which assume the reduced weight of component, the reduced maximum effort of material under the impact of service loads achieved through topology modification for optimum strength distribution in the sensitive areas, and the development of rocker arm manufacturing technology. As a result of conducted studies, the unit...

  3. Mechanical and thermal cycling effects on the flexural strength of glass ceramics fused to titanium

    NARCIS (Netherlands)

    Vasquez, Vanessa; Ozcan, Mutlu; Nishioka, Renato; Souza, Rodrigo; Mesquita, Alfredo; Pavanelli, Carlos

    This study evaluated the effects of mechanical and thermal cycling on the flexural strength (ISO 9693) of three brands of ceramics fused to commercially pure titanium (cpTi). Metallic frameworks of 25 x 3 x 0.5 mm dimensions (N = 84) were cast in cpTi, followed by 150-mu m aluminum oxide airborne

  4. Borated aluminum alloy manufacturing technology

    International Nuclear Information System (INIS)

    Shimojo, Jun; Taniuchi, Hiroaki; Kajihara, Katsura; Aruga, Yasuhiro

    2003-01-01

    Borated aluminum alloy is used as the basket material of cask because of its light weight, thermal conductivity and superior neutron absorbing abilities. Kobe Steel has developed a unique manufacturing process for borated aluminum alloy using a vacuum induction melting method. In this process, aluminum alloy is melted and agitated at higher temperatures than common aluminum alloy fabrication methods. It is then cast into a mold in a vacuum atmosphere. The result is a high quality aluminum alloy which has a uniform boron distribution and no impurities. (author)

  5. Compressive Strength of EN AC-44200 Based Composite Materials Strengthened with α-Al2O3 Particles

    Directory of Open Access Journals (Sweden)

    Kurzawa A.

    2017-06-01

    Full Text Available The paper presents results of compressive strength investigations of EN AC-44200 based aluminum alloy composite materials reinforced with aluminum oxide particles at ambient and at temperatures of 100, 200 and 250°C. They were manufactured by squeeze casting of the porous preforms made of α-Al2O3 particles with liquid aluminum alloy EN AC-44200. The composite materials were reinforced with preforms characterized by the porosities of 90, 80, 70 and 60 vol. %, thus the alumina content in the composite materials was 10, 20, 30 and 40 vol.%. The results of the compressive strength of manufactured materials were presented and basing on the microscopic observations the effect of the volume content of strengthening alumina particles on the cracking mechanisms during compression at indicated temperatures were shown and discussed. The highest compressive strength of 470 MPa at ambient temperature showed composite materials strengthened with 40 vol.% of α-Al2O3 particles.

  6. Vacuum Die Casting Process and Simulation for Manufacturing 0.8 mm-Thick Aluminum Plate with Four Maze Shapes

    Directory of Open Access Journals (Sweden)

    Chul Kyu Jin

    2015-02-01

    Full Text Available Using vacuum die casting, 0.8 mm-thick plates in complicated shapes are manufactured with the highly castable aluminum alloy Silafont-36 (AlSi9MgMn. The sizes and shapes of the cavities, made of thin plates, feature four different mazes. To investigate formability and mechanical properties by shot condition, a total of six parameters (melt temperatures of 730 °C and 710 °C; plunger speeds of 3.0 m/s and 2.5 m/s; vacuum pressure of 250 mbar and no vacuum are varied in experiments, and corresponding simulations are performed. Simulation results obtained through MAGMA software show similar tendencies to those of the experiments. When the melt pouring temperature is set to 730 °C rather than 710 °C, formability and mechanical properties are superior, and when the plunger speed is set to 3.0 m/s rather than to 2.5 m/s, a fine, even structure is obtained with better mechanical properties. The non-vacuumed sample is half unfilled. The tensile strength and elongation of the sample fabricated under a melt temperature of 730 °C, plunger speed of 3.0 m/s, and vacuum pressure of 250 mbar are 265 MPa and 8.5%, respectively.

  7. Endurance in Al Alloy Melts and Wear Resistance of Titanium Matrix Composite Shot-Sleeve for Aluminum Alloy Die-casting

    International Nuclear Information System (INIS)

    Choi, Bong-Jae; Kim, Young-Jig; Sung, Si-Young

    2012-01-01

    The main purpose of this study was to evaluate the endurance against Al alloy melts and wear resistance of an in-situ synthesized titanium matrix composite (TMC) sleeve for aluminum alloy die-casting. The conventional die-casting shot sleeve material was STD61 tool steel. TMCs have great thermal stability, wear and oxidation resistance. The in-situ reaction between Ti and B4C leads to two kinds of thermodynamically stable reinforcements, such as TiBw and TiCp. To evaluate the feasibility of the application to a TMCs diecasting shot sleeve, the interfacial reaction behavior was examined between Al alloys melts with TMCs and STD61 tool steel. The pin-on-disk type dry sliding wear test was also investigated for TMCs and STD61 tool steel.

  8. Pressing Speed, Specific Pressure and Mechanical Properties of Aluminium Cast

    Directory of Open Access Journals (Sweden)

    Gaspar S.

    2016-06-01

    Full Text Available Recent research in the process of aluminum alloy die castings production, which is nowadays deeply implemented into the rapidly growing automobile, shipping and aircraft industries, is aimed at increasing the useful qualitative properties of the die casting in order to obtain its high mechanical properties at acceptable economic cost. Problem of technological factors of high pressure die casting has been a subject of worldwide research (EU, US, Japan, etc.. The final performance properties of die castings are subjected to a large number of technological factors. The main technological factors of high pressure die casting are as follows: plunger pressing speed, specific (increase pressure, mold temperature as well as alloy temperature. The contribution discusses the impact of the plunger pressing speed and specific (increase pressure on the mechanical properties of the casting aluminum alloy.

  9. Nuclear-waste encapsulation by metal-matrix casting

    International Nuclear Information System (INIS)

    Nelson, R.G.; Nesbitt, J.F.; Slate, S.C.

    1981-05-01

    Several encapsulation casting processes are described that were developed or used at the Pacific Northwest Laboratory to embed simulated high-level wastes of two different forms (glass marbles and ceramic pellets) in metal matrices. Preliminary evaluations of these casting processes and the products are presented. Demonstrations have shown that 5- to 10-mm-dia glass marbles can be encapsulated on an engineering scale with lead or lead alloys by gravity or vacuum processes. Marbles approx. 12 mm in dia were successfully encapsulated in a lead alloy on a production scale. Also, 4- to 9-mm-dia ceramic pellets in containers of various sizes were completely penetrated and the individual pellets encased with aluminum-12 wt % silicon alloy by vacuum processes. Indications are that of the casting processes tested, aluminum 12 wt % silicon alloy vacuum-cast around ceramic pellets had the highest degree of infiltration or coverage of pellet surfaces

  10. The Effect of Applied Pressure During Feeding of Critical Cast Aluminum Alloy Components With Particular Reference to Fatigue Resistance

    Energy Technology Data Exchange (ETDEWEB)

    J.T. Berry; R. Luck; B. Zhang; R.P. Taylor

    2003-06-30

    the medium to long freezing range alloys of aluminum such as A356, A357, A206, 319 for example are known to exhibit dispersed porosity, which is recognized as a factor affecting ductility, fracture toughness, and fatigue resistance of light alloy castings. The local thermal environment, for example, temperature gradient and freezing from velocity, affect the mode of solidification which, along with alloy composition, heat treatment, oxide film occlusion, hydrogen content, and the extent to which the alloy contracts on solidification, combine to exert strong effects on the porosity formation in such alloys. In addition to such factors, the availability of liquid metal and its ability to flow through the partially solidified casting, which will be affect by the pressure in the liquid metal, must also be considered. The supply of molten metal will thus be controlled by the volume of the riser available for feeding the particular casting location, its solidification time, and its location together with any external pressure that might be applied at the riser.

  11. Estimation of hardness and compressive strength of SP 100 aluminum powder epoxy

    Energy Technology Data Exchange (ETDEWEB)

    Han, Jeong Young [Pusan National Univ., Busan (Korea, Republic of); Kim, Myung Hun [Korea Institute of Footwear and Leather Technology, Busan (Korea, Republic of); Kang, Sung Soo [Jeonju Univ., Jeonju (Korea, Republic of)

    2012-09-15

    In this study, we performed experimental tests on five SP 100 aluminum powder epoxy specimens with several after curing conditions in order to estimate their hardness with temperature and compressive strength. In the surface hardness test, it was found that the higher the after curing temperature, the higher was the hardness. In particular, it was found that the hardness of the specimens in cases 3 and 4 was much higher than in the other cases. In addition, in the compression tests carried out to evaluate the compressive strength, it was found that the specimens showed relatively similar stiffness and strength with after curing, and specimens with no after curing showed compression stress strain curves similar to those of thermoplastic resins.

  12. Estimation of hardness and compressive strength of SP 100 aluminum powder epoxy

    International Nuclear Information System (INIS)

    Han, Jeong Young; Kim, Myung Hun; Kang, Sung Soo

    2012-01-01

    In this study, we performed experimental tests on five SP 100 aluminum powder epoxy specimens with several after curing conditions in order to estimate their hardness with temperature and compressive strength. In the surface hardness test, it was found that the higher the after curing temperature, the higher was the hardness. In particular, it was found that the hardness of the specimens in cases 3 and 4 was much higher than in the other cases. In addition, in the compression tests carried out to evaluate the compressive strength, it was found that the specimens showed relatively similar stiffness and strength with after curing, and specimens with no after curing showed compression stress strain curves similar to those of thermoplastic resins

  13. Improvement in thermal fatigue resistance of cast iron piston; Chutetsu piston no tainetsu hiro sekkei

    Energy Technology Data Exchange (ETDEWEB)

    Amano, K; Uosaki, Y; Takeshige, N [Mazda Motor Corp., Hiroshima (Japan)

    1997-10-01

    Cast iron piston is superior in reduction of diesel engine emission to aluminum piston because of its characteristic of heat insulation. In order to study thermal fatigue characteristics of cast iron, thermal fatigue tests were carried out on two kinds of ferrite ductile cast iron. Differences between cast iron piston and aluminum piston in thermal fatigue resistance have been investigated by using FEM analysis. 5 refs., 14 figs., 1 tab.

  14. Formation of microstructure and properties on hot working and heat treatment of high strength modular cast iron

    International Nuclear Information System (INIS)

    Trajno, A.I.; Yusupov, V.S.; Kugushin, A.A.

    1999-01-01

    The possibility of plastic deformation of high strength modular cast iron (HSNCI) is under study. The microstructure and mechanical properties of hot worked and heat treated cast iron are investigated for the composition, %: Fe - 2.9 C - 2.4 Si - 0.7 Ni - 0.05 Mg - 0.04 Ce. It is stated that HSNCI can withstand various types of hot working without fracturing. Graphite inclusions lose their modular shape irreversibly during plastic deformation. Subsequent heat treatment affects the metal matrix only. The heating in oxidizing environment is noted to result in cast iron surface decarbonization [ru

  15. Microstructure and mechanical properties of lost foam cast 356 alloys

    Directory of Open Access Journals (Sweden)

    Qi-gui Wang

    2015-05-01

    Full Text Available Microstructure and mechanical properties of lost foam cast aluminum alloys have been investigated in both primary A356 (0.13% Fe and secondary 356 (0.47%. As expected, secondary 356 shows much higher content of Fe-rich intermetallic phases, and in particular the porosity in comparison with primary A356. The average area percent and size (length of Fe-rich intermetallics change from about 0.5% and 6 祄 in A356 to 2% and 25 祄 in 356 alloy. The average area percent and maximum size of porosity also increase from about 0.4% and 420 祄 to 1.4% and 600 祄, respectively. As a result, tensile ductility decreases about 60% and ultimate tensile strength declines about 8%. Lower fatigue strength was also experienced in the secondary 356 alloy. Low cycle fatigue (LCF strength decreased from 187 MPa in A356 to 159 MPa in 356 and high cycle fatigue (HCF strength also declined slightly from 68 MPa to 64 MPa.

  16. Pressure slip casting and cold isostatic pressing of aluminum titanate green ceramics: A comparative evaluation

    Directory of Open Access Journals (Sweden)

    Ramanathan Papitha

    2013-12-01

    Full Text Available Aluminum titanate (Al2TiO5 green bodies were prepared from mixture of titania and alumina powders with different particle sizes by conventional slip casting (CSC, pressure slip casting (PSC and cold isostatic pressing (CIP. Precursor-powder mixtures were evaluated with respect to the powder properties, flow behaviours and shaping parameters. Green densities were measured and correlated with the fractographs. A substantial increase in green densities up to 60 %TD (theoretical density of 4.02 g/cm3, calculated based on rule of mixtures is observed with the application of 2–3 MPa pressure with PSC. While particle size distribution and solid loading are the most influential parameters in the case of CSC, with PSC pressure also plays a key role in achieving the higher green densities. Being a dry process, high pressure of > 100 MPa for CIP is essential to achieve densities in the range of 60–65 %TD. Slip pressurization under PSC conditions facilitate the rearrangement of particles through rolling, twisting and interlocking unlike CIP processing where pressure is needed to overcome the inter-particle friction.

  17. Effects of SiO2 nano-particles on tribological and mechanical properties of aluminum matrix composites by different dispersion methods

    Science.gov (United States)

    Azadi, Mahboobeh; Zolfaghari, Mehrdad; Rezanezhad, Saeid; Azadi, Mohammad

    2018-05-01

    This study has been presented with mechanical properties of aluminum matrix composites, reinforced by SiO2 nano-particles. The stir casting method was employed to produce various aluminum matrix composites. Different composites by varying the SiO2 nano-particle content (including 0.5 and 1 weight percents) and two dispersion methods (including ball-milling and pre-heating) were made. Then, the density, the hardness, the compression strength, the wear resistance and the microstructure of nano-composites have been studied in this research. Besides, the distribution of nano-particles in the aluminum matrix for all composites has been also evaluated by the field emission scanning electron microscopy (FESEM). Obtained results showed that the density, the elongation and the ultimate compressive strength of various nano-composites decreased by the presence of SiO2 nano-particles; however, the hardness, the wear resistance, the yield strength and the elastic modulus of composites increased by auditioning of nano-particles to the aluminum alloy. FESEM images indicated better wetting of the SiO2 reinforcement in the aluminum matrix, prepared by the pre-heating dispersion method, comparing to ball-milling. When SiO2 nano-particles were added to the aluminum alloy, the morphology of the Si phase and intermetallic phases changed, which enhanced mechanical properties. In addition, the wear mechanism plus the friction coefficient value were changed for various nano-composites with respect to the aluminum alloy.

  18. Impact Strength of Austenitic and Ferritic-Austenitic Cr-Ni Stainless Cast Steel in -40 and +20°C Temperature

    Directory of Open Access Journals (Sweden)

    Kalandyk B.

    2014-10-01

    Full Text Available Studies described in this paper relate to common grades of cast corrosion resistant Cr-Ni steel with different matrix. The test materials were subjected to heat treatment, which consisted in the solution annealing at 1060°C followed by cooling in water. The conducted investigations, besides the microstructural characteristics of selected cast steel grades, included the evaluation of hardness, toughness (at a temperature of -40 and +20oC and type of fracture obtained after breaking the specimens on a Charpy impact testing machine. Based on the results of the measured volume fraction of ferrite, it has been found that the content of this phase in cast austenitic steel is 1.9%, while in the two-phase ferritic-austenitic grades it ranges from 50 to 58%. It has been demonstrated that within the scope of conducted studies, the cast steel of an austenitic structure is characterised by higher impact strength than the two-phase ferritic-austenitic (F-A grade. The changing appearance of the fractures of the specimens reflected the impact strength values obtained in the tested materials. Fractures of the cast austenitic Cr-Ni steel obtained in these studies were of a ductile character, while fractures of the cast ferritic-austenitic grade were mostly of a mixed character with the predominance of brittle phase and well visible cleavage planes.

  19. Casting characteristics of Al-Mg alloy 535 cast in permanent moulds

    International Nuclear Information System (INIS)

    Fasoyinu, F.A.; Thomson, J.; Cousineau, D.; Castles, T.; Sahoo, M.

    2002-01-01

    Aluminum alloy 535 could be used for automotive and marine applications because of its good corrosion resistance against mild alkaline and salt spray exposure. The majority of components from this alloy are usually produced by sand casting because it is prone to hot shortness and has poor fluidity when poured in permanent moulds. In an attempt to improve its castability in permanent moulds, casting characteristics such as casting fluidity and hot tear resistance have been studied. In addition, the effectiveness of titanium, boron, scandium, zirconium and a combination of selected elements from this group as grain refiners were evaluated. It s shown that alloy 535 exhibits good casting fluidity when poured with adequate metal superheat and that there is significant improvement in hot tear resistance following grain refinement. (author)

  20. Modeling and Optimization of Direct Chill Casting to Reduce Ingot Cracking

    Energy Technology Data Exchange (ETDEWEB)

    Das, S.K.; Ningileri, S.; Long, Z.; Saito, K.; Khraisheh, M.; Hassan, M.H.; Kuwana, K.; Han, Q.; Viswanathan, S.; Sabau, A.S.; Clark, J.; Hyrn, J. (ANL)

    2006-08-15

    Approximately 68% of the aluminum produced in the United States is first cast into ingots prior to further processing into sheet, plate, extrusions, or foil. The direct chill (DC) semi-continuous casting process has been the mainstay of the aluminum industry for the production of ingots due largely to its robust nature and relative simplicity. Though the basic process of DC casting is in principle straightforward, the interaction of process parameters with heat extraction, microstructural evolution, and development of solidification stresses is too complex to analyze by intuition or practical experience. One issue in DC casting is the formation of stress cracks [1-15]. In particular, the move toward larger ingot cross-sections, the use of higher casting speeds, and an ever-increasing array of mold technologies have increased industry efficiencies but have made it more difficult to predict the occurrence of stress crack defects. The Aluminum Industry Technology Roadmap [16] has recognized the challenges inherent in the DC casting process and the control of stress cracks and selected the development of 'fundamental information on solidification of alloys to predict microstructure, surface properties, and stresses and strains' as a high-priority research need, and the 'lack of understanding of mechanisms of cracking as a function of alloy' and 'insufficient understanding of the aluminum solidification process', which is 'difficult to model', as technology barriers in aluminum casting processes. The goal of this Aluminum Industry of the Future (IOF) project was to assist the aluminum industry in reducing the incidence of stress cracks from the current level of 5% to 2%. Decreasing stress crack incidence is important for improving product quality and consistency as well as for saving resources and energy, since considerable amounts of cast metal could be saved by eliminating ingot cracking, by reducing the scalping thickness of

  1. Influence of Extrusion Temperature on the Aging Behavior and Mechanical Properties of an AA6060 Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    Nadja Berndt

    2018-01-01

    Full Text Available Processing of AA6060 aluminum alloys for semi-products usually includes hot extrusion with subsequent artificial aging for several hours. Processing below the recrystallization temperature allows for an increased strength at a significantly reduced annealing time by combining strain hardening and precipitation hardening. In this study, we investigate the potential of cold and warm extrusion as alternative processing routes for high strength aluminum semi-products. Cast billets of the age hardening aluminum alloy AA6060 were solution annealed and then extruded at room temperature, 120 or 170 °C, followed by an aging treatment. Electron microscopy and mechanical testing were performed on the as-extruded as well as the annealed materials to characterize the resulting microstructural features and mechanical properties. All of the extruded profiles exhibit similar, strongly graded microstructures. The strain gradients and the varying extrusion temperatures lead to different stages of dynamic precipitation in the as-extruded materials, which significantly alter the subsequent aging behavior and mechanical properties. The experimental results demonstrate that extrusion below recrystallization temperature allows for high strength at a massively reduced aging time due to dynamic precipitation and/or accelerated precipitation kinetics. The highest strength and ductility were achieved by extrusion at 120 °C and subsequent short-time aging.

  2. Fabrication of sacrificial anode cathodic protection through casting method

    International Nuclear Information System (INIS)

    Mohd Sharif Sattar; Muhamad Daud; Siti Radiah Mohd Kamarudin; Azali Muhamad; Zaiton Selamat; Rusni Rejab

    2007-01-01

    Aluminum is one of the few metals that can be cast by all of the processes used in casting metals. These processes consist of die casting, permanent mold casting, sand casting (green sand and dry sand), plaster casting, investment casting, and continuous casting. Other processes such as lost foam, squeeze casting, and hot isostatic pressing are also used. Permanent mold casting method was selected in which used for fabricating of sacrificial anode cathodic protection. This product was ground for surface finished and fabricated in the cylindrical form and reinforced with carbon steel at a center of the anode. (Author)

  3. Friction stir weld assisted diffusion bonding of 5754 aluminum alloy to coated high strength steels

    International Nuclear Information System (INIS)

    Haghshenas, M.; Abdel-Gwad, A.; Omran, A.M.; Gökçe, B.; Sahraeinejad, S.; Gerlich, A.P.

    2014-01-01

    Highlights: • Successful lap joints of Al 5754 sheet to coated DP600 and 22MnB5 steels. • Negligible effect of welding speed on mechanical properties of Al 5754/22MnB5 joints. • Lower strength of Al 5754/22MnB5 joints compared with Al 5754/DP600 joints. - Abstract: In the present paper friction stir-induced diffusion bonding is used for joining sheets of 5754 aluminum alloy to coated high strength steels (DP600 and 22MnB5) by promoting diffusion bonding in an overlap configuration. Mechanical performance and microstructures of joints were analyzed by overlap shear testing, metallography, and X-ray diffraction. Our results show that the strength of joint is dependent upon tool travel speed and the depth of the tool pin relative to the steel surface. The thickness and types of intermetallic compounds formed at the interface play a significant role in achieving a joint with optimum performance. That is, the formation of high aluminum composition intermetallic compounds (i.e. Al 5 Fe 2 ) at the interface of the friction stir lap joint appeared to have a more negative effect on joint strength compared to the presence of high iron composition intermetallic phases (i.e. FeAl). This is in agreement with previously reported findings that FeAl intermetallic can improve the fracture toughness and interface strength in Al/St joints

  4. Evaluation of cast Ti-Fe-O-N alloys for dental applications

    International Nuclear Information System (INIS)

    Koike, Marie; Ohkubo, Chikahiro; Sato, Hideki; Fujii, Hideki; Okabe, Toru

    2005-01-01

    Good mechanical properties, biocompatibility and corrosion resistance make titanium an excellent material for biomedical applications. However, when better mechanical properties than those offered by commercially pure titanium (CPTi) are needed, Ti-6Al-4V is sometimes a good alternative. Some new titanium alloys, developed as industrial structural materials, aim at an intermediate range of strength between that of CP Ti and Ti-6Al-4V. Two of these alloys are Super-TIX800TM (Ti-1% Fe-0.35% O-0.01% N) and Super-TIX800NTM (Ti-1% Fe-0.3% O-0.04% N) (both produced by Nippon Steel Corp., Japan). Besides being stronger than CP Ti, the cost of manufacturing these alloys is reportedly lower than for Ti-6Al-4V since they do not contain any expensive elements. In addition, they are not composed of elements such as aluminum or vanadium, which have caused biocompatibility concerns in medical and dental appliances. To evaluate these alloys as candidates for dental use, it is helpful to compare them to CP Ti (ASTM Grade 2) and Ti-6Al-4V (ASTM Grade 5), which have already been employed in dentistry. We evaluated the tensile properties, mold filling capacity, corrosion characteristics and grindability of these industrial alloys prepared by investment casting. Compared to the strengths of cast CPTi, the yield strength and tensile strength of these cast alloys were more than 20% and approximately 30% higher, respectively. On the other hand, both of these properties were 30% lower than for Ti-6Al-4V. Better grindability and wear resistance were additional benefits of these new alloys for dental applications

  5. High strength bimetallic composite material fabricated by electroslag casting and characteristics of its composite interface

    Directory of Open Access Journals (Sweden)

    Tian-shun Dong

    2016-11-01

    Full Text Available Bimetallic composite material of bainitic steel and PD3 steel was produced with electroslag casting process, and element distribution of its composite interface was investigated by theoretical calculation and energy dispersive spectrometer (EDS. Results show that the tensile strength (1,450 MPa, hardness (HRC 41-47 and impact toughness (94.7J·cm-2 of bainitic steel were comparatively high, while its elongation was slightly low (4.0%. Tensile strength (1,100 MPa, hardness (>HRC 31 and elongation (7.72% of the interface were also relatively high, but its impact toughness was low at 20.4 J·cm-2. Results of theoretical calculation of the element distribution in the interface region were basically consistent with that of EDS. Therefore, electroslag casting is a practical process to produce bimetallic composite material of bainitic steel and PD3 steel, and theoretical calculation also is a feasible method to study element distribution of their interface.

  6. Effect of Sphere Properties on Microstructure and Mechanical Performance of Cast Composite Metal Foams

    Directory of Open Access Journals (Sweden)

    Matias Garcia-Avila

    2015-05-01

    Full Text Available Aluminum-steel composite metal foams (Al-S CMF are manufactured using steel hollow spheres, with a variety of sphere carbon content, surface roughness, and wall porosity, embedded in an Aluminum matrix through gravity casting technique. The microstructural and mechanical properties of the material were studied using scanning electron microscopy, energy dispersive spectroscopy, and quasi-static compressive testing. Higher carbon content and surface roughness in the sphere wall were responsible for an increase in formation of intermetallic phases which had a strengthening effect at lower strain levels, increasing the yield strength of the material by a factor of 2, while higher sphere wall porosity resulted in a decrease on the density of the material and improving its cushioning and ductility maintaining its energy absorption capabilities.

  7. Role of manufacturing process parameters on the characteristics of aluminum matrix composites

    International Nuclear Information System (INIS)

    Zaid, A.I.O.

    2003-01-01

    Metal matrix composites, (MMC), are engineered combinations of two or more materials (one of which is a metal) in which tailored properties are achieved by systematic combinations consisting of continuous or discontinuous fibers, whiskers, or particles in a metal result in combinations of very high specific strength. Furthermore, systematic design and procedures can be developed to achieve unique combinations of engineering properties such as high elevated-temperature strengths, damping or electrical properties. In this paper, the theory and practice of MMC are reviewed and discussed. The different techniques used in the manufacturing of MMC in general and aluminum matrix composites in particular e.g. unidirectional solidification, squeeze casting, vortex method and compocasting are presented and discussed. The parameters involved in these techniques and their effects on the characteristics of MMC product are also given and discussed. These include: crucible size and shape, melt temperature, size and shape of the impeller, stirring speed, rate of addition of the particles, the degree of agitation and cooling rate. Furthermore, the effect of these parameters on the mechanical strength and machinability are also presented and discussed. Finally, recent research results in aluminum matrix composites and their future developments are outlined and discussed. (author)

  8. Processing of Aluminum-Graphite Particulate Metal Matrix Composites by Advanced Shear Technology

    Science.gov (United States)

    Barekar, N.; Tzamtzis, S.; Dhindaw, B. K.; Patel, J.; Hari Babu, N.; Fan, Z.

    2009-12-01

    To extend the possibilities of using aluminum/graphite composites as structural materials, a novel process is developed. The conventional methods often produce agglomerated structures exhibiting lower strength and ductility. To overcome the cohesive force of the agglomerates, a melt conditioned high-pressure die casting (MC-HPDC) process innovatively adapts the well-established, high-shear dispersive mixing action of a twin screw mechanism. The distribution of particles and properties of composites are quantitatively evaluated. The adopted rheo process significantly improved the distribution of the reinforcement in the matrix with a strong interfacial bond between the two. A good combination of improved ultimate tensile strength (UTS) and tensile elongation (ɛ) is obtained compared with composites produced by conventional processes.

  9. Properties of aluminum alloys tensile, creep, and fatigue data at high and low temperatures

    CERN Document Server

    1999-01-01

    This book compiles more than 300 tables listing typical average properties of a wide range of aluminum alloys. The individual test results were compiled, plotted in various ways, and analyzed. The average values from the tensile and creep tests were then normalized to the published typical room-temperature tensile properties of the respective alloys for easy comparison. This extensive project was done by Alcoa Laboratories over a period of several years. The types of data presented include: Typical Mechanical Properties of Wrought and Cast Aluminum Alloys at Various Temperatures, including tensile properties at subzero temperatures, at temperature after various holding times at the test temperature, and at room temperature after exposure at various temperatures for various holding times; creep rupture strengths for various times at various temperatures; stresses required to generate various amounts of creep in various lengths of time; rotating-beam fatigue strengths; modulus of elasticity as a function of t...

  10. Contributions to yield strength in an ultrafine grained 1050 aluminum alloy after DC current annealing

    International Nuclear Information System (INIS)

    Cao, Yiheng; He, Lizi; Zhou, Yizhou; Wang, Ping; Cui, Jianzhong

    2016-01-01

    The ultrafine grained (UFG) 1050 aluminum alloy was prepared by equal channel angular pressing at cryogenic temperature (cryoECAP). The evolution of the yield strength and microstructures of UFG 1050 aluminum alloy after direct electric current (DC current) annealing at 150–400 °C for 1 h were investigated by tensile test, electron back scattering diffraction pattern (EBSD) and transmission electron microscopy (TEM). For the cryoECAPed and annealed samples at 150–250 °C, the predominant boundaries are high angle boundaries (HABs) (>60%), many dislocations accumulate at subgrain and/or grain boundaries, the yield strength (126–159 MPa) mainly comes from the dislocation and grain boundary strengthening contributions. While an unusual increase in the yield strength (by 8.1–11.2%) observed in samples annealed at 150–200 °C is attributed to an additional strengthening contribution from the more HABs having stable structures which can act as effective barriers to dislocation motion during tensile deformation. When annealing at 300–400 °C, the microstructures are free of dislocations, the yield strength (29–45 MPa) comes from the grain boundary strengthening contribution. With the application of DC current, the larger grain size, lower dislocation density and higher fraction of LABs having misorientation angle between 3−7° in samples annealed at 150–250 °C result in the lower yield strength, while the smaller average grain sizes in samples annealed at 300–400 °C cause the higher yield strength.

  11. Contributions to yield strength in an ultrafine grained 1050 aluminum alloy after DC current annealing

    Energy Technology Data Exchange (ETDEWEB)

    Cao, Yiheng [Key Lab of Electromagnetic Processing of Materials, Ministry of Education, Northeastern University, Shenyang 110819 (China); He, Lizi, E-mail: helizi@epm.neu.edu.cn [Key Lab of Electromagnetic Processing of Materials, Ministry of Education, Northeastern University, Shenyang 110819 (China); School of Materials Science and Engineering, Northeastern University, Shenyang 110819 (China); Zhou, Yizhou [Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China); Wang, Ping; Cui, Jianzhong [Key Lab of Electromagnetic Processing of Materials, Ministry of Education, Northeastern University, Shenyang 110819 (China); School of Materials Science and Engineering, Northeastern University, Shenyang 110819 (China)

    2016-09-30

    The ultrafine grained (UFG) 1050 aluminum alloy was prepared by equal channel angular pressing at cryogenic temperature (cryoECAP). The evolution of the yield strength and microstructures of UFG 1050 aluminum alloy after direct electric current (DC current) annealing at 150–400 °C for 1 h were investigated by tensile test, electron back scattering diffraction pattern (EBSD) and transmission electron microscopy (TEM). For the cryoECAPed and annealed samples at 150–250 °C, the predominant boundaries are high angle boundaries (HABs) (>60%), many dislocations accumulate at subgrain and/or grain boundaries, the yield strength (126–159 MPa) mainly comes from the dislocation and grain boundary strengthening contributions. While an unusual increase in the yield strength (by 8.1–11.2%) observed in samples annealed at 150–200 °C is attributed to an additional strengthening contribution from the more HABs having stable structures which can act as effective barriers to dislocation motion during tensile deformation. When annealing at 300–400 °C, the microstructures are free of dislocations, the yield strength (29–45 MPa) comes from the grain boundary strengthening contribution. With the application of DC current, the larger grain size, lower dislocation density and higher fraction of LABs having misorientation angle between 3−7° in samples annealed at 150–250 °C result in the lower yield strength, while the smaller average grain sizes in samples annealed at 300–400 °C cause the higher yield strength.

  12. The Anisotropy of Replicated Aluminum Foams

    Directory of Open Access Journals (Sweden)

    Eugeny L. Furman

    2014-01-01

    Full Text Available The replication casting process gives the open-cell aluminum foams that can be used in many industrial applications as well as in filtering technology. The essential requirement for filters is the uniformity of filtering degree which is defined by the minimal pore size. However the structure of replication castings is often inhomogeneous and the minimal pore radius is decreasing in the direction of melt infiltration. The objective of this investigation is to study the dynamics of melt impregnation of the porous medium by vacuum suction to identify the possibility of reducing the anisotropy. Theoretical data illustrate the processes at the boundary between melt and gas medium. The experiments were carried out using the replication aluminum samples produced according to commercial technology. It was found that the permeability coefficient varies throughout the height of castings. A method for estimation of pressure on the line of melt movement was proposed. The resistance of NaCl layer and circular vents of the mold causes the inhomogeneity of castings. Finally the ways of minimizing the anisotropy were offered.

  13. Effect of material strength on the relationship between the principal Hugoniot and quasi-isentrope of beryllium and 6061-T6 aluminum below 35 GPa

    International Nuclear Information System (INIS)

    Moss, W.C.

    1985-01-01

    Quasi-isentropic (QI) compression can be achieved by loading a specimen with a low strain rate, long rise time uniaxial strain wave. Recent experimental data show that the quasi-isentrope of 6061-T6 aluminum lies a few percent above the principal Hugoniot, that is, at a given specific volume, the QI stress exceeds the principal Hugoniot stress. It has been suggested that this effect is due to material strength. Using Hugoniot data, shock-reshock, and shock-unload data for beryllium and 6061-T6 aluminum, we have constructed the quasi-isentropes as functions of specific volume. Our results show that the QI stress exceeds the principal Hugoniot stress above a Hugoniot stress of 8.4 GPa in beryllium, and between Hugoniot stresses of 3.8 and 21.4 GPa in aluminum. The effect is due to strength and implies that the QI yield strength can be large. Our calculations show that the QI yield strength is 0.9 GPa in aluminum at a QI stress of 9 GPa, and 5.2 GPa in beryllium at a QI stress of 35 GPa

  14. Ductile Bulk Aluminum-Based Alloy with Good Glass-Forming Ability and High Strength

    International Nuclear Information System (INIS)

    Long-Chao, Zhuo; Shu-Jie, Pang; Hui, Wang; Tao, Zhang

    2009-01-01

    Based on a new approach for designing glassy alloy compositions, bulk Al-based alloys with good glass-forming ability (GFA) are synthesized. The cast Al 86 Si 0.5 Ni 4.06 Co 2.94 Y 6 Sc 0.5 rod with a diameter of 1 mm shows almost fully amorphous structure besides about 5% fcc-Al nucleated in the center of the rod. The bulk alloy with high Al concentration exhibits an ultrahigh yield strength of 1.18 GPa and maximum strength of 1.27 GPa as well as an obvious plastic strain of about 2.4% during compressive deformation. This light Al-based alloy with good GFA and mechanical properties is promising as a new high specific strength material with good deformability. (condensed matter: structure, mechanical and thermal properties)

  15. The strength evaluation and σ-phase aging behavior of cast stainless steel

    International Nuclear Information System (INIS)

    Kwon, Jae Do; Park, Joong Cheul; Lee, Woo Ho; Jang, Sun Sik

    1999-01-01

    σ-phase of cast stainless steel(CF8M) was artificially precipitated by means of thermal aging at 700 deg C with various holding time (0.33, 5, 15, 50 and 150 hrs) to evaluate the behavior of thermal aging status of strength change. The structure observation, hardness test, tensile test, impact test and fatigue crack growth rates test for as-received and degraded material were also performed to evaluate static strength, toughness and fatigue crack growth behavior corresponding to the aging condition of CF8M. The results showed that the area fraction of σ-phase and hardness value increased with thermal aging time. But, for the impact values, upper shelf energy decreased and fatigue crack growth rates increased with σ-phase aging progressed than that of virgin material

  16. Shaping the Strength of Cast Rocker Arm for Special Purpose Vehicle

    Directory of Open Access Journals (Sweden)

    Żuczek R.

    2015-09-01

    Full Text Available The article discusses the weldment to casting conversion process of rocker arm designed for operation in a special purpose vehicle to obtain a consistency of objective functions, which assume the reduced weight of component, the reduced maximum effort of material under the impact of service loads achieved through topology modification for optimum strength distribution in the sensitive areas, and the development of rocker arm manufacturing technology. As a result of conducted studies, the unit weight of the item was reduced by 25%, and the stress limit values were reduced to a level guaranteeing safe application.

  17. Modeling and Analysis of Mechanical Properties of Aluminium Alloy (A413 Processed through Squeeze Casting Route Using Artificial Neural Network Model and Statistical Technique

    Directory of Open Access Journals (Sweden)

    R. Soundararajan

    2015-01-01

    Full Text Available Artificial Neural Network (ANN approach was used for predicting and analyzing the mechanical properties of A413 aluminum alloy produced by squeeze casting route. The experiments are carried out with different controlled input variables such as squeeze pressure, die preheating temperature, and melt temperature as per Full Factorial Design (FFD. The accounted absolute process variables produce a casting with pore-free and ideal fine grain dendritic structure resulting in good mechanical properties such as hardness, ultimate tensile strength, and yield strength. As a primary objective, a feed forward back propagation ANN model has been developed with different architectures for ensuring the definiteness of the values. The developed model along with its predicted data was in good agreement with the experimental data, inferring the valuable performance of the optimal model. From the work it was ascertained that, for castings produced by squeeze casting route, the ANN is an alternative method for predicting the mechanical properties and appropriate results can be estimated rather than measured, thereby reducing the testing time and cost. As a secondary objective, quantitative and statistical analysis was performed in order to evaluate the effect of process parameters on the mechanical properties of the castings.

  18. In situ 3D characterization of high temperature fatigue damage mechanisms in a cast aluminum alloy using synchrotron X-ray tomography

    International Nuclear Information System (INIS)

    Dezecot, Sebastien; Buffiere, Jean-Yves; Koster, Alain; Maurel, Vincent; Szmytka, Fabien; Charkaluk, Eric; Dahdah, Nora; El Bartali, Ahmed; Limodin, Nathalie; Witz, Jean-Francois

    2016-01-01

    Fatigue tests were performed at 250 °C on a cast AlSi7Cu3Mg aluminum alloy and monitored with Synchrotron in situ X-ray tomography in order to understand the micro-mechanisms of crack initiation and propagation. The analysis of the 3D images reveals that internal shrinkage pores are responsible for the main crack initiation. Crack propagation is mainly due to the complex and highly interconnected network of hard particles of the eutectic regions.

  19. Investigation of Material Performance Degradation for High-Strength Aluminum Alloy Using Acoustic Emission Method

    Directory of Open Access Journals (Sweden)

    Yibo Ai

    2015-02-01

    Full Text Available Structural materials damages are always in the form of micro-defects or cracks. Traditional or conventional methods such as micro and macro examination, tensile, bend, impact and hardness tests can be used to detect the micro damage or defects. However, these tests are destructive in nature and not in real-time, thus a non-destructive and real-time monitoring and characterization of the material damage is needed. This study is focused on the application of a non-destructive and real-time acoustic emission (AE method to study material performance degradation of a high-strength aluminum alloy of high-speed train gearbox shell. By applying data relative analysis and interpretation of AE signals, the characteristic parameters of materials performance were achieved and the failure criteria of the characteristic parameters for the material tensile damage process were established. The results show that the AE method and signal analysis can be used to accomplish the non-destructive and real-time detection of the material performance degradation process of the high-strength aluminum alloy. This technique can be extended to other engineering materials.

  20. Development of high-strength and high-RRR aluminum-stabilized superconductor for the ATLAS thin solenoid

    CERN Document Server

    Wada, K; Sakamoto, H; Shimada, T; Nagasu, Y; Inoue, I H; Tsunoda, K; Endo, S; Yamamoto, A; Makida, Y; Tanaka, K; Doi, Y; Kondo, T

    2000-01-01

    The ATLAS central solenoid magnet is being constructed to provide a magnetic field of 2 Tesla in the central tracking part of the ATLAS detector at the LHC. Since the solenoid coil is placed in front of the liquid-argon electromagnetic calorimeter, the solenoid coil must be as thin (and transparent) as possible. The high-strength and high- RRR aluminum-stabilized superconductor is a key technology for the solenoid to be thinnest while keeping its stability. This has been developed with an alloy of 0.1 wt% nickel addition to 5N pure aluminum and with the subsequent mechanical cold working of 21% in area reduction. A yield strength of 110 MPa at 4.2 K has been realized keeping a residual resistivity ratio (RRR) of 590, after a heat treatment corresponding to coil curing at 130 degrees C for 15 hrs. This paper describes the optimization of the fabrication process and characteristics of the developed conductor. (8 refs).

  1. Investigation of microporosity in die-cast AlSi12(Cu) alloys by neutron- and X-ray radiography

    International Nuclear Information System (INIS)

    Zsolt, S.; Marton, B.

    1999-01-01

    The porosity of the casting can dramatically reduce the solidity and reliability of the objects made from aluminum alloys. The X-ray radiography is able to find the placement of the porosity of the aluminum devices. After a special 'water saturation' process the dynamic neutron radiography is available to discover the 'dangerous' surface nearporosity in the aluminum samples. The X-ray and neutron radiography were used as complementary examination techniques to study the porosity of the aluminum castings.(author)

  2. CORROSION RESISTANCE OF DYNAMIC LOADED CAST ALLOY AS12

    Directory of Open Access Journals (Sweden)

    A. A. Andrushevich

    2017-01-01

    Full Text Available The assessment of influence of powder particles in the mode of super deep penetration (SDP on change of corrosion resistance of aluminum cast alloy AK12 is executed. The aluminum alloy reinforced by fiber zones with the reconstructed structure has the increased corrosion resistance.

  3. Influence of Casting Section Thickness on Fatigue Strength of Austempered Ductile Iron

    Science.gov (United States)

    Olawale, J. O.; Ibitoye, S. A.

    2017-10-01

    The influence of casting section thickness on fatigue strength of austempered ductile iron was investigated in this study. ASTM A536 65-45-12 grade of ductile iron was produced, machined into round samples of 10, 15, 20 and 25 mm diameter, austenitized at a temperature of 820 °C, quenched into an austempering temperature (TA) of 300 and 375 °C and allowed to be isothermally transformed at these temperatures for a fixed period of 2 h. From the samples, fatigue test specimens were machined to conform to ASTM E-466. Scanning electron microscopy (SEM) and x-ray diffraction (XRD) methods were used to characterize microstructural morphology and phase distribution of heat-treated samples. The fatigue strength decreases as the section thickness increases. The SEM image and XRD patterns show a matrix of acicular ferrite and carbon-stabilized austenite with ferrite coarsening and volume fraction of austenite reducing as the section thickness increases. The study concluded that the higher the value of carbon-stabilized austenite the higher the fatigue strength while it decreases as the ausferrite structure becomes coarse.

  4. Study of local-zone microstructure, strength and fracture toughness of hybrid laser-metal-inert-gas-welded A7N01 aluminum alloy joint

    Energy Technology Data Exchange (ETDEWEB)

    Wang, Xiaomin, E-mail: xmwang991011@163.com [School of Life Science and Engineering, Southwest Jiaotong University, Chengdu 610031, Sichuan (China); Li, Bo [School of Materials Science and Engineering, Southwest Jiaotong University, Chengdu 610031, Sichuan (China); Li, Mingxing; Huang, Cui [School of Life Science and Engineering, Southwest Jiaotong University, Chengdu 610031, Sichuan (China); Chen, Hui [School of Materials Science and Engineering, Southwest Jiaotong University, Chengdu 610031, Sichuan (China)

    2017-03-14

    Mechanical properties of hybrid laser-metal-inert-gas-welded A7N01-T5 aluminum alloy joints were studied by using local samples that were extracted from the base metal (BM), heat-affected zone (HAZ), and fusion zone (FZ) of the joint to investigate the triangular relationship of microstructure, strength and fracture toughness of the local zones. The BM had the highest yield strength, ultimate tensile strength (UTS) and lowest elongation, which contrasts with the FZ. The yield strength of the HAZ is lower than that of the BM, whereas its UTS is very close to that of the BM, and its elongation is higher than that of the BM. The fracture toughness of the three local zones decreased as HAZ>BM>FZ. To analyze differences in local mechanical behavior, the detailed microstructure of the three local zones was studied by optical microscopy and electron backscattered diffraction, whereas the fracture surface and precipitation were studied by scanning and transmission electron microscopy. The variation of grain size, especially the morphology and distribution of strengthening phase in HAZ in welding process is the key factor that leads to its different mechanical properties from that of BM, which can be elucidated by different dislocation mechanism, sheared mechanism or Orowan mechanism. The as-cast microstructure and second-phase particles that segregate between dendritic branches provide the FZ with the lowest yield strength and UTS. The factors including area fraction of the precipitates, the difference of strength between the matrix and the grain boundaries, the precipitate-free zone along grain boundaries, as well as the grain boundaries angle are taken into account to explain the difference of fracture toughness among BM, HAZ and FZ, and their fracture modes.

  5. Microstructure and mechanical properties of Al–1Mn and Al–10Si alloy circular clad ingot prepared by direct chill casting

    International Nuclear Information System (INIS)

    Fu, Ying; Jie, Jinchuan; Wu, Li; Park, Joonpyo; Sun, Jianbo; Kim, Jongho; Li, Tingju

    2013-01-01

    An innovative direct chill casting process to prepare Al–10 wt%Si and Al–1 wt%Mn alloy circular clad ingots has been developed in the present study. The experimental casting parameters were determined by theoretical analysis, numerical simulation and experimental processes. The interface of clad ingots was investigated by methods of metallographic examination, electron probe microanalysis (EPMA) and transmission electron microscopy (TEM). The results showed that excellent metallurgical bonding of two different aluminum alloys could be achieved by direct chill casting. The Al–1Mn alloy which was poured into the mold earlier served as the substrate for heterogeneous nucleation of Al–10Si alloy. Because of diffusion of Si and Mn elements, a diffusion layer with a thickness of about 40 μm on average between the Al–10Si and Al–1Mn alloys could be obtained. The tensile strength of the clad ingot was 106.8 MPa and the fractured position was located in the Al–1Mn alloy side, indicating the strength of the interfacial region is higher than that of Al–1Mn alloy.

  6. Spall behavior of cast iron with varying microstructures

    International Nuclear Information System (INIS)

    Plume, Gifford; Rousseau, Carl-Ernst

    2014-01-01

    The spall strength of cast iron with varying microstructures has been investigated using plate impact at moderate speed. Stress history measurements were made with manganin stress gauges embedded between the back face of the specimen and a low impedance polycarbonate backing. Five separate cast irons were tested. Four of these consisted of gray cast iron with graphite in flake form, with three classified as Type VII A2 and the fourth containing a bimodal distribution of Types VII A4 and VII D8. The fifth casting consisted of ductile cast iron with graphite in nodular form, classified as Type I, size class 5. The spall strength for the Type VII A2 gray cast irons varied between 40 and 370 MPa, and that of the additional gray cast iron, between 410 and 490 MPa. The spall strength of the ductile cast iron fell within the range of 0.94–1.2 GPa. It is shown that the spall strength is linked to the damage level at the spall plane, where an increased level of tensile stress is required to generate higher levels of damage. Post mortem analysis was performed on the recovered samples, revealing the graphite phase to be the primary factor governing the spall fracture of cast irons, where crack nucleation is directly correlated to the debonding of graphite from the metal matrix. The average length of graphite found within a casting is linked to the material's strength, where strength increases as a function of decreasing length. The morphology and mean free path of graphite precipitates further govern the subsequent coalescence of initiated cracks to form a complete fracture plane. In cases where graphite spacing is large, increased energy level is required to complete the fracture process. A secondary factor governing the spall fracture of cast irons has also been linked to the microstructure of the metal matrix, with pearlite yielding higher spall strengths than free ferrite.

  7. Spall behavior of cast iron with varying microstructures

    Energy Technology Data Exchange (ETDEWEB)

    Plume, Gifford; Rousseau, Carl-Ernst, E-mail: rousseau@uri.edu [Mechanical Engineering, University of Rhode Island, 92 Upper College Rd., Kingston, Rhode Island 02881 (United States)

    2014-07-21

    The spall strength of cast iron with varying microstructures has been investigated using plate impact at moderate speed. Stress history measurements were made with manganin stress gauges embedded between the back face of the specimen and a low impedance polycarbonate backing. Five separate cast irons were tested. Four of these consisted of gray cast iron with graphite in flake form, with three classified as Type VII A2 and the fourth containing a bimodal distribution of Types VII A4 and VII D8. The fifth casting consisted of ductile cast iron with graphite in nodular form, classified as Type I, size class 5. The spall strength for the Type VII A2 gray cast irons varied between 40 and 370 MPa, and that of the additional gray cast iron, between 410 and 490 MPa. The spall strength of the ductile cast iron fell within the range of 0.94–1.2 GPa. It is shown that the spall strength is linked to the damage level at the spall plane, where an increased level of tensile stress is required to generate higher levels of damage. Post mortem analysis was performed on the recovered samples, revealing the graphite phase to be the primary factor governing the spall fracture of cast irons, where crack nucleation is directly correlated to the debonding of graphite from the metal matrix. The average length of graphite found within a casting is linked to the material's strength, where strength increases as a function of decreasing length. The morphology and mean free path of graphite precipitates further govern the subsequent coalescence of initiated cracks to form a complete fracture plane. In cases where graphite spacing is large, increased energy level is required to complete the fracture process. A secondary factor governing the spall fracture of cast irons has also been linked to the microstructure of the metal matrix, with pearlite yielding higher spall strengths than free ferrite.

  8. Market Opportunity of Some Aluminium Silicon Alloys Materials through Changing the Casting Process

    Directory of Open Access Journals (Sweden)

    Delfim SOARES

    2012-08-01

    Full Text Available Fatigue is considered to be the most common mechanism by which engineering components fail, and it accounts for at least 90% of all service failures attributed to mechanical causes. Mechanical properties (tensile strength, tensile strain, Young modulus, etc as well as fatigue properties (fatigue life are very dependent on casting method. The most direct effects of casting techniques are on the metallurgical microstructure that bounds the mechanical properties. One of the important variables affected by the casting technique is the cooling rate which is well known to strongly restrict the microstructure. In the present research has been done a comparison of fatigue properties of two aluminum silicon alloys obtained by two casting techniques. It was observed that the fatigue life is increasing with 24% for Al12Si and 31% for AL18Si by using centrifugal casting process instead of gravity casting. This increasing in fatigue life means that a component tailored from materials obtained by centrifugal casting will stay longer in service. It was made an estimation of the time required to recover the costs of technology in order to use the centrifuge process that will allow to obtain materials with improved properties. The amortization can be achieved by using two different marketing techniques: through the release of the product at the old price and with much longer life of the component which means "same price - longer life", or increasing price, by highlighting new product performance which means "higher price - higher properties".

  9. Microstructure, hardness, corrosion resistance and porcelain shear bond strength comparison between cast and hot pressed CoCrMo alloy for metal-ceramic dental restorations.

    Science.gov (United States)

    Henriques, B; Soares, D; Silva, F S

    2012-08-01

    The purpose of this study was to compare the microstructure, hardness, corrosion resistance and metal-porcelain bond strength of a CoCrMo dental alloy obtained by two routes, cast and hot pressing. CoCrMo alloy substrates were obtained by casting and hot pressing. Substrates' microstructure was examined by the means of Optical Microscopy (OM) and by Scanning Electron Microscope (SEM) and Energy Dispersive X-ray Spectroscopy (EDS). Hardness tests were performed in a microhardness indenter. The electrochemical behavior of substrates was investigated through potentiodynamic tests in a saline solution (8g NaCl/L). Substrates were bonded to dental porcelain and metal-porcelain bond strength was assessed by the means of a shear test performed in a universal test machine (crosshead speed: 0.5 mm/min) until fracture. Fractured surfaces as well as undestroyed interface specimens were examined with Stereomicroscopy and SEM-EDS. Data was analyzed with Shapiro-Wilk test to test the assumption of normality. The t-test (pmicrostructures whereas hot pressed specimens exhibited a typical globular microstructure with a second phase spread through the matrix. The hardness registered for hot pressed substrates was greater than that of cast specimens, 438±24HV/1 and 324±8HV/1, respectively. Hot pressed substrates showed better corrosion properties than cast ones, i.e. higher OCP; higher corrosion potential (E(corr)) and lower current densities (i(corr)). No significant difference was found (p<0.05) in metal-ceramic bond strength between cast (116.5±6.9 MPa) and hot pressed (114.2±11.9 MPa) substrates. The failure type analysis revealed an adhesive failure for all specimens. Hot pressed products arise as an alternative to cast products in dental prosthetics, as they impart enhanced mechanical and electrochemical properties to prostheses without compromising the metal-ceramic bond strength. Copyright © 2012 Elsevier Ltd. All rights reserved.

  10. Fiscal 2000 achievement report. Venture business assisting type regional consortium - Minor business creation base type (Development of aluminum alloy casting system using aluminum titanate ceramic member); 2000 nendo chiiki consortium kenkyu kaihatsu jigyo seika hokokusho. Chitansan aluminium ceramics buzai wo shiyoshita aluminium gokin chuzo system no kaihatsu

    Energy Technology Data Exchange (ETDEWEB)

    NONE

    2001-03-01

    An automatic liquid metal charging system driven by a linear induction type electromagnetic pump is developed, with its members to be in contact with liquid aluminum alloy being constituted of aluminum titanate ceramics not to be wetted by liquid aluminum alloy and highly resistant to thermal impact. Technologies for casting aluminum titanate ceramic members in plaster molds, CIP (cold isostatic pressing) molding, and burning were established. The mechanism of wettability of liquid aluminum alloy on aluminum titanate ceramic members was elucidated, and an aluminum titanate ceramic member with a dense spinel layer formed thereon in situ was developed for improvement on non-wettability. The developed member remained non-wettable more than six times longer than conventional members. A special electronic counter mechanism was developed by installing in a conduit an aluminum titanate ceramic made impeller whose revolution was converted into electric signals for the measurement of the amount of charged liquid. A non-asbestos polycrystalline alumina-silica fiber was selected as the insulator for the melting/holding furnace, which enabled 30% energy conservation as compared with the conventional type. (NEDO)

  11. Development of non-dendritic microstructures in AA6061 cast billets

    Energy Technology Data Exchange (ETDEWEB)

    Zhang, X.-D.; Chadwick, T.A.; Bryant, J.D. [Reynolds Metals Co., Chester, VA (United States)

    2000-07-01

    Non-dendritic structures have been shown to have many advantages over conventional, dendritic structures in castable aluminum alloys. Examples include high structural integrity, reduced porosity, excellent formability and enhanced near net-shape forming capability. Non-dendritic materials are characterized by an equiaxed, globularized grain structure. Previous work has focused on the application of these structures in traditional casting alloys such as A356 and A357, and on the processing of these alloys during semi-solid forming and squeeze casting. There is considerably less information on the impact of non-dendritic microstructures upon solid state deformation, and the use of such microstructures in the processing of traditional wrought aluminum alloys. In this paper, we will present our recent work in casting non-dendritic AA6061 alloy using different techniques, and discuss the effects of cast structure on deformation behavior during solid state processing at elevated temperatures. Cast microstructures were modified during direct chill casting using three different methods: magneto-hydrodynamic (MHD) agitation, mechanical stirring, and high loadings of grain refiner. A detailed microstructure characterization will be presented and discussed in terms of structural integrity, grain morphology, and their effects on deformation in the solid state. (orig.)

  12. Microstructural analysis and mechanical characterization of aluminum matrix nanocomposites reinforced with uncoated and Cu-coated alumina particles

    Energy Technology Data Exchange (ETDEWEB)

    Beygi, H., E-mail: hossein.beygi@stu-mail.um.ac.ir; Sajjadi, S.A.; Zebarjad, S.M.

    2014-06-01

    Aluminum matrix composites used in the aerospace, military and automotive industries are typically fabricated by a stir casting method. However, when nanoparticles are used for reinforcement, fabrication of composite materials by this method leads to the formation of a large number of structural defects. In this study, copper coating of alumina reinforcement particles is investigated as a technique for improving the structure of Al-Al{sub 2}O{sub 3} composites. Microstructural investigations by optical microscopy (OM), scanning electron microscopy (SEM) equipped with energy dispersion spectroscopy (EDS) and transmission electron microscopy (TEM) showed that the alumina particles were coated uniformly with copper shells. Copper coating of the reinforcing particles significantly increased their wettability in the molten aluminum alloy, strengthened the matrix-particle interfaces and improved the distribution of reinforcing particles within the matrix. Due to these microstructural improvements, the hardness, compressive strength, yield stress, tensile strength and elongation of the composites were enhanced by copper coating of the alumina particles.

  13. Microstructural analysis and mechanical characterization of aluminum matrix nanocomposites reinforced with uncoated and Cu-coated alumina particles

    International Nuclear Information System (INIS)

    Beygi, H.; Sajjadi, S.A.; Zebarjad, S.M.

    2014-01-01

    Aluminum matrix composites used in the aerospace, military and automotive industries are typically fabricated by a stir casting method. However, when nanoparticles are used for reinforcement, fabrication of composite materials by this method leads to the formation of a large number of structural defects. In this study, copper coating of alumina reinforcement particles is investigated as a technique for improving the structure of Al-Al 2 O 3 composites. Microstructural investigations by optical microscopy (OM), scanning electron microscopy (SEM) equipped with energy dispersion spectroscopy (EDS) and transmission electron microscopy (TEM) showed that the alumina particles were coated uniformly with copper shells. Copper coating of the reinforcing particles significantly increased their wettability in the molten aluminum alloy, strengthened the matrix-particle interfaces and improved the distribution of reinforcing particles within the matrix. Due to these microstructural improvements, the hardness, compressive strength, yield stress, tensile strength and elongation of the composites were enhanced by copper coating of the alumina particles

  14. Study of strength properties of semi-finished products from economically alloyed high-strength aluminium-scandium alloys for application in automobile transport and shipbuilding

    Science.gov (United States)

    Baranov, Vladimir; Sidelnikov, Sergey; Zenkin, Evgeny; Frolov, Viktor; Voroshilov, Denis; Yakivyuk, Olga; Konstantinov, Igor; Sokolov, Ruslan; Belokonova, Irina

    2018-04-01

    The results of a study on the strength of rolled products from aluminium alloys doped with scandium under various processing conditions of hot and cold rolling are presented. The regularities of metal flow and the level of strength of deformed semi-finished products from aluminum-scandium alloys are established, depending on the total degree of deformation and the various modes of single reduction during rolling. It is shown that when using one heating of a cast billet to obtain high-quality semi-finished products, the temperature during the rolling process should not be lower than 350-370°, and the total degree of deformation does not exceed 50-60%. It was found that the semi-finished products from alloys with a content of scandium in the range 0.11-0.12% in the deformed state had elevated values of ultimate tensile strength and yield strength of the metal, which allows them to be recommended for industrial production of sheet metal products.

  15. Fabrication of Aluminum Tubes Filled with Aluminum Alloy Foam by Friction Welding

    Directory of Open Access Journals (Sweden)

    Yoshihiko Hangai

    2015-10-01

    Full Text Available Aluminum foam is usually used as the core of composite materials by combining it with dense materials, such as in Al foam core sandwich panels and Al-foam-filled tubes, owing to its low tensile and bending strengths. In this study, all-Al foam-filled tubes consisting of ADC12 Al-Si-Cu die-cast aluminum alloy foam and a dense A1050 commercially pure Al tube with metal bonding were fabricated by friction welding. First, it was found that the ADC12 precursor was firmly bonded throughout the inner wall of the A1050 tube without a gap between the precursor and the tube by friction welding. No deformation of the tube or foaming of the precursor was observed during the friction welding. Next, it was shown that by heat treatment of an ADC12-precursor-bonded A1050 tube, gases generated by the decomposition of the blowing agent expand the softened ADC12 to produce the ADC12 foam interior of the dense A1050 tube. A holding time during the foaming process of approximately tH = 8.5 min with a holding temperature of 948 K was found to be suitable for obtaining a sound ADC12-foam-filled A1050 tube with sufficient foaming, almost uniform pore structures over the entire specimen, and no deformation or reduction in the thickness of the tube.

  16. Investigations on mechanical properties of aluminum hybrid composites

    Directory of Open Access Journals (Sweden)

    Dora Siva Prasad

    2014-01-01

    Full Text Available A double stir casting process was used to fabricate aluminum composites reinforced with various volume fractions of 2, 4, 6, and 8 wt% RHA and SiC particulates in equal proportions. Properties such as hardness, density, porosity and mechanical behavior of the unreinforced and Al/x%RHA/x%SiC (x = 2, 4, 6, and 8 wt% reinforced hybrid composites were examined. Scanning electron microscope (model JSM-6610LV was used to study the microstructural characterization of the composites. It was observed that the hardness and porosity of the hybrid composite increased with increasing reinforcement volume fraction and density decreased with increasing particle content. It was also observed that the UTS and yield strength increase with an increase in the percent weight fraction of the reinforcement particles, whereas elongation decreases with the increase in reinforcement. The increase in strength of the hybrid composites is probably due to the increase in dislocation density. A systematic study of the base alloy and composites was done using the Brinell hardness measurement and the corresponding age hardening curves were obtained. It was observed that in comparison to that of the base aluminum alloy, the precipitation kinetics of the composites were accelerated by adding the reinforcement. This effectively reduced the time for obtaining the maximum hardness by the aging heat treatment.

  17. The influence of the admixture of the fullerene C60 on the strength properties of aluminum and copper under shock-wave loading

    International Nuclear Information System (INIS)

    Bezruchko, G S; Razorenov, S V; Popov, M Y

    2014-01-01

    Hugoniot elastic limit (HEL) and dynamic (spall) strength measurements of pressed aluminum and copper samples with an admixture of the fullerene C60 with 2-5 wt% under shock-wave loading were carried out. The peak pressure in the shock-wave was equal to 6 GPa. The measurements of the elastic-plastic and strength properties were based on the recording and the subsequent analysis of the sample free surface velocity histories, recorded by Velocity Interferometric System for Any Reflection (VISAR). It was found that the admixture of 5 wt% fullerene in aluminum samples led to an increase of the Hugoniot elastic limit for aluminum samples by a factor of ten. The copper samples with the admixture of 2 wt% fullerene also demonstrated an increase of the Hugoniot elastic limit in comparison with commercial copper. The measured values of the Hugoniot elastic limit were equal to 0.82-1.56 GPa for aluminum samples and 1.35-3.46 GPa for copper samples, depending on their porosity. As expected, the spall strength of the samples with fullerene decreased by about three times in comparison with the undoped samples as a result of the influence of the solid fullerene particles which were concentrators of tension stresses in the material under dynamic fracture.

  18. Selective Adsorption of Sodium Aluminum Fluoride Salts from Molten Aluminum

    Energy Technology Data Exchange (ETDEWEB)

    Leonard S. Aubrey; Christine A. Boyle; Eddie M. Williams; David H. DeYoung; Dawid D. Smith; Feng Chi

    2007-08-16

    Aluminum is produced in electrolytic reduction cells where alumina feedstock is dissolved in molten cryolite (sodium aluminum fluoride) along with aluminum and calcium fluorides. The dissolved alumina is then reduced by electrolysis and the molten aluminum separates to the bottom of the cell. The reduction cell is periodically tapped to remove the molten aluminum. During the tapping process, some of the molten electrolyte (commonly referred as “bath” in the aluminum industry) is carried over with the molten aluminum and into the transfer crucible. The carryover of molten bath into the holding furnace can create significant operational problems in aluminum cast houses. Bath carryover can result in several problems. The most troublesome problem is sodium and calcium pickup in magnesium-bearing alloys. Magnesium alloying additions can result in Mg-Na and Mg-Ca exchange reactions with the molten bath, which results in the undesirable pickup of elemental sodium and calcium. This final report presents the findings of a project to evaluate removal of molten bath using a new and novel micro-porous filter media. The theory of selective adsorption or removal is based on interfacial surface energy differences of molten aluminum and bath on the micro-porous filter structure. This report describes the theory of the selective adsorption-filtration process, the development of suitable micro-porous filter media, and the operational results obtained with a micro-porous bed filtration system. The micro-porous filter media was found to very effectively remove molten sodium aluminum fluoride bath by the selective adsorption-filtration mechanism.

  19. Microstructural and mechanical properties of gravity-die-cast A356 alloy inoculated with yttrium and Al-Ti-B grain refiner simultaneously

    Directory of Open Access Journals (Sweden)

    Y.P. Lim

    2011-10-01

    Full Text Available In the present work, the effect of inoculating yttrium and Al-5Ti-1B simultaneously on A356 aluminum alloy has been studied. Gravity die casting process is used to cast the ASTM tensile test specimens for analysis. In each experiment, the Ti and B contents were maintained constantly at 0.1 and 0.02 wt% respectively. The addition of yttrium was manipulated at the amount of 0, 0.1, 0.2, 0.3, 0.4 and 0.5 wt%. Microstructural characterization of the as-cast A356 alloy was investigated by means of optical microscope and its phases are detected by XRD. The mechanical properties tested are tensile strength and hardness. The inoculation of yttrium was found to enhance the grain refinement effect of Al-5Ti-1B grain refiner and improve the mechanical properties. The optimal weight percentage of yttrium was found to be 0.3. The grain refining efficiency of combining yttrium and Al-5Ti-1B on A356 aluminum alloy was mainly attributed to the heterogeneous nucleation of TiB2 and TiAl3 particles which were dispersed more evenly in the presence of yttrium and the grain growth restriction effected by the accumulation of Al-Y compound at grain boundaries.

  20. Influence of Low-Frequency Vibration and Modification on Solidification and Mechanical Properties of Al-Si Casting Alloy.

    Science.gov (United States)

    Selivorstov, Vadim; Dotsenko, Yuri; Borodianskiy, Konstantin

    2017-05-20

    One of the major aims of the modern materials foundry industry is the achievement of advanced mechanical properties of metals, especially of light non-ferrous alloys such as aluminum. Usually an alloying process is applied to obtain the required properties of aluminum alloys. However, the presented work describes an alternative approach through the application of vibration treatment, modification by ultrafine powder and a combination of these two methods. Microstructural studies followed by image analysis revealed the refinement of α-Al grains with an increase in the Si network area around them. As evidence, the improvement of the mechanical properties of Al casting alloy was detected. It was found that the alloys subjected to the vibration treatment displayed an increase in tensile and yield strengths by 20% and 10%, respectively.

  1. Fabrication of thin cadmium cylinder coated with aluminum for neutron irradiation capsules

    International Nuclear Information System (INIS)

    Takeyama, Tomonori; Chiba, Masaaki

    2001-03-01

    In order to fabricate the irradiation capsule screened thermal neutron, a thin cadmium cylinder coated with aluminum was developed. The capsule is used for the fast neutron irradiation test. Requested specification of the cylinder are the thickness of 5.5 mm, the inner diameter of 23 mm, the length of 750 mm and the coated thickness of aluminum of 0.75 mm. Moreover, cadmium and aluminum adhere to each other. The cylinder was developed and fabricated by means of casting. The a new vacuum chamber in which solving and casting work is possible was fabricated to prevent cadmium oxidation and work safely from poison of cadmium. (author)

  2. Microstructure, mechanical analysis and optimal selection of 7075 aluminum alloy based composite reinforced with alumina nanoparticles

    International Nuclear Information System (INIS)

    Ezatpour, H.R.; Torabi Parizi, M.; Sajjadi, S.A.; Ebrahimi, G.R.; Chaichi, A.

    2016-01-01

    Aluminum metal-matrix nanocomposites (AMMNCs) fabricated by conventional stir-casting process usually show high porosity and poor distribution of nanoparticles within the matrix. In the current study, for the improvement of nanoparticles distribution in the aluminum matrix and enhancement of the mechanical properties, a mixture of Al/nano-Al 2 O 3 powders were injected by pure argon gas into the molten 7075 aluminum alloy and this mixture was extruded at high temperature. Mechanical behavior of the final product was investigated by tensile and compression tests, hardness measurements, Scanning Electron Microscopy (SEM), High Resolution Transmission Electron Microscopy (HRTEM) and Optical Microscopy. This nanocomposite exhibited some superior properties such as a fine grain microstructure and a reasonable uniform distribution of nanoparticles in the matrix. Mechanical experiments results confirmed that the addition of Al 2 O 3 nanoparticles and the extrusion process effectively improved ultimate tensile strength, compression strength and hardness. In next step, we used a Preference Selection Index (PSI) materials selection method to select best combination of strength and workability of Al7075−Al 2 O 3 nanocomposites. By this method, extruded Al7075/0.4 and 0.8 wt % Al 2 O 3 has best combination of strength and workability. - Highlights: • Injection Al/Al 2 O 3 powder is benefit way for improving nanoparticles distribution. • Nanocomposites present superior mechanical properties. • Extrusion process improved significantly mechanical properties of nanocomposites. • Preference Selection Index is a simple and benefit method in material selection.

  3. Microstructure, mechanical analysis and optimal selection of 7075 aluminum alloy based composite reinforced with alumina nanoparticles

    Energy Technology Data Exchange (ETDEWEB)

    Ezatpour, H.R., E-mail: H.R.Ezatpour@gmail.com [Faculty of Engineering, Sabzevar University of New Technology, Sabzevar (Iran, Islamic Republic of); Torabi Parizi, M. [Dept. of Materials Science and Metallurgical Engineering, Engineering Faculty, Semnan University of Semnan, Semnan (Iran, Islamic Republic of); Sajjadi, S.A. [Dept. of Materials Science and Metallurgical Engineering, Engineering Faculty, Ferdowsi University of Mashhad, Mashhad (Iran, Islamic Republic of); Ebrahimi, G.R. [Department of Materials and Polymer Engineering, Hakim Sabzevari University, Sabzevar (Iran, Islamic Republic of); Chaichi, A. [Dept. of Materials Science and Engineering, Sharif University of Technology, Tehran (Iran, Islamic Republic of)

    2016-08-01

    Aluminum metal-matrix nanocomposites (AMMNCs) fabricated by conventional stir-casting process usually show high porosity and poor distribution of nanoparticles within the matrix. In the current study, for the improvement of nanoparticles distribution in the aluminum matrix and enhancement of the mechanical properties, a mixture of Al/nano-Al{sub 2}O{sub 3} powders were injected by pure argon gas into the molten 7075 aluminum alloy and this mixture was extruded at high temperature. Mechanical behavior of the final product was investigated by tensile and compression tests, hardness measurements, Scanning Electron Microscopy (SEM), High Resolution Transmission Electron Microscopy (HRTEM) and Optical Microscopy. This nanocomposite exhibited some superior properties such as a fine grain microstructure and a reasonable uniform distribution of nanoparticles in the matrix. Mechanical experiments results confirmed that the addition of Al{sub 2}O{sub 3} nanoparticles and the extrusion process effectively improved ultimate tensile strength, compression strength and hardness. In next step, we used a Preference Selection Index (PSI) materials selection method to select best combination of strength and workability of Al7075−Al{sub 2}O{sub 3} nanocomposites. By this method, extruded Al7075/0.4 and 0.8 wt % Al{sub 2}O{sub 3} has best combination of strength and workability. - Highlights: • Injection Al/Al{sub 2}O{sub 3} powder is benefit way for improving nanoparticles distribution. • Nanocomposites present superior mechanical properties. • Extrusion process improved significantly mechanical properties of nanocomposites. • Preference Selection Index is a simple and benefit method in material selection.

  4. Identifying Combination of Friction Stir Welding Parameters to Maximize Strength of Lap Joints of AA2014-T6 Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    Rajendrana C.

    2017-01-01

    Full Text Available AA2014 aluminum alloy (Al-Cu alloy has been widely utilized in fabrication of lightweight structures like aircraft structures, demanding high strength to weight ratio and good corrosion resistance. The fusion welding of these alloys will lead to solidification problems such as hot cracking. Friction stir welding is a new solid state welding process, in which the material being welded does not melt and recast. Lot of research works have been carried out by many researchers to optimize process parameters and establish empirical relationships to predict tensile strength of friction stir welded butt joints of aluminum alloys. However, very few investigations have been carried out on friction stir welded lap joints of aluminum alloys. Hence, in this investigation, an attempt has been made to optimize friction stir lap welding (FSLW parameters to attain maximum tensile strength using statistical tools such as design of experiment (DoE, analysis of variance (ANOVA, response graph and contour plots. By this method, it is found that maximum tensile shear fracture load of 12.76 kN can be achieved if a joint is made using tool rotational speed of 900 rpm, welding speed of 110 mm/min, tool shoulder diameter of 12 mm and tool tilt angle of 1.5°.

  5. Effect of flask vibration time on casting integrity, Surface Penetration and Coating Inclusion in lost foam casting of Al-Si Alloy

    International Nuclear Information System (INIS)

    Karimian, Majid; Idris, M. H.; Ourdjini, A.; Muthu, Kali

    2011-01-01

    The paper presents the result of an experimental investigation conducted on medium aluminum silicon alloy casting- LM6, using no-vacuum assisted lost foam casting process. The study is directed for establishing the relationship between the flask vibrations times developed for molded sample on the casting integrity, surface penetration and coating inclusion defects of the casting. Four different flask vibration times namely 180, 120, 90 and 60 sec. were investigated. The casting integrity was investigated in terms of fulfilling in all portions and edges. The surface penetration was measured using optical microscope whilst image analyzer was used to quantify the percentage of coating inclusion in the casting. The results show that vibration time has significant influence on the fulfilling as well as the internal integrity of the lost foam casting. It was found that the lower vibration time produced comparatively sound casing.

  6. Influence of mean stress on fatigue strength of ferritic-pearlite ductile cast iron with small defects

    Science.gov (United States)

    Deguchi, T.; Kim, H. J.; Ikeda, T.; Yanase, K.

    2017-05-01

    Because of their excellent mechanical properties, low cost and good workability, the application of ductile cast iron has been increased in various industries such as the automotive, construction and rail industries. For safety designing of the ductile cast iron component, it is necessary to understand the effect of stress ratio, R, on fatigue limit of ductile cast iron in the presence of small defects. Correspondingly in this study, rotating bending fatigue tests at R = -1 and tension-compression fatigue tests at R = -1 and 0.1 were performed by using a ferritic-pearlitic ductile cast iron. To study the effects of small defects, we introduced a small drilled hole at surface of a specimen. The diameter and depth of a drilled hole were 50, 200 and 500 μm, respectively. The non-propagating cracks emanating from graphite particles and holes edge were observed at fatigue limit, irrespective of the value of stress ratio. From the microscopic observation of crack propagation behavior, it can be concluded that the fatigue limit is determined by the threshold condition for propagation of a small crack. It was found that the effect of stress ratio on the fatigue limit of ductile cast iron with small defects can be successfully predicted based on \\sqrt {area} parameter model. Furthermore, a use of the tensile strength, σ B, instead of the Vickers hardness, HV, is effective for fatigue limit prediction.

  7. Heat and corrosion resistant cast CN-12 type stainless steel with improved high temperature strength and ductility

    Science.gov (United States)

    Mazias, Philip J.; McGreevy, Tim; Pollard,Michael James; Siebenaler, Chad W.; Swindeman, Robert W.

    2007-08-14

    A cast stainless steel alloy and articles formed therefrom containing about 0.5 wt. % to about 10 wt. % manganese, 0.02 wt. % to 0.50 wt. % N, and less than 0.15 wt. % sulfur provides high temperature strength both in the matrix and at the grain boundaries without reducing ductility due to cracking along boundaries with continuous or nearly-continuous carbides. Alloys of the present invention also have increased nitrogen solubility thereby enhancing strength at all temperatures because nitride precipitates or nitrogen porosity during casting are not observed. The solubility of nitrogen is dramatically enhanced by the presence of manganese, which also retains or improves the solubility of carbon thereby providing additional solid solution strengthening due to the presence of manganese and nitrogen, and combined carbon. Such solution strengthening enhances the high temperature precipitation-strengthening benefits of fine dispersions of NbC. Such solid solution effects also enhance the stability of the austenite matrix from resistance to excess sigma phase or chrome carbide formation at higher service temperatures. The presence of sulfides is substantially eliminated.

  8. Development of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications

    Energy Technology Data Exchange (ETDEWEB)

    Carter, Jon T. [General Motors LLC, Warren, MI (United States); Wang, Gerry [Meridian Lightweight Technologies, Plymouth MI (United States); Luo, Alan [General Motors LLC, Warren, MI (United States)

    2017-11-29

    improvement in tensile properties with vacuum casting. Plant trials with large castings revealed cavity fill issues attributed to cooling and partial solidification of metal in the shot sleeve while waiting for vacuum to be established in the die cavity. 6. Developed age-hardenable Mg-based alloys as potential alternatives to the AM60 and AZ91 alloys typically used in automotive applications. Mg-7%Al-based alloys having Sn or Sn+Si additions exhibited significant age hardening, but more work is needed to demonstrate significant improvement in tensile properties. Corrosion behavior of these alloys is between those of AM60 and AZ91 alloys. 7. Evaluated the die casting of magnesium directly onto either steel or aluminum tubes as a potential process to make large lightweight subassemblies. Samples were free of gross defects, but additional work is needed to increase the interfacial shear strength. Overall, the project demonstrated that an automotive door-in-white design incorporating a die cast magnesium inner panel and a stamped aluminum outer panel can achieve approximately 50% mass reduction compared to the stamped steel baseline door-in-white. This leads to reduced energy consumption when driving the vehicle, which should more than offset the increased embedded energy of manufacture associated with the lighter metals. However, additional design work would be needed in order to meet the mechanical performance required of a door. Development of high-strength, high-ductility magnesium alloy castings would help make this technology more attractive for potential use in the side doors on automobiles. Also, increased use of recycled magnesium and aluminum would reduce the embedded energy and greenhouse gas emissions associated with the manufacture of this type of lightweight door. Commercialization planning of the type of lightweight door technology addressed in this project would be contingent upon the doors meeting all technical performance requirements of the car maker. The

  9. Die design and process optimization of die cast V6 engine blocks

    Directory of Open Access Journals (Sweden)

    Henry Hu

    2005-02-01

    Full Text Available The use of aluminum, particularly for engine blocks, has grown considerably in the past ten years, and continues to rise in the automotive industry. In order to enhance the quality and engineering functionality of die cast engine blocks, die design and processes have to be optimized. In this study, a computer simulation software, MAGMAsoft, as an advanced tool for optimizing die design and casting process, was emplooyed to virtually visualize cavity filling and patterns of a V6 engine block. The original die design and process was simulated first to establish a baseline. A reality check was used to verify the predicted results. Then, the die modification with a different unner system was made by using a CAD software, Unigraphics (UG. The simulation on combinations of the modified die design and revised process was performed to examine the effect of die modification and process change on flow filling of V6 engine blocks. The simulated prediction indicateds that the enhancement of cavity filling due to the die and process modification minimizeds the occurrence of defects during casting, and consequently improves the quality of blocks. The results of mechanical testing show a significant increase in fatigue strengths, and a moderately improvement on tensile properties for the blocks die cast with the new die design and prpocess in comparison with those produced by the original ones.

  10. A measure of the interfacial shear strength between SiC(CVD)/B(CVD) filament--aluminum matrix by fragmentation method

    International Nuclear Information System (INIS)

    Jiang, Y.Q.; Chen, X.J.; Yang, D.M.; Fei, X.; Pan, J.

    1993-01-01

    The tensile specimens used are of dog-bone shape and consist of single axial SiC (CVD) /B (CVD) filament processed by CVD and embedded in a LD-2 aluminum alloy. Model composite specimens have been fabricated by a high pressure squeeze casting technique. This paper describes the application of an Acoustic Emission Technique for locating the position of fiber breaks and thus determining the length distribution of fiber fragments resulting when a composite specimen containing a single fiber is loaded to failure. The critical lengths (minimal lengths) are checked by Corrosion Method

  11. Die casting copper motor rotors: mold materials and processing for cost-effective manufacturing

    Energy Technology Data Exchange (ETDEWEB)

    Peters, D.T.; Cowie, J.G.; Brush, E.F. Jr.

    2000-07-01

    This project seeks to demonstrate mold materials for copper pressure die-casting that are cost-effective and practical for production use in die-casting copper motor rotors. The incorporation of die-cast copper for conductor bars and end rings of the induction motor in place of aluminum would result in attractive improvements in motor energy efficiency through reductions in motor losses ranging from 15% to 20%. Die-cast motor rotors are produced in aluminum today because rotor fabrication by pressure die-casting is an established practice. Lack of a durable and cost-effective mold material has been the technical barrier preventing manufacture of the die-cast copper rotor. This project tested H-13 steel die inserts that establish the baseline. Nickel-, tungsten-, and molybdenum-based high temperature alloys were extensively tested. Results indicate that substantially extended die life is possible using high temperature die materials, pre-heated and operated at elevated temperatures. Pre-heating and high operating temperatures were shown to be critical in extending the die life by decreasing the cyclic stresses associated with thermal expansion. Extended die life provides the opportunity for economically viable copper motor rotor die-casting. (orig.)

  12. A novel aluminum based nanocomposite with high strength and good ductility

    Energy Technology Data Exchange (ETDEWEB)

    Ramezanalizadeh, Hossein, E-mail: hralizadeh@ut.ac.ir [School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of); Emamy, Masoud [School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of); Shokouhimehr, Mohammadreza [School of Chemical and Biological Engineering, College of Engineering, Seoul National University, Seoul (Korea, Republic of)

    2015-11-15

    Aluminum based nanocomposite containing nano-sized Al{sub 3}Mg{sub 2} reinforcing was fabricated via mechanical milling followed by hot extrusion techniques. For this, Al and Al{sub 3}Mg{sub 2} powders were mixed mechanically and milled at different times (0, 2, 5, 7, 10, 15 and 20 h) to achieve Al–10 wt.% Al{sub 3}Mg{sub 2} composite powders. Hot extrusion of cold pressed powders was done at 400 °C with extrusion ratio of 6:1. Microstructures of the powders and consolidated materials were studied using transmission electron microscopy, scanning electron microscope and X-ray diffraction. Fracture surfaces were also investigated by scanning electron microscopy equipped with EDS analyzer. The results showed that an increase in milling time caused to reduce the grain size unlike the lattice strain of Al matrix. In addition, the fabricated composites exhibited homogeneous distribution and less agglomerations of the n-Al{sub 3}Mg{sub 2} with increasing milling time. The mechanical behavior of these nanocomposites was investigated by hardness and tensile tests, which revealed it has four times the strength of a conventional Al along with good ductility. It was found that the ultimate tensile strength (UTS) and elongation of the nanocomposites were significantly improved with increases in milling time up to 15 h. This improvement was attributed to the grain refinement strengthening and homogeneous distribution of the n-Al{sub 3}Mg{sub 2}. Fracture surfaces showed that the interfacial bonding between Al and Al{sub 3}Mg{sub 2} could be improved with increasing in milling time. Also HRTEM results from interface showed that a metallurgical clean interface and intimate contact between matrix and second phase. By extending the milling process up to 20 h, there was no significant improvement in mechanical behavior of materials, due to the completion of milling process and dynamic and static recovery of composite at higher milling times. - Highlights: • A novel aluminum

  13. Effect of Sr addition on the characteristics of as-cast and rolled 3003/4004 clad aluminum

    Energy Technology Data Exchange (ETDEWEB)

    Yan, Guangyuan; Mao, Feng; Jie, Jinchuan; Cao, Zhiqiang, E-mail: caozq@dlut.edu.cn; Li, Tingju; Wang, Tongmin, E-mail: tmwang@dlut.edu.cn

    2016-09-05

    This paper examines the effects of Sr addition on the microstructure, composition distribution and Vickers hardness in the interfacial region of the as-cast and rolled 3003/4004 clad aluminum. The results reveal that the optimum adding amount of Sr on the as-cast Al-1.2Mn/Al−10Si-xSr clad is 0.08 wt%. With Sr content increasing from 0 to 0.08 wt%, the average length and number of the primary α-Al phase growing from the diffusion layer significantly decreased and whose morphology appears in columar dendritic crystals, the celluar dendrite crystals, deep celluar crystals, fine celluar crystals and planar crystals, while the dendritic-crystal primary α-Al phase nucleating and growing from inner Al−Si alloy side also show obvious decease in secondary dendrite spacing; meanwhile, eutectic Si phases were gradually modified from coarse plates, coralloid-plates mixed structure to fine branchy coralloid structure in three-dimensional morphology. After rolling, the diffusion layer thickness of the Al-1.2Mn/Al−10Si−0.08Sr clad is decreased by 66.7%, compared to that of unmodified clad alloy. This decreased diffusion layer thickness may be determined by augmented plastic strain and restraining diffusion of Si atoms in diffusion layer. Morever, average Vickers hardness on interface and Al−Si side of the Al-1.2Mn/Al−10Si−0.08Sr clad showed slight increase and more uniform distribution than that of unmodified clad alloy. This uniform distribution and improved hardness primarily attribute to presence of fine branchy coralloid silicon phase and its stronger dispersion strengthening as well as solution strengthening caused by interdiffusion of Si, Mn and Sr elements. - Highlights: • 3003/4004 clad aluminum was firstly modified by various Sr addition levels. • The optimum adding amount of Sr on the Al−1.2Mn/Al−10Si−xSr clad is 0.08 wt%. • Sr can refine primary α-Al and eutectic silicon phase of the clad simultaneously. • The Sr-modified rolled clad has

  14. Thermomechanical processing of aluminum micro-alloyed with Sc, Zr, Ti, B, and C

    Science.gov (United States)

    McNamara, Cameron T.

    Critical exploration of the minimalistic high strength low alloy aluminum (HSLA-Al) paradigm is necessary for the continued development of advanced aluminum alloys. In this study, scandium (Sc) and zirconium (Zr) are examined as the main precipitation strengthening additions, while magnesium (Mg) is added to probe the synergistic effects of solution and precipitation hardening, as well as the grain refinement during solidification afforded by a moderate growth restriction factor. Further, pathways of recrystallization are explored in several potential HSLA-Al syste =ms sans Sc. Aluminum-titanium-boron (Al-Ti-B) and aluminum-titanium-carbon (Al-Ti-C) grain refining master alloys are added to a series of Al-Zr alloys to examine both the reported Zr poisoning effect on grain size reduction and the impact on recrystallization resistance through the use of electron backscattered diffraction (EBSD) imaging. Results include an analysis of active strengthening mechanisms and advisement for both constitution and thermomechanical processing of HSLA-Al alloys for wrought or near-net shape cast components. The mechanisms of recrystallization are discussed for alloys which contain a bimodal distribution of particles, some of which act as nucleation sites for grain formation during annealing and others which restrict the growth of the newly formed grains.

  15. Bending strength and fracture surface topography of natural fiber-reinforced shell for investment casting process

    Directory of Open Access Journals (Sweden)

    Kai Lu

    2016-05-01

    Full Text Available In order to improve the properties of silica sol shell for investment casting process, various contents of cattail fibers were added into the slurry to prepare a fiber-reinforced shell in the present study. The bending strength of fiber-reinforced shell was investigated and the fracture surfaces of shell specimens were observed using SEM. It is found that the bending strength increases with the increase of fiber content, and the bending strength of a green shell with 1.0 wt.% fiber addition increases by 44% compared to the fiber-free shell. The failure of specimens of the fiber-reinforced green shell results from fiber rupture and debonding between the interface of fibers and adhesive under the bending load. The micro-crack propagation in the matrix is inhibited by the micro-holes for ablation of fibers in specimens of the fiber-reinforced shell during the stage of being fired. As a result, the bending strength of specimens of the fired shell had no significant drop. Particularly, the bending strength of specimens of the fired shell reinforced with 0.6wt.% fiber reached the maximum value of 4.6 MPa.

  16. Friction welding of ductile cast iron using interlayers

    International Nuclear Information System (INIS)

    Winiczenko, Radoslaw; Kaczorowski, Mieczyslaw

    2012-01-01

    Highlights: → The results of the study of the friction welding of ductile cast iron using interlayers are presented. → The results of the analysis shows that the joint has the tensile strength compared to that of basic material. → In case of ductile cast iron, it is possible to reach the tensile strength equals even 700 MPa. → The process of friction welding was accompanied with diffusion of Cr, Ni and C atoms across the interface. -- Abstract: In this paper, ductile cast iron-austenitic stainless steel, ductile cast iron-pure Armco iron and ductile cast iron-low carbon steel interlayers were welded, using the friction welding method. The tensile strength of the joints was determined, using a conventional tensile test machine. Moreover, the hardness across the interface of materials was measured on metallographic specimens. The fracture surface and microstructure of the joints was examined using either light stereoscope microscopy as well as electron microscopy. In this case, scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were applied. The results of the analysis shows that the joint has the tensile strength compared to that of basic material. In case of ductile cast iron, it is possible to reach the tensile strength equals even 700 MPa. It was concluded that the process of friction welding was accompanied with diffusion of Cr, Ni and C atoms across the ductile cast iron-stainless steel interface. This leads to increase in carbon concentration in stainless steel where chromium carbides were formed, the size and distribution of which was dependent on the distance from the interface.

  17. Optimization of aluminum thickness for absorption of undesired Ti K X-rays in the measurement of low energy brachytherapy source strength

    Energy Technology Data Exchange (ETDEWEB)

    Kashian, S., E-mail: skashian@aeoi.org.ir [Radiation Applications Research School, Nuclear Science and Technology Research Institute, Tehran (Iran, Islamic Republic of); Physics Department, Shiraz University, Shiraz 71454 (Iran, Islamic Republic of); Raisali, G., E-mail: graisali@aeoi.org.ir [Radiation Applications Research School, Nuclear Science and Technology Research Institute, Tehran (Iran, Islamic Republic of); Eskandari, M.R., E-mail: eskandari@susc.ac.ir [Physics Department, Shiraz University, Shiraz 71454 (Iran, Islamic Republic of); Nuclear Engineering Department, Shiraz University, Shiraz (Iran, Islamic Republic of); Khalafi, H., E-mail: hkhalafi@aeoi.org.ir [Radiation Applications Research School, Nuclear Science and Technology Research Institute, Tehran (Iran, Islamic Republic of)

    2011-02-15

    The contribution of Ti K X-rays to total air kerma strength for low energy brachytherapy sources ({sup 125}I and {sup 103}Pd) are calculated for different source-to-aperture distances of an indigenously designed free air ionization chamber. For 30 cm source-to-aperture distance, calculated contribution of Ti K X-rays is 4%. The Ti K X-rays can be eliminated by a relatively thin aluminum filter, but the primary photons emitted by the source will also be attenuated. This effect should be compensated by applying a suitable correction factor. The uncertainty in the attenuation correction factor has been also calculated for different thicknesses of aluminum by a Monte Carlo uncertainty analysis algorithm programmed in FORTRAN. The results show that the optimum thickness of the aluminum absorber is 100 {mu}m, for which the contribution of Ti K X-rays in air kerma strength is reduced to less than one hundredth of the uncertainty in the correction factor, ensuring that the uncertainty in the air kerma strength will be mainly due to the uncertainty in the correction factor. The calculated uncertainties are 1.7 x 10{sup -3}, and 3.4 x 10{sup -3} for {sup 125}I and {sup 103}Pd sources, respectively.

  18. Effect of aluminum anodizing in phosphoric acid electrolyte on adhesion strength and thermal performance

    Science.gov (United States)

    Lee, Sulki; Kim, Donghyun; Kim, Yonghwan; Jung, Uoochang; Chung, Wonsub

    2016-01-01

    This study examined the adhesive bond strength and thermal performance of the anodized aluminum 6061 in phosphoric acid electrolyte to improve the adhesive bond strength and thermal performance for use in metal core printed circuit boards (MCPCB). The electrolyte temperature and applied voltage were altered to generate varied pore structures. The thickness, porosity and pore diameter of the anodized layer were measured. The pore morphologies were affected most by temperature, which was the driving force for ion transportation. The mechanism of adhesive bond was penetration of the epoxy into the pores. The optimal anodization conditions for maximum adhesive bond strength, 27 MPa, were 293 K and 100V. The maximum thermal conductivity of the epoxy-treated anodized layer was 1.6 W/m·K at 273 K. Compared with the epoxy-treated Al layer used for conventional MCPCBs, the epoxy-treated anodized layer showed advanced thermal performance due to a low difference of thermal resistance and high heat dissipation.

  19. Breaking through the strength-ductility trade-off dilemma in an Al-Si-based casting alloy.

    Science.gov (United States)

    Dang, B; Zhang, X; Chen, Y Z; Chen, C X; Wang, H T; Liu, F

    2016-08-09

    Al-Si-based casting alloys have a great potential in various industrial applications. Common strengthening strategies on these alloys are accompanied inevitably by sacrifice of ductility, known as strength-ductility trade-off dilemma. Here, we report a simple route by combining rapid solidification (RS) with a post-solidification heat treatment (PHT), i.e. a RS + PHT route, to break through this dilemma using a commercial Al-Si-based casting alloy (A356 alloy) as an example. It is shown that yield strength and elongation to failure of the RS + PHT processed alloy are elevated simultaneously by increasing the cooling rate upon RS, which are not influenced by subsequent T6 heat treatment. Breaking through the dilemma is attributed to the hierarchical microstructure formed by the RS + PHT route, i.e. highly dispersed nanoscale Si particles in Al dendrites and nanoscale Al particles decorated in eutectic Si. Simplicity of the RS + PHT route makes it being suitable for industrial scaling production. The strategy of engineering microstructures offers a general pathway in tailoring mechanical properties of other Al-Si-based alloys. Moreover, the remarkably enhanced ductility of A356 alloy not only permits strengthening further the material by work hardening but also enables possibly conventional solid-state forming of the material, thus extending the applications of such an alloy.

  20. Effect of heat treatment operations on the Rm tensile strength of silumins

    Directory of Open Access Journals (Sweden)

    J. Pezda

    2010-10-01

    Full Text Available Owing to good technological properties, low weight and good corrosion resistance, aluminum-silicon alloys are widely used as a material for cast machinery components. State of macro- and microstructure of a castings manufactured from Al-Si alloys, which is determined by a shape and distribution of hardening phases, segregation of alloying constituents and impurities, as well as distribution of porosity, create conditions to obtainment of proper mechanical properties. These properties can be improved through modification of the alloy and performed heat treatment operations. The paper presents effect of modification and heat treatment process on the Rm tensile strength of a selected silumins (EN AB-AlSi9Cu3(Fe, EN AB-AlSi12CuNiMg, EN AB-AlSi17Cu1Ni1Mg. Investigated alloys were put to treatments of refining and modification, and next to heat treatment. Temperature range of the heat treatment operations was determined on base of curves from the ATD method. Obtained results illustrate registered curves of melting and solidification from the ATD method and strength tests. On base of performed initial tests one determined parameters of the heat treatment process (temperature and duration of solutionig and ageing treatments enabling obtainment of improved Rm tensile strength of the investigated alloys.

  1. Modeling and Optimization of Direct Chill Casting to Reduce Ingot Cracking

    Energy Technology Data Exchange (ETDEWEB)

    Das, Subodh K.

    2006-01-09

    reheating-cooling method (RCM), was developed and validated for measuring mechanical properties in the nonequilibrium mushy zones of alloys. The new method captures the brittle nature of aluminum alloys at temperatures close to the nonequilibrium solidus temperature, while specimens tested using the reheating method exhibit significant ductility. The RCM has been used for determining the mechanical properties of alloys at nonequilibrium mushy zone temperatures. Accurate data obtained during this project show that the metal becomes more brittle at high temperatures and high strain rates. (4) The elevated-temperature mechanical properties of the alloy were determined. Constitutive models relating the stress and strain relationship at elevated temperatures were also developed. The experimental data fit the model well. (5) An integrated 3D DC casting model has been used to simulate heat transfer, fluid flow, solidification, and thermally induced stress-strain during casting. A temperature-dependent HTC between the cooling water and the ingot surface, cooling water flow rate, and air gap were coupled in this model. An elasto-viscoplastic model based on high-temperature mechanical testing was used to calculate the stress during casting. The 3D integrated model can be used for the prediction of temperature, fluid flow, stress, and strain distribution in DC cast ingots. (6) The cracking propensity of DC cast ingots can be predicted using the 3D integrated model as well as thermodynamic models. Thus, an ingot cracking index based on the ratio of local stress to local alloy strength was established. Simulation results indicate that cracking propensity increases with increasing casting speed. The composition of the ingots also has a major effect on cracking formation. It was found that copper and zinc increase the cracking propensity of DC cast ingots. The goal of this Aluminum Industry of the Future (IOF) project was to assist the aluminum industry in reducing the incidence of stress

  2. exploration the extrudability of aluminum matrix composite (lm6/tic)

    African Journals Online (AJOL)

    lanez

    2017-11-24

    Nov 24, 2017 ... Aluminum matrix composites (LM6/TiC) is a mix of excellent properties of aluminum casting alloy (LM6), and particles of (TiC) which make it the first choice in many applications like airplane and marine industries. During this research the extrudability and mechanical specifications of this composite ...

  3. Mechanical properties of as-cast microalloyed steels produced via investment casting

    International Nuclear Information System (INIS)

    Najafi, H.; Rassizadehghani, J.; Norouzi, S.

    2011-01-01

    Tensile and room temperature Charpy V-notch impact tests were used to evaluate the variations in the as-cast mechanical properties of a low-carbon steel produced via shell mould investment casting and containing combinations of vanadium, niobium and titanium. Tensile results indicate that the yield strength and ultimate tensile strength (UTS) have increased up to respectively 615 MPa and 770 MPa due to the fine-scale microalloy precipitates in the microalloyed samples. Room temperature impact test results show that while addition of vanadium individually has not changed the impact energy, Nb has decreased it considerably. However, examination of fracture surfaces reveals that all microalloyed samples have failed by transgranular cleavage. Based on the transmission electron microscope (TEM) studies, it seems that carbonitrides being greater than 50 nm in size and formed along prior austenite grain boundaries before γ transformation are responsible for the observed reduction in impact energies and brittle fracture. In comparison to sand mould casting, the yield and UTS obtained from investment casting are superior. Furthermore, although the impact energies of Nb-containing alloys are approximately the same as those obtained from sand moulds, the impact energy of the alloy containing only vanadium has improved considerably.

  4. Low-temperature resistance of cyclically strained aluminum

    International Nuclear Information System (INIS)

    Segal, H.R.; Richard, T.G.

    1977-01-01

    An experimental study of the resistance changes in high-purity, reinforced aluminum due to cyclic straining is presently underway. The purpose of this work is to determine the optimum purity of aluminum to be used as a stabilizing material for superconducting magnets used for energy storage. Since pure aluminum has a low yield strength, it is not capable of supporting the stress levels in an energized magnet. Therefore, it has been bonded to a high-strength material--in this case, 6061 aluminum alloy. This bonding permits pure aluminum to be strained cyclically beyond its elastic limit with recovery of large plastic strains upon release of the load. The resistance change in this composite material is less than that of pure, unreinforced aluminum

  5. Laboratory Powder Metallurgy Makes Tough Aluminum Sheet

    Science.gov (United States)

    Royster, D. M.; Thomas, J. R.; Singleton, O. R.

    1993-01-01

    Aluminum alloy sheet exhibits high tensile and Kahn tear strengths. Rapid solidification of aluminum alloys in powder form and subsequent consolidation and fabrication processes used to tailor parts made of these alloys to satisfy such specific aerospace design requirements as high strength and toughness.

  6. Casting defects and mechanical properties of high pressure die cast Mg-Zn-Al-RE alloys

    Energy Technology Data Exchange (ETDEWEB)

    Xiao, Wenlong; Easton, Mark A.; Zhu, Suming; Nie, Jianfeng [CAST Cooperative Research Centre, Department of Materials Engineering Monash University, Melbourne, VIC (Australia); Dargusch, Matthew S. [School of Mechanical and Mining Engineering, University of Queensland, Brisbane, QLD (Australia); Gibson, Mark A. [CSIRO Process Science and Engineering, Melbourne, VIC (Australia); Jia, Shusheng [Key Laboratory of Automobile Materials, Ministry of Education, Department of Materials Science and Engineering Jilin University, Changchun (China)

    2012-02-15

    The die casting defects and tensile properties of high pressure die cast (HPDC) Mg-Zn-Al-RE alloys with various combinations of Zn and Al were studied. The results show that die casting defects in Mg-Zn-Al-RE alloys are affected by the percentage of Zn and Al contents. The hot tearing susceptibility (HTS) of Mg-Zn-Al-RE alloys tends to increase with increasing Zn content up to 6 wt%, while a further increase of Al and/or Zn content reduces the HTS. In tensile tests, the yield strength (YS) is generally improved by increasing Zn or Al content, whereas the tensile strength (TS) and ductility appear to depend largely on the presence of casting defects. Compared with Mg-Zn-Al alloys, the mechanical properties of the Mg-Zn-Al-RE alloy are significantly improved. The Mg-4Zn-4Al-4RE alloy is found to have few casting defects and the optimal tensile properties. (Copyright copyright 2012 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

  7. Evaluation of interlocking bond strength between structured 1.0338 steel sheets and high pressure die cast AlMg5Si2

    Science.gov (United States)

    Senge, S.; Brachmann, J.; Hirt, G.; Bührig-Polaczek, A.

    2018-05-01

    Multi-material components open up new possibilities for functional design. Such components combine beneficial physical properties of different materials in a single component as for instance chemical resistance, high strength or low density. The challenge is a reliable bond between both materials to enable a long term usage. This paper deals with a form closure connection to ensure a solid connection between steel strips and high pressure die cast aluminium. Two different sizes of channel structures with width ratios of 1.0 and 1.35 are produced on a steel sheet. An ensuing flat rolling pass is performed to create undercuts with a width of up to 50 µm, enabling an interlocking of the molten aluminium in the concluding casting process. For both rolling processes the resulting geometry is analysed depending on the thickness reduction. In a subsequent high pressure die casting process, aluminium is applied resulting in a complete form filling for the coarser structure. Comparing structures with and without undercuts, only structures suited with undercuts remain gap-free after solidification contraction. The finer structure could not be filled completely; nevertheless these structures result in shear strength of up to 45 MPa transversal to the channel-direction.

  8. Cast iron for reactor technology - special structural and mechanical properties

    International Nuclear Information System (INIS)

    Janakiev, N.

    The graphitic phase, its formation and the effect on the mechanical properties of cast iron used for reactor shielding are described. Tensile strength, bending strength and Brinell hardness were studied. With the specimen wall thickness of 400 mm the average measured tensile strength was 180 N/mm 2 , which satisfies the given requirements as do the values of bending strength and material hardness. As against materials 200 mm in thickness, graphite was found by metallographic tests to be of a significantly coarser structure, which may be explained by slower cooling. Tensile strength was also tested for nodular cast irons and lamellar graphite cast irons. It was shown that compression increased with decreasing specimen diameter at constant pressure, at a constant diameter compression increased nearly in proportion to compressive stress. No significant differences were found if compressive stress was 80% of fracture stress. The modulus of elasticity was found to decrease with increasing graphite content while it was found to increase with fine graphite lamellae at the same carbon concentration. It also decreased with increasing straining. A Mo-alloyed cast iron was found to show slower creep rates at a compressive stress of up to 90 N/mm 2 (calculated to the same initial strengths) than Cu-alloyed cast iron. Upon increasing compressive stress to 140 N/mm 2 and creep time to more than 2000 hours, the creep behaviour of Cu-alloyed cast iron was better. Coarser perlite is likely to be more creep resistant than fine perlite. In neutron irradiation of cast iron a clear trend towards hardening was found due to the effect of neutrons on the cast iron structure. (J.B.)

  9. The influence of Ti on the microstructure and tensile properties of cast Al–4.5Cu–0.3Mg alloy

    Energy Technology Data Exchange (ETDEWEB)

    Kamali, H. [School of Metallurgy and Materials Engineering, University of Tehran, P.O. Box 14395-731, Tehran (Iran, Islamic Republic of); Emamy, M., E-mail: emamy@ut.ac.ir [School of Metallurgy and Materials Engineering, University of Tehran, P.O. Box 14395-731, Tehran (Iran, Islamic Republic of); Razaghian, A. [Imam Khomeini International University, Qazvin (Iran, Islamic Republic of)

    2014-01-10

    Current study was undertaken to investigate the effect of different amounts of titanium (0.001–0.5 wt%) on the microstructure, tensile properties and quality index of a high strength aluminum alloy (Al–4.5 Cu–0.3Mg). It was found that this alloy is susceptible to hot tearing and at least 0.05 wt% Ti is necessary to remove such a defect. The microstructural studies of the alloy revealed that Ti addition reduces the grain size from 190 μm to 48 μm, but adding higher Ti content (>0.05 wt% Ti) does not change the grain size considerably. Further investigations on tensile tests revealed that the addition of Ti increases ultimate tensile strength (UTS) but reduces elongation values. T6 heat treatment improved UTS, elongation and quality index values of the casting. Fracture surfaces via scanning electron microscopy (SEM) revealed ductile fracture mode in both as-cast and heat-treated conditions. At higher Ti contents, the presence of Al{sub 3}Ti intermetallic on grain boundaries was found to be the favored path for crack growth.

  10. Cast dielectric composite linear accelerator

    Science.gov (United States)

    Sanders, David M [Livermore, CA; Sampayan, Stephen [Manteca, CA; Slenes, Kirk [Albuquerque, NM; Stoller, H M [Albuquerque, NM

    2009-11-10

    A linear accelerator having cast dielectric composite layers integrally formed with conductor electrodes in a solventless fabrication process, with the cast dielectric composite preferably having a nanoparticle filler in an organic polymer such as a thermosetting resin. By incorporating this cast dielectric composite the dielectric constant of critical insulating layers of the transmission lines of the accelerator are increased while simultaneously maintaining high dielectric strengths for the accelerator.

  11. Design for low-cost gas metal arc weld-based aluminum 3-D printing

    Science.gov (United States)

    Haselhuhn, Amberlee S.

    Additive manufacturing, commonly known as 3-D printing, has the potential to change the state of manufacturing across the globe. Parts are made, or printed, layer by layer using only the materials required to form the part, resulting in much less waste than traditional manufacturing methods. Additive manufacturing has been implemented in a wide variety of industries including aerospace, medical, consumer products, and fashion, using metals, ceramics, polymers, composites, and even organic tissues. However, traditional 3-D printing technologies, particularly those used to print metals, can be prohibitively expensive for small enterprises and the average consumer. A low-cost open-source metal 3-D printer has been developed based upon gas metal arc weld (GMAW) technology. Using this technology, substrate release mechanisms have been developed, allowing the user to remove a printed metal part from a metal substrate by hand. The mechanical and microstructural properties of commercially available weld alloys were characterized and used to guide alloy development in 4000 series aluminum-silicon alloys. Wedge casting experiments were performed to screen magnesium, strontium, and titanium boride alloying additions in hypoeutectic aluminum-silicon alloys for their properties and the ease with which they could be printed. Finally, the top performing alloys, which were approximately 11.6% Si modified with strontium and titanium boride were cast, extruded, and drawn into wire. These wires were printed and the mechanical and microstructural properties were compared with those of commercially available alloys. This work resulted in an easier-to-print aluminum-silicon-strontium alloy that exhibited lower porosity, equivalent yield and tensile strengths, yet nearly twice the ductility compared to commercial alloys.

  12. Dissimilar joining of galvanized high-strength steel to aluminum alloy in a zero-gap lap joint configuration by two-pass laser welding

    International Nuclear Information System (INIS)

    Ma, Junjie; Harooni, Masoud; Carlson, Blair; Kovacevic, Radovan

    2014-01-01

    Highlights: • Defect-free two-pass laser partially penetrated lap joint of galvanized steel to aluminum was achieved. • The thickness of the Al-rich intermetallic compounds could be controlled by optimal parameters. • The dynamic behavior of the molten pool and keyhole were monitored by a high speed charge-coupled device camera. • The presence of zinc in the intermetallic compounds could improve the strength of the lap joints. - Abstract: A welding procedure based on using two-pass laser scans is introduced for dissimilar joining of overlapped galvanized high-strength dual-phase (DP) steel DP590 to aluminum alloy (AA) 6061 sheets. The first pass is based on a defocused laser spot that scans across the top of the two overlapped sheets and heats the zinc coating at the faying surface to be melted and partially vaporized, while the second pass is executed with a focused laser spot in order to perform the welding. Completely defect-free galvanized steel to aluminum lap joints were obtained by using this two-pass laser welding procedure. An on-line machine vision system was applied to monitor the keyhole dynamics during the laser welding process. An energy-dispersive X-ray spectroscopy (EDS) was carried out to determine the atomic percent of zinc, aluminum, and iron in the galvanized steel to aluminum lap joints. Mechanical testing and micro-hardness test were conducted to evaluate the mechanical properties of the galvanized steel to aluminum lap joints. The experimental results showed that the lap joint of galvanized steel to aluminum obtained by the two-pass laser welding approach had a higher failure value than those joints obtained when the zinc at the faying surface was mechanically removed under the same welding speed and laser power

  13. Packaging material and aluminum. Hoso zairyo to aluminum

    Energy Technology Data Exchange (ETDEWEB)

    Itaya, T [Mitsubishi Aluminum Co. Ltd., Tokyo (Japan)

    1992-02-01

    The present paper introduces aluminum foil packaging materials among the relation between packing materials and aluminum. The characteristics of aluminum foil in the packaging area are in its barrier performance, non-toxicity, tastelessness and odorlessness. Its excellent functions and processibility suit best as functional materials for food, medicine and industrial material packaging. While an aluminum foil may be used as a single packing material as in foils used in homes, many of it as a packaging material are used in combination with adhesives, papers or plastic films, or coated or printed. It is used as composite materials laminated or coated with other materials according to their use for the purpose of complementing the aluminum foil as the base material. Representative method to laminate aluminum foils include the wet lamination, dry lamination, thermally dissolved lamination and extruded lamination. The most important quality requirement in lamination is the adhesion strength, which requires a close attention in selecting the kinds of adhesive, laminating conditions, and aging conditions. 8 figs., 6 tabs.

  14. MICROSTRUCTURAL FEATURES EVALUATION OF AGE-HARDENED A 226 CAST ALLOY BY IMAGE ANALYSIS

    Directory of Open Access Journals (Sweden)

    Lenka Kuchariková

    2018-01-01

    Full Text Available Age-hardening provides one of the most widely used mechanisms for the strengthening of aluminum alloys. The age-hardening involves three steps: solution treatment, quenching and aging. The temperature of solution treatment and aging is very important in order to reach desired properties of castings. The optimum temperature of solution treatment and aging led to formation microstructural features in form which does not lead to decreasing properties, but increasing ones. The major microstructural features in A 226 cast alloys which are responsible for increasing properties are: eutectic Si particles, Cu-rich phases, Fe-rich phases and porosity. The increase of properties depends on morphology, size and volume of microstructural features. In order to assess age-hardening influence on microstructural features in A226 cast alloys were used as possibilities of evaluation by means of image analysis. Quantitative analysis decelerate changes in microstructure includes the spheroidization and coarsening of eutectic silicon, gradual disintegration, shortening and thinning of Fe-rich intermetallic phases, the dissolution of precipitates and the precipitation of finer hardening phase (Al2Cu further increase in the hardness and tensile strength in the alloy. Changes of mechanical properties were measured in line with STN EN ISO.

  15. Dry Sliding Wear Charactristics of Aluminum 6061-T6, Magnesium AZ31 and Rock Dust Composite

    Science.gov (United States)

    Balachandar, R.; Balasundaram, R.; Rajkumar, G.

    2018-02-01

    In recent years, the use of aluminum composite is gaining popularity in a wide range of applications like automobiles, aerospace and constructions (both interior & exterior) panels etc., due to its high strength, low density characteristics. Various reinforcing materials are used with aluminum 6061-T6 in order to have better mechanical properties. The addition of 0.3% of magnesium AZ31 will increase the ultimate tensile strength by 25 %. The reinforcement of rock dust will decrease the density. Hence, in order to have an advantages of magnesium AZ31 and rock dust, in this work, these two constitutes are varied from 1% to 2% on the base material of Al6061-T6 in stir casting. To evaluate the wear characteristics, Pin on disc is used in these composites. The input parameters are speed, time & load. The output response is wear. To minimize the number of experiments, L9 orthogonal array is used. The test results showed that a composite of 97% of Al (6061-T6), 1% Mg (AZ31) & 2 % of rock dust produced less wear. To find the best value of operating parameter for each sample, ANN-GA is used.

  16. Constitutive behavior of as-cast AA1050, AA3104, and AA5182

    Science.gov (United States)

    van Haaften, W. M.; Magnin, B.; Kool, W. H.; Katgerman, L.

    2002-07-01

    Recent thermomechanical modeling to calculate the stress field in industrially direct-chill (DC) cast-aluminum slabs has been successful, but lack of material data limits the accuracy of these calculations. Therefore, the constitutive behavior of three aluminum alloys (AA1050, AA3104, and AA5182) was determined in the as-cast condition using tensile tests at low strain rates and from room temperature to solidus temperature. The parameters of two constitutive equations, the extended Ludwik equation and a combination of the Sellars-Tegart equation with a hardening law, were determined. In order to study the effect of recovery, the constitutive behavior after prestraining at higher temperatures was also investigated. To evaluate the quantified constitutive equations, tensile tests were performed simulating the deformation and cooling history experienced by the material during casting. It is concluded that both constitutive equations perform well, but the combined hardening-Sellars-Tegart (HST) equation has temperature-independent parameters, which makes it easier to implement in a DC casting model. Further, the deformation history of the ingot should be taken into account for accurate stress calculations.

  17. Influence of heat treatment on microstructure and tensile properties of a cast Al-Cu-Si-Mn alloy

    Directory of Open Access Journals (Sweden)

    Liu Zhixue

    2013-11-01

    Full Text Available Solution and aging treatments are important approaches to improve mechanical properties and microstructure of aluminum-base alloys. In this research, a new type high strength Al-Cu-Si-Mn cast alloy was prepared. The effect of different solution and aging treatment temperatures on microstructure and mechanical properties of the Al-Cu-Si-Mn cast alloy were studied by means of microstructure observation and mechanical properties testing. Results showed that after solution treated at different temperatures for 12 h and aged at 175 ℃ for 12 h, with the increase of the solution temperature, both the tensile strength and the elongation of the alloy firstly increase and then decrease, and reach their peak values at 530 ℃. When the solution temperature is below 530 ℃, the microstructure of the alloy consists of α phase, undissolved θ phase and T phase; while when it exceeds 530 ℃, the microstructure only consists of α phase and T phase. After solution treated at 530 ℃ for 12 h and aged at different temperatures for 12 h, both the tensile strength and the elongation of the alloy firstly increase and then decrease with the increasing of temperature, and reach their peak values at 175 ℃. Therefore, the optimal heat treatment process for the alloy in this study is 12 h solution at 530 ℃ and 12 h aging at 175 ℃, and the corresponding tensile strength is 417 MPa, elongation is 4.0%.

  18. Effect of Mg and Cu on mechanical properties of high-strength welded joints of aluminum alloys obtained by laser welding

    Science.gov (United States)

    Annin, B. D.; Fomin, V. M.; Karpov, E. V.; Malikov, A. G.; Orishich, A. M.

    2017-09-01

    Results of experimental investigations of welded joints of high-strength aluminum-lithium alloys of the Al-Cu-Li and Al-Mg-Li systems are reported. The welded joints are obtained by means of laser welding and are subjected to various types of processing for obtaining high-strength welded joints. A microstructural analysis is performed. The phase composition and mechanical properties of the welded joints before and after heat treatment are studied. It is found that combined heat treatment of the welded joint (annealing, quenching, and artificial ageing) increases the joint strength, but appreciably decreases the alloy strength outside the region thermally affected by the welding process.

  19. The stress-corrosion cracking behavior of high-strength aluminum powder metallurgy alloys

    Science.gov (United States)

    Pickens, J. R.; Christodoulou, L.

    1987-01-01

    The susceptibility to stress-corrosion cracking (SCC) of rapidly solidified (RS) aluminum powder metallurgy (P/M) alloys 7090 and 7091, mechanically alloyed aluminum P/M alloy IN* 9052, and ingot metallurgy (I/M) alloys of similar compositions was compared using bolt-loaded double cantilever beam specimens. In addition, the effects of aging, grain size, grain boundary segregation, pre-exposure embrittlement, and loading mode on the SCC of 7091 were independently assessed. Finally, the data generated were used to elucidate the mechanisms of SCC in the three P/M alloys. The IN 9052 had the lowest SCC susceptibility of all alloys tested in the peak-strength condition, although no SCC was observed in the two RS alloys in the overaged condition. The susceptibility of the RS alloys was greater in the underaged than the peak-aged temper. We detected no significant differences in susceptibility of 7091 with grain sizes varying from 2 to 300 μm. Most of the crack advance during SCC of 7091 was by hydrogen embrittlement (HE). Furthermore, both RS alloys were found to be susceptible to preexposure embrittlement—also indicative of HE. The P/M alloys were less susceptible to SCC than the I/M alloys in all but one test.

  20. Effect of T6 heat treatment on tensile strength of EN AB-48000 alloy modified with strontium

    Directory of Open Access Journals (Sweden)

    J. Pezda

    2011-07-01

    Full Text Available Among alloys of non-ferrous metals, aluminum alloys have found their broadest application in foundry industry. Silumins are widely used in automotive, aviation and shipbuilding industries; as having specific gravity nearly three times lower than specific gravity of cast iron. The silumins can be characterized by high mechanical properties. To upgrade mechanical properties of a castings made from silumins one makes use of heat treatment, what leads to change of their structure and advantageously affects on mechanical properties of the silumins. In the paper are presented test results concerning effect of dispersion hardening on change of tensile strength of EN AB-48000 silumin modified with strontium. Investigated alloy was melted in electric resistance furnace. Temperature ranges of solution heat treatment and ageing heat treatment were selected on base of curves from ATD method, recorded for refined alloy and for modified alloy. The heat treatment resulted in change of Rm tensile strength, while performed investigations have enabled determination of temperatures and durations of solution heat treatment and ageing heat treatment, which precondition obtainment of the best tensile strength Rm of the investigated alloy.

  1. Deposition behavior of residual aluminum in drinking water distribution system: Effect of aluminum speciation.

    Science.gov (United States)

    Zhang, Yue; Shi, Baoyou; Zhao, Yuanyuan; Yan, Mingquan; Lytle, Darren A; Wang, Dongsheng

    2016-04-01

    Finished drinking water usually contains some residual aluminum. The deposition of residual aluminum in distribution systems and potential release back to the drinking water could significantly influence the water quality at consumer taps. A preliminary analysis of aluminum content in cast iron pipe corrosion scales and loose deposits demonstrated that aluminum deposition on distribution pipe surfaces could be excessive for water treated by aluminum coagulants including polyaluminum chloride (PACl). In this work, the deposition features of different aluminum species in PACl were investigated by simulated coil-pipe test, batch reactor test and quartz crystal microbalance with dissipation monitoring. The deposition amount of non-polymeric aluminum species was the least, and its deposition layer was soft and hydrated, which indicated the possible formation of amorphous Al(OH)3. Al13 had the highest deposition tendency, and the deposition layer was rigid and much less hydrated, which indicated that the deposited aluminum might possess regular structure and self-aggregation of Al13 could be the main deposition mechanism. While for Al30, its deposition was relatively slower and deposited aluminum amount was relatively less compared with Al13. However, the total deposited mass of Al30 was much higher than that of Al13, which was attributed to the deposition of particulate aluminum matters with much higher hydration state. Compared with stationary condition, stirring could significantly enhance the deposition process, while the effect of pH on deposition was relatively weak in the near neutral range of 6.7 to 8.7. Copyright © 2015. Published by Elsevier B.V.

  2. Experimental study on the warm forming and quenching behavior for hot stamping of high-strength aluminum alloys

    Science.gov (United States)

    Degner, J.; Horn, A.; Merklein, M.

    2017-09-01

    Within the last decades, stringent regulations on fuel consumption, CO2 emissions and product recyclability forced the automotive sector to implement new strategies within the field of car body manufacturing. Due to their low density and good corrosion resistance, aluminum became one of the most relevant lightweight materials. Recently, especially high- strength aluminum alloys for structural components gained importance. Since the low formability of these alloys limits their application, there is a need for novel process strategies in order to enhance the forming behavior. One promising approach is the hot stamping of aluminum alloys. The combination of quenching and forming in one step after solution heat treatment leads to a significant improvement of the formability. Furthermore, higher manufacturing accuracy can be achieved due to reduced spring back. Within this contribution, the influence of forming temperature on the subsequent material behavior and the heat transfer during quenching will be analyzed. Therefore, the mechanical and thermal material characteristics such as flow behavior and heat transfer coefficient during hot stamping are investigated.

  3. Influence of Temperature on Mechanical Behavior During Static Restore Processes of Al-Zn-Mg-Cu High Strength Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    ZHANG Kun

    2017-06-01

    Full Text Available Flow stress behaviors of as-cast Al-Zn-Mg-Cu high strength aluminum alloy during static restore processes were investigated by: Isothermal double-pass compression tests at temperatures of 300-400℃, strain rates of 0.01-1 s-1, strains of 33% +20% with the holding times of 0~900 s after the first pass compression. The results indicate that the deformation temperature has a dramatical effect on mechanical behaviors during static restore processes of the alloy. (1 At 300 ℃ and 330 ℃ lower temperatures, the recovery during the deformation is slow, and deformation energy stored in matrix is higher, flow stresses at the second pass deformation decreased during the recovery and recrystallization, and the stress softening phenomena is observed. Stress softening is increased with the increasing holding time; Precipitation during the holding time inhibites the stress softening. (2 At 360 ℃ and 400 ℃ higher temperatures, the recovery during deformation is rapid, and deformation energy stored in matrix is lower. Solid solubility is higher after holding, so that flow stress at the second pass deformation is increased, stress hardening phenomena is observed. Stress hardening decreased with the increasing holding time duo to the recovery and recrystallization during holding period at 360 ℃; Precipitation during holding also inhibited the stress softening. However, Stress hardening remains constant with the increasing holding time duo to the reasanenal there are no recovery and recrystallization during holding period at 400 ℃.

  4. Casting defects and fatigue behaviour of ductile cast iron for wind turbine components: A comprehensive study

    Energy Technology Data Exchange (ETDEWEB)

    Haerkegaard, G. [Norwegian University of Science and Technology, Dept. of Engineering Design and Materials, Trondheim (Norway); Shirani, M.

    2011-12-15

    Two types of EN-GJS-400-18-LT ductile cast iron were investigated in this research, clean baseline material in the shape of castings with different thicknesses and also defective material from a rejected wind turbine hub. P-S-N curves for baseline EN-GJS-400-18-LT specimens with different dimensions and from castings with different thicknesses at different load ratios were established. Geometrical size effect, technological size effects and mean stress effect on fatigue strength of baseline EN-GJS-400-18-LT were evaluated. Fatigue strength of baseline EN-GJS-400-18-LT was compared with that of defective material from the rejected hub. The effect of defects type, shape, size and position on fatigue strength of this material was evaluated. The hypothesis that the endurance observed in an S-N test can be predicted based on the analysis of crack growth from casting defects through defect-free 'base' material was tested for the analyzed defective material. 3D X-ray computed tomography was use to detect defects in defective specimens and find the defect size distribution. The obtained defect size distribution for the defective material was used in random defect analysis to establish the scatter of fatigue life for defective specimens. Finally both safe-life design and damage tolerant design of wind turbine castings were analyzed and compared. (Copyright copyright 2011 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

  5. Microtensile bond strength of composite resin to human enamel prepared using erbium: Yttrium aluminum garnet laser.

    Science.gov (United States)

    Delfino, Carina Sinclér; Souza-Zaroni, Wanessa Christine; Corona, Silmara Aparecida Milori; Palma-Dibb, Regina Guenka

    2007-02-01

    The Erbium: Yttrium Aluminum Garnet (YAG) laser used for preparation of cavity can alter the substrate and it could influence the bond strength of enamel. The aim of this in vitro study was to evaluate the influence of Er:YAG laser's energy using microtensile bond test. Three groups were obtained (cavity preparation) and each group was divided into two subgroups (adhesive system). After that the adhesive protocol was performed, sections with a cross-sectional area of 0.8 mm2 (+/-0.2 mm2) were obtained. The specimens were mounted in a universal testing machine (0.5 mm/min). Statistical analysis showed a decrease in bond strength for lased groups (p adhesive system was used the laser 300 mJ subgroup showed higher bond strength compared to the laser 250 mJ (p adhesive procedures than conventional bur-cut cavities. Copyright 2006 Wiley Periodicals, Inc.

  6. APPLICATION OF SPHEROIDIZING «CHIPS»-MASTER ALLOY ON COPPER BASE CONTAINING NANOSCALE PARTICLES OF YTTRIUM OXIDE FOR HIGH-STRENGTH CAST IRON

    Directory of Open Access Journals (Sweden)

    A. S. Kalinichenko

    2016-01-01

    Full Text Available The peculiarity of the technology of obtaining high-strength cast iron is application in out-furnace treatment various inoculants containing magnesium. In practice of foundry production spheroidizing master alloys based on ferrosilicon (Fe-Si-Mg type and «heavy» alloying alloys on copper and nickel base are widespread. The urgent issue is to improve their efficiency by increasing the degree of magnesium assimilation, reduction of specific consumption of additives, and minimizing dust and gas emissions during the process of spheroidizing treatment of liquid iron. One method of solving this problem is the use of inoculants in a compact form in which the process of dissolution proceeds more efficiently. For example, rapidly quenched granules or «chip»-inoculants are interesting to apply.The aim of present work was to study the peculiarities of production and application of «Chips»-inoculants on copper and magnesium base with additions of yttrium oxide. The principle of mechatronics was used, including the briquetting inoculants’ components after their mixing with the subsequent high-speed mechanical impact and obtaining plates with a thickness of 1–2 mm.Spheroidizing treatment of molten metal has been produced by ladle method using «Chips»-inoculants in the amount of 0.8%. Secondary graphitization inoculation was not performed. Studies have shown that when the spheroidizing treatment of ductile iron was performed with inoculants developed, the process of interaction of magnesium with the liquid melt runs steadily without significant pyroeffect and emissions of metal outside of the ladle.This generates a structure of spheroidal graphite of regular shape (SGf5. The presence in the inoculant of yttrium oxide has a positive impact on the spheroidal graphite counts and the tendency of high-strength cast iron to form «white» cast iron structure. Mechanical properties of the obtained alloy correspond to high-strength cast iron HSCI60.

  7. Evaluation of Cracking Causes of AlSi5Cu3 Alloy Castings

    Directory of Open Access Journals (Sweden)

    Eperješi Š.

    2014-10-01

    Full Text Available Recently, the castings made from aluminum-silicon alloys by pressure die casting are increasingly used in the automotive industry. In practice, on these castings are high demands, mainly demands on quality of their structure, operating life and safety ensuring of their utilization. The AlSi5Cu3 alloy castings are widely used for production of car components. After the prescribed tests, the cracks and low mechanical properties have been identified for several castings of this alloy, which were produced by low pressure casting into a metal mould and subsequent they were heat treated. Therefore, analyses of the castings were realized to determine the causes of these defects. Evaluation of structure of the AlSi5Cu3 alloy and causes of failure were the subjects of investigation presented in this article.

  8. Temperature field in the hot-top during casting a new super-high strength Al-Zn-Mg-Cu alloy by low frequency electromagnetic process

    Directory of Open Access Journals (Sweden)

    Yubo ZUO

    2005-08-01

    Full Text Available The billets of a new super-high strength Al-Zn-Mg-Cu alloy in 200 mm diameter were produced by the processed of low frequency electromagnetic casting (LFEC and conventional direct chill(DCcasting, respectively. The effects of low frequency electromagnetic field on temperature field of the melt in the hot-top were investigated by temperature thermocouples into the casting during the processes. The results show that during LFEC process the temperature field in the melt applying the hot-top is very uniform, which is helpful to reduce the difference of thermal gradients between the surface and the center, and then to reduce the thermal stress and to eliminate casting crack.

  9. Filler metal alloy for welding cast nickel aluminide alloys

    Science.gov (United States)

    Santella, M.L.; Sikka, V.K.

    1998-03-10

    A filler metal alloy used as a filler for welding cast nickel aluminide alloys contains from about 15 to about 17 wt. % chromium, from about 4 to about 5 wt. % aluminum, equal to or less than about 1.5 wt. % molybdenum, from about 1 to about 4.5 wt. % zirconium, equal to or less than about 0.01 wt. % yttrium, equal to or less than about 0.01 wt. % boron and the balance nickel. The filler metal alloy is made by melting and casting techniques such as are melting the components of the filler metal alloy and cast in copper chill molds. 3 figs.

  10. Casting dimensional control and fatigue life prediction for permanent mold casting dies. Technical progress report, September 29, 1993-- September 30, 1994

    Energy Technology Data Exchange (ETDEWEB)

    NONE

    1994-11-01

    First year efforts as part of a three year program to address metal casting dimensional control and fatigue life prediction for permanent mold casting dies are described. Procedures have been developed and implemented to collect dimensional variability data from production steel castings. The influence of process variation and casting geometry variables on dimensional tolerances have been investigated. Preliminary results have shown that these factors have a significant influence on dimensional variability, although this variability is considerably less than the variability indicated in current tolerance standards. Gage repeatability and reproducibility testing must precede dimensional studies to insure that measurement system errors are acceptably small. Also initial efforts leading to the development and validation of a CAD/CAE model to predict the thermal fatigue life of permanent molds for aluminum castings are described. An appropriate thermomechanical property database for metal, mold and coating materials has been constructed. A finite element model has been developed to simulate the mold temperature distribution during repeated casting cycles. Initial validation trials have indicated the validity of the temperature distribution model developed.

  11. Comparative Evaluation of Cast Aluminum Alloys for Automotive Cylinder Heads: Part I—Microstructure Evolution

    Science.gov (United States)

    Roy, Shibayan; Allard, Lawrence F.; Rodriguez, Andres; Watkins, Thomas R.; Shyam, Amit

    2017-05-01

    The present study stages a comparative evaluation of microstructure and associated mechanical and thermal response for common cast aluminum alloys that are used for manufacturing automotive cylinder heads. The systems considered are Al-Cu (206-T6), Al-Si-Cu (319-T7), and Al-Si (356-T6, A356-T6, and A356 + 0.5Cu-T6). The focus of the present manuscript is on the evaluation of microstructure at various length scales after aging, while the second manuscript will deal with the mechanical and thermal response of these alloys due to short-term (aging) and long-term (pre-conditioning) heat treatments. At the grain-scale, the Al-Cu alloy possessed an equiaxed microstructure as opposed to the dendritic structure for the Al-Si-Cu or Al-Si alloys which is related to the individual solidification conditions for these alloy systems. The composition and morphology of intermetallic precipitates within the grain and at the grain/dendritic boundary are dictated by the alloy chemistry, solidification, and heat treatment conditions. At the nanoscale, these alloys contain various metastable strengthening precipitates (GPI and θ^'' in Al-Cu alloy, θ^' in Al-Si-Cu alloy, and β^' in Al-Si alloys) with varying size, morphology, coherency, and thermal stability.

  12. New Process for Grain Refinement of Aluminum. Final Report

    Energy Technology Data Exchange (ETDEWEB)

    Dr. Joseph A. Megy

    2000-09-22

    A new method of grain refining aluminum involving in-situ formation of boride nuclei in molten aluminum just prior to casting has been developed in the subject DOE program over the last thirty months by a team consisting of JDC, Inc., Alcoa Technical Center, GRAS, Inc., Touchstone Labs, and GKS Engineering Services. The Manufacturing process to make boron trichloride for grain refining is much simpler than preparing conventional grain refiners, with attendant environmental, capital, and energy savings. The manufacture of boride grain refining nuclei using the fy-Gem process avoids clusters, salt and oxide inclusions that cause quality problems in aluminum today.

  13. Diffusion-controlled growth of hydrogen pores in aluminum-silicon castings: In situ observation and modeling

    Energy Technology Data Exchange (ETDEWEB)

    Atwood, R.C.; Sridhar, S.; Zhang, W.; Lee, P.D.

    2000-01-24

    In situ observations were made of the nucleation and growth kinetics of hydrogen porosity during the directional solidification of aluminium-7 wt% silicon (Al7Si) with TiB{sub 2} grain refiner added, using an X-ray temperature gradient stage (XTGS). The effect of altering the solidification velocity on the growth rate and morphology of the porosity formed was characterized by tracking individual pores with digital analysis of the micro-focal video images. It was found that increasing the solidification velocity caused the pore radius to decrease and pore density to increase. Insight gained from the experimental results was used to develop a computational model of the evolution of hydrogen pores during solidification of aluminum-silicon cast alloys. The model solves for the diffusion-limited growth of the pores in spherical coordinates, using a deterministic solution of the grain nucleation and growth as a sub-model to calculate the parameters that depend upon the fraction solid. Sensitivity analysis was carried out to assess the effects of equiaxed grain density, pore density, initial hydrogen content and cooling rate. The model agrees with the experimental results within the resolution limits of the XTGS experiments performed.

  14. Fracture Mechanisms in Steel Castings

    Directory of Open Access Journals (Sweden)

    Stradomski Z.

    2013-09-01

    Full Text Available The investigations were inspired with the problem of cracking of steel castings during the production process. A single mechanism of decohesion - the intergranular one - occurs in the case of hot cracking, while a variety of structural factors is decisive for hot cracking initiation, depending on chemical composition of the cast steel. The low-carbon and low-alloyed steel castings crack due to the presence of the type II sulphides, the cause of cracking of the high-carbon tool cast steels is the net of secondary cementite and/or ledeburite precipitated along the boundaries of solidified grains. Also the brittle phosphor and carbide eutectics precipitated in the final stage solidification are responsible for cracking of castings made of Hadfield steel. The examination of mechanical properties at 1050°C revealed low or very low strength of high-carbon cast steels.

  15. Microstructural evolution and mechanical properties of a novel FeCrNiBSi advanced high-strength steel: Slow, accelerated and fast casting cooling rates

    Energy Technology Data Exchange (ETDEWEB)

    Askari-Paykani, Mohsen; Shahverdi, Hamid Reza, E-mail: shahverdi@modares.ac.ir; Miresmaeili, Reza

    2016-06-21

    In the current work, three different solidification routes and a two-step heat treatment process were applied to a novel FeCrNiBSi alloy system to introduce a new candidate for advanced high-strength steels. The evolution of the microstructure after solidification, heat treatment, and tensile deformation was characterized using optical and electron microscopy techniques, as well as hardness and room temperature uniaxial tensile tests. The effects of the different solidification routes and heat treatment parameters on the deformation and fracture mechanisms of this steel are discussed. Grain refinement, precipitation hardening, and solid solution as a result of the fast casting cooling rate led to an increase in strength at improved ductility. This result can be explained partly by the less severe stress/strain partitioning at the matrix grain/M{sub 2}B interfaces and better interface cohesion. Moreover, the stress/strain partitioning characteristics between the matrix grains and M{sub 2}B led to a higher initial strain hardening rate. The fast casting cooling rate further promoted ductile fracture mechanisms, which is a result of increased cleavage fracture stress. The higher casting cooling rate and two-step heat treatment resulted in a strong increase in formability index, from 8 GPa% to 24 GPa%, at which the mechanical properties occupy the TRIP envelope. Heat treatment of the fast-cooling specimens led to a small reduction in yield and tensile strength and 22% total elongation percentage improvement (from 10% to 32%).

  16. Automatic inspection of surface defects in die castings after machining

    Directory of Open Access Journals (Sweden)

    S. J. Świłło

    2011-07-01

    Full Text Available A new camera based machine vision system for the automatic inspection of surface defects in aluminum die casting was developed by the authors. The problem of surface defects in aluminum die casting is widespread throughout the foundry industry and their detection is of paramount importance in maintaining product quality. The casting surfaces are the most highly loaded regions of materials and components. Mechanical and thermal loads as well as corrosion or irradiation attacks are directed primarily at the surface of the castings. Depending on part design and processing techniques, castings may develop surface discontinuities such as cracks or tears, inclusions due to chemical reactions or foreign material in the molten metal, and pores that greatly influence the material ability to withstand these loads. Surface defects may act as a stress concentrator initiating a fracture point. If a pressure is applied in this area, the casting can fracture. The human visual system is well adapted to perform in areas of variety and change; the visual inspection processes, on the other hand, require observing the same type of image repeatedly to detect anomalies. Slow, expensive, erratic inspection usually is the result. Computer based visual inspection provides a viable alternative to human inspectors. Developed by authors machine vision system uses an image processing algorithm based on modified Laplacian of Gaussian edge detection method to detect defects with different sizes and shapes. The defect inspection algorithm consists of three parameters. One is a parameter of defects sensitivity, the second parameter is a threshold level and the third parameter is to identify the detected defects size and shape. The machine vision system has been successfully tested for the different types of defects on the surface of castings.

  17. Improved TIG weld joint strength in aluminum alloy 2219-T87 by filler metal substitution

    Science.gov (United States)

    Poorman, R. M.; Lovoy, C. V.

    1972-01-01

    The results of an investigation on weld joint characteristics of aluminum alloy 2219-T87 are given. Five different alloys were utilized as filler material. The mechanical properties of the joints were determined at ambient and cryogenic temperatures for weldments in the as-welded condition and also, for weldments after elevated temperature exposures. Other evaluations included hardness surveys, stress corrosion susceptibility, and to a limited extent, the internal metallurgical weld structures. The overall results indicate that M-943 filler weldments are superior in strength to weldments containing either the standard 2319 filler or fillers 2014, 2020, and a dual wire feed consisting of three parts 2319 and one part 5652. In addition, no deficiencies were evident in M-934 filler weldments with regard to ductility, joint strength after elevated temperature exposure, weld hardness, metallographic structures, or stress corrosion susceptibility.

  18. Influence of melting and filtration processes on the structure and mechanical properties of aluminum alloys

    Directory of Open Access Journals (Sweden)

    M. Dudyk

    2008-10-01

    Full Text Available In the article are presented the results of the study on the applied upgrading processes such as refining, modification and filtration of thenear eutectics alloy EN AC- 44000, AlSi11, (AK11, cast into the chill. The upgrading processes applied to the said alloy caused, incomparison to the alloy which was not upgraded, significant differences in the shape of the crystallization curves, obtained in the graphicrecord of the ATD-AED method. It was demonstrated the existence of connections between the thermal and electric phenomena duringsolidification and crystallization of the studied silumin. The obtained results of the metallographic analysis showed the occurrence of theimpurities within the alloy structure in the form of porosity and oxides following the metallurgical processing (in pig sows. The primarystudies on microstructure of the cast ceramic filters have demonstrated the purposefulness of introduction of the filtration process to thetechnology of aluminum alloys manufacturing. The microstructures of the filters cast with the studied alloys illustrate the extent anddeployment of the impurities retained (in the filter during the process of samples casting for measurement of the mechanical strengthproperties. On the example of the near eutectics alloy AK11, it has been demonstrated, that in comparison to the refined alloy there isa possibility to obtain significant improvement of mechanical properties, and especially elongation A5 and impact strength KCV.

  19. The aluminum smelting process.

    Science.gov (United States)

    Kvande, Halvor

    2014-05-01

    This introduction to the industrial primary aluminum production process presents a short description of the electrolytic reduction technology, the history of aluminum, and the importance of this metal and its production process to modern society. Aluminum's special qualities have enabled advances in technologies coupled with energy and cost savings. Aircraft capabilities have been greatly enhanced, and increases in size and capacity are made possible by advances in aluminum technology. The metal's flexibility for shaping and extruding has led to architectural advances in energy-saving building construction. The high strength-to-weight ratio has meant a substantial reduction in energy consumption for trucks and other vehicles. The aluminum industry is therefore a pivotal one for ecological sustainability and strategic for technological development.

  20. Characterization of Ni–Cr alloys using different casting techniques and molds

    International Nuclear Information System (INIS)

    Chen, Wen-Cheng; Teng, Fu-Yuan; Hung, Chun-Cheng

    2014-01-01

    This study differentiated the mechanical properties of nickel–chromium (Ni–Cr) alloys under various casting techniques (different casting molds and casting atmospheres). These techniques were sampled by a sand mold using a centrifugal machine in ambient air (group I) and electromagnetic induction in an automatic argon castimatic casting machine (group II). The specimen casting used a graphite mold by a castimatic casting machine (group III). The characteristics of the Ni–Cr alloys, yield and ultimate tensile strength, bending modulus, microhardness, diffraction phase, grindability, ability to spring back, as well as ground microstructure and pattern under different casting conditions were evaluated. The group III specimens exhibited the highest values in terms of strength, modulus, hardness, and grindability at a grind rate of 500 rpm. Moreover, group III alloys exhibited smaller grain sizes, higher ability to spring back, and greater ductility than those casted by sand investment (groups I and II). The main factor, “casting mold,” significantly influenced all mechanical properties. The graphite mold casting of the Ni–Cr dental alloys in a controlled atmosphere argon casting system provided an excellent combination of high mechanical properties and good ability to spring back, and preserved the ductile properties for application in Ni–Cr porcelain-fused system. The results can offer recommendations to assist a prosthetic technician in selecting the appropriate casting techniques to obtain the desired alloy properties. - Highlights: • Properties of Ni–Cr alloys using various casting techniques are characterized. • Alloys cast by graphite mold exhibited higher recovery angle and more ductility. • Alloys cast by graphite mold exhibited higher strength and grinding rate. • Alloys in this study increase operative room to adjust the precision for prosthesis

  1. Characterization of Ni–Cr alloys using different casting techniques and molds

    Energy Technology Data Exchange (ETDEWEB)

    Chen, Wen-Cheng, E-mail: wencchen@fcu.edu.tw [Advanced Medical Devices and Composites Laboratory, Department of Fiber and Composite Materials, College of Engineering, Feng Chia University, Taichung 40724, Taiwan (China); Teng, Fu-Yuan [Department of Dentistry, Kaohsiung Armed Forces General Hospital, Kaohsiung 802, Taiwan (China); School of Dentistry, College of Dental Medicine, Kaohsiung Medical University, Kaohsiung 807, Taiwan (China); Hung, Chun-Cheng [School of Dentistry, College of Dental Medicine, Kaohsiung Medical University, Kaohsiung 807, Taiwan (China); Department of Dentistry, Kaohsiung Medical University Hospital, Kaohsiung 807, Taiwan (China)

    2014-02-01

    This study differentiated the mechanical properties of nickel–chromium (Ni–Cr) alloys under various casting techniques (different casting molds and casting atmospheres). These techniques were sampled by a sand mold using a centrifugal machine in ambient air (group I) and electromagnetic induction in an automatic argon castimatic casting machine (group II). The specimen casting used a graphite mold by a castimatic casting machine (group III). The characteristics of the Ni–Cr alloys, yield and ultimate tensile strength, bending modulus, microhardness, diffraction phase, grindability, ability to spring back, as well as ground microstructure and pattern under different casting conditions were evaluated. The group III specimens exhibited the highest values in terms of strength, modulus, hardness, and grindability at a grind rate of 500 rpm. Moreover, group III alloys exhibited smaller grain sizes, higher ability to spring back, and greater ductility than those casted by sand investment (groups I and II). The main factor, “casting mold,” significantly influenced all mechanical properties. The graphite mold casting of the Ni–Cr dental alloys in a controlled atmosphere argon casting system provided an excellent combination of high mechanical properties and good ability to spring back, and preserved the ductile properties for application in Ni–Cr porcelain-fused system. The results can offer recommendations to assist a prosthetic technician in selecting the appropriate casting techniques to obtain the desired alloy properties. - Highlights: • Properties of Ni–Cr alloys using various casting techniques are characterized. • Alloys cast by graphite mold exhibited higher recovery angle and more ductility. • Alloys cast by graphite mold exhibited higher strength and grinding rate. • Alloys in this study increase operative room to adjust the precision for prosthesis.

  2. Effect of Aluminum Addition on the Evolution of Microstructure, Crystallographic Texture and Mechanical Properties of Single Phase Hexagonal Close Packed Mg-Li Alloys

    Science.gov (United States)

    Bhagat Singh, P.; Sabat, R. K.; Kumaran, S.; Suwas, S.

    2018-02-01

    In the present investigation, an effort has been made to understand the effect of aluminum addition to α Mg-Li alloys. The corresponding composition Mg-4Li- xAl ( x = 0, 2, 4 and 6 wt.%) alloys have been prepared by stir casting route under an argon environment. Extrusion was carried out at 300 °C with the extrusion ratio of 15:1. Significant grain refinement was observed after extrusion. X-ray diffraction-based investigation of the cast and extruded alloys showed the presence of intermetallic compounds such as Mg17Al12 and AlLi in the Al-rich alloys namely, Mg-4Li- xAl ( x = 4 and 6 wt.%). These precipitates were also present in the extruded plus annealed samples, indicating the stability of the precipitates at high temperature. The bulk x-ray texture measurement revealed a crystallographic texture where the c-axis of the h.c.p crystals was perpendicular to the extrusion direction (ED) for extruded sample. A texture transition was observed on annealing. The c-axis was oriented parallel to the ED. Mechanical properties of the cast, extruded and extruded plus annealed material illustrate that the addition of Al led to enhancement in hardness, yield strength and ultimate tensile strength.

  3. Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency

    Science.gov (United States)

    Stromme, Eric T.; Henderson, Hunter B.; Sims, Zachary C.; Kesler, Michael S.; Weiss, David; Ott, Ryan T.; Meng, Fanqiang; Kassoumeh, Sam; Evangelista, James; Begley, Gerald; Rios, Orlando

    2018-04-01

    Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatment line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. This work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.

  4. Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency

    Science.gov (United States)

    Stromme, Eric T.; Henderson, Hunter B.; Sims, Zachary C.; Kesler, Michael S.; Weiss, David; Ott, Ryan T.; Meng, Fanqiang; Kassoumeh, Sam; Evangelista, James; Begley, Gerald; Rios, Orlando

    2018-06-01

    Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatment line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. This work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.

  5. Grain refinement of permanent mold cast copper base alloys. Final report

    Energy Technology Data Exchange (ETDEWEB)

    Sadayappan, M.; Thomson, J. P.; Elboujdaini, M.; Gu, G. Ping; Sahoo, M.

    2004-04-29

    Grain refinement behavior of copper alloys cast in permanent molds was investigated. This is one of the least studied subjects in copper alloy castings. Grain refinement is not widely practiced for leaded copper alloys cast in sand molds. Aluminum bronzes and high strength yellow brasses, cast in sand and permanent molds, were usually fine grained due to the presence of more than 2% iron. Grain refinement of the most common permanent mold casting alloys, leaded yellow brass and its lead-free replacement EnviroBrass III, is not universally accepted due to the perceived problem of hard spots in finished castings and for the same reason these alloys contain very low amounts of iron. The yellow brasses and Cu-Si alloys are gaining popularity in North America due to their low lead content and amenability for permanent mold casting. These alloys are prone to hot tearing in permanent mold casting. Grain refinement is one of the solutions for reducing this problem. However, to use this technique it is necessary to understand the mechanism of grain refinement and other issues involved in the process. The following issues were studied during this three year project funded by the US Department of Energy and the copper casting industry: (1) Effect of alloying additions on the grain size of Cu-Zn alloys and their interaction with grain refiners; (2) Effect of two grain refining elements, boron and zirconium, on the grain size of four copper alloys, yellow brass, EnviroBrass II, silicon brass and silicon bronze and the duration of their effect (fading); (3) Prediction of grain refinement using cooling curve analysis and use of this method as an on-line quality control tool; (4) Hard spot formation in yellow brass and EnviroBrass due to grain refinement; (5) Corrosion resistance of the grain refined alloys; (6) Transfer the technology to permanent mold casting foundries; It was found that alloying elements such as tin and zinc do not change the grain size of Cu-Zn alloys

  6. Modern Cast Irons in Chemical Engineering

    Science.gov (United States)

    1934-11-09

    fl’ceew. T I SOCIETY OF CHEMICAL INDUSTRY CHEMICAL ENGINEERING GROUP MODERN CAST IRONS IN CHEMICAL ENGINEERING By J. G. PEARCE, M.Sc., F.Inst.P...CAST IRONS IN CHEMICAL ENGINEERING By J. G. PEARCE, M.Sc., F.Inst.P., M.I.E.E.* INTRODUCTION to chemical or thermal resistance. Small blow-holes Any...consideration of modern cast irons in chemical seldom appear to reduce the mechanical strength of engineering should strictly be prefaced by a definition

  7. 75 FR 20387 - Contech Castings, LLC, Including Workers Whose Unemployment Insurance (UI) Wages Are Reported...

    Science.gov (United States)

    2010-04-19

    ... Apply for Worker Adjustment Assistance In accordance with Section 223 of the Trade Act of 1974, as... aluminum and magnesium die casted component parts for automobiles. New information shows that the assets of... workers of the subject firm who were adversely affected by increased imports of aluminum and magnesium die...

  8. The Properties of Ammonium Dinitramine (ADN): Part 2: Melt Casting

    Science.gov (United States)

    Hahma, A.; Edvinsson, H.; Östmark, H.

    2010-04-01

    A melt casting technique for ammonium dinitramine (ADN) and ADN/aluminum was developed. ADN proved relatively easy to cast, when 1% of magnesium oxide was used as a stabilizer and crystallization kernels. Densities of ADN/MgO 99/1 were 92 to 97% of theoretical mean density (TMD) and those of ADN/Al/MgO 64/35/1 were between 95 and 99% of TMD. Sedimentation of Al in the melt was prevented and the particle wetting was ensured by selecting a suitable particle size for Al. No gelling agents or other additives were used. The casting process and factors influencing it are discussed.

  9. Tribological Behavior of Aluminum Alloy AlSi10Mg-TiB2 Composites Produced by Direct Metal Laser Sintering (DMLS)

    Science.gov (United States)

    Lorusso, Massimo; Aversa, Alberta; Manfredi, Diego; Calignano, Flaviana; Ambrosio, Elisa Paola; Ugues, Daniele; Pavese, Matteo

    2016-08-01

    Direct metal laser sintering (DMLS) is an additive manufacturing technique for the production of parts with complex geometry and it is especially appropriate for structural applications in aircraft and automotive industries. Aluminum-based metal matrix composites (MMCs) are promising materials for these applications because they are lightweight, ductile, and have a good strength-to-weight ratio This paper presents an investigation of microstructure, hardness, and tribological properties of AlSi10Mg alloy and AlSi10Mg alloy/TiB2 composites prepared by DMLS. MMCs were realized with two different compositions: 10% wt. of microsize TiB2, 1% wt. of nanosize TiB2. Wear tests were performed using a pin-on-disk apparatus on the prepared samples. Performances of AlSi10Mg samples manufactured by DMLS were also compared with the results obtained on AlSi10Mg alloy samples made by casting. It was found that the composites displayed a lower coefficient of friction (COF), but in the case of microsize TiB2 reinforcement the wear rate was higher than with nanosize reinforcements and aluminum alloy without reinforcement. AlSi10Mg obtained by DMLS showed a higher COF than AlSi10Mg obtained by casting, but the wear rate was higher in the latter case.

  10. Evaluating the Tensile Properties of Aluminum Foundry Alloys through Reference Castings-A Review.

    Science.gov (United States)

    Anilchandra, A R; Arnberg, Lars; Bonollo, Franco; Fiorese, Elena; Timelli, Giulio

    2017-08-30

    The tensile properties of an alloy can be exploited if detrimental defects and imperfections of the casting are minimized and the microstructural characteristics are optimized through several strategies that involve die design, process management and metal treatments. This paper presents an analysis and comparison of the salient characteristics of the reference dies proposed in the literature, both in the field of pressure and gravity die-casting. The specimens produced with these reference dies, called separately poured specimens, are effective tools for the evaluation and comparison of the tensile and physical behaviors of Al-Si casting alloys. Some of the findings of the present paper have been recently developed in the frame of the European StaCast project whose results are complemented here with some more recent outcomes and a comprehensive analysis and discussion.

  11. Centrifugal casting of ZA8 zinc alloy and composite A356/silicon carbide: Study and modeling of phases' and particles' segregation

    Science.gov (United States)

    Balout, Bahaa

    Centrifugation is a casting technology that allows the production of cylindrical and graduated parts with different mechanical properties through the section. The need for materials with good quality and specific mechanical properties has been driven this technology in order to produce different types of materials such as zinc alloys and graduated metal matrix composites reinforced by hard and wear resistant particles. The goal of this research project is to study and model the eutectic macrosegregation, the solidification speed, and the speeds of solidification fronts during centrifugal casting of ZA8 zinc-aluminum alloy in order to improve the part quality and increase its strength and field reliability. Moreover, the segregation of the particles during centrifugal casting of an aluminum matrix composite reinforced by silicon carbide particles (A356/SiC) is also studied to improve and control the graduation of the parts. The cooling rate, the speed, acceleration/deceleration, displacement, and segregation of the particles across the section will be modeled by discretization of Stokes' law in time in order to take into consideration the change in the centrifugal radius and melt viscosity during cooling process. This study will allow the control of the graduation degree of particles across the section in order to improve the properties and wear resistance of the composite. This composite can be used in systems where friction is critical and load is high (reinforcements of parts for the cylinders of pneumatic systems). The results show that the maximum macrosegregation zone of the eutectic across the casting section corresponds to the last point of solidification. The eutectic macrosegregation produced during centrifugal casting of thin walled part is a normal segregation which varies depending on the solidification speed and the ratio between the speeds of solidification fronts. On the other hand, it was found that the position and volume fraction of the particles

  12. Modelling of Filling, Microstructure Formation, Local Mechanical Properties and Stress – Strain Development in High-Pressure Die Cast Aluminium Castings

    DEFF Research Database (Denmark)

    Kotas, Petr; Hattel, Jesper Henri; Thorborg, Jesper

    2009-01-01

    .e. whether the casting is based on cast iron- or aluminium-alloys. The distribution of local properties in a casting might vary substantially which makes it complex to optimize the casting with good accuracy. Often, mechanical simulations of the load situation are based on the assumption that the cast...... in an aluminium alloy is considered including simulation of the entire casting process with emphasis on microstructure formation related to mechanical properties such as elastic modulus, yield stress, ultimate strength and elongation as well as residual stresses. Subsequently, the casting is subjected to service...... loads and the results of this analysis are discussed in relation to the predicted local properties as well as the residual stresses originating from the casting simulation....

  13. Material properties of Al-Si-Cu aluminium alloy produced by the rotational cast technology

    Directory of Open Access Journals (Sweden)

    Muhammad Syahid

    2017-03-01

    Full Text Available The aim of the present study is to explore microstructural and mechanical properties of cast Al-Si-Cu aluminum alloy (ADC12. To obtain excellent material properties, the cast Al alloys were produced by an originally developed mold rotational machine, namely liquid aluminum alloy is solidified during high speed rotating. The casting process was conducted under various casting conditions, in which the following factors were altered, e.g., melt temperature, metal mold temperature and different rotational speed. Microstructural characteristics were examined by direct observation using an optical microscope and a scanning electron microscope (SEM, and the secondary dendrite arm spacing of alpha-Al phase (SDAS and the size of Si eutectic phase were identified. Mechanical properties were investigated by micro-hardness and tensile tests. Rotation speed and melt temperature were directly attributed to the SDAS, and severe shear stress arising from the rotation made fine and complicated grain structure, leading to the high mechanical properties. The extent of the shear stress was altered depending on the area of the sample due to the different shear stress. Furthermore, high melt temperature and high rotational speed decrease the size of Si eutectic phases. The high mechanical properties were detected for the cast samples produced by the casting condition as follows: melt temperature 700oC, mold temperature 400oC and rotation speed 400 rpm

  14. Cast iron as structural material for hot-working reactor vessels (PCIV)

    International Nuclear Information System (INIS)

    Ostendorf, H.; Schmidt, G.; Pittack, W.

    1977-01-01

    Cast iron with lamellar graphite is best suited for prestressed structures, because its compressive strength is nearly 4 times its tensile strength. In comparison to room temperature, cast iron with lamellar graphite shows essentially no loss of strength up to temperatures of 400 0 C. Under the particular aspect to use cast iron for hot-working prestressed reactor pressure vessels (PCIV) (Prestressed cast iron vessel=PCIV) a materials testing program is carried out, which meets the strict certification requirements for materials in the construction of reactor pressure vessels and which completes the presently available knowledge of cast iron. Especially in the following fields an extension and supplement of the present level of knowledge is necessary. - Mechanical properties under compressive stresses. - Material properties at elevated temperatures. - Influence of irradiation on mechanical and physical properties. - Production standards and quality control. The state of the research and the available data of the material testing program are reported. (Auth.)

  15. Cast iron as structural material for hot-working reactor vessels (PCIV)

    International Nuclear Information System (INIS)

    Ostendorf, H.; Schmidt, G.; Pittack, W.

    1977-01-01

    Cast iron with lamellar graphite is best suited for prestressed structures, because its compressive strength is nearly 4 times its tensile strength. In comparison to room temperature, cast iron with lamellar graphite shows essentially no loss of strength up to temperatures of 400 0 C. Under the particular aspect to use cast iron for hot-working prestressed reactor pressure vessels (PCIV) (Prestressed cast iron vessel=PCIV) a materials testing program is carried out, which meets the strict certification requirements for materials in the construction of reactor pressure vessels and which completes the presently available knowledge of cast iron. Especially in the following fields an extension and supplement of the present level of knowledge is necessary: mechanical properties under compressive stresses; material properties at elevated temperatures; influence of irradiation on mechanical and physical properties; production standards and quality control. The state of the research and the available data of the material testing program are reported

  16. Evaluation of Serial Casting for Boys with Duchenne Muscular Dystrophy: A Case Report.

    Science.gov (United States)

    Carroll, Kate; de Valle, Katy; Kornberg, Andrew; Ryan, Monique; Kennedy, Rachel

    2018-02-01

    To report the effects of below-knee serial casting in two boys with Duchenne muscular dystrophy who presented with well-preserved strength and calf shortening. Bilateral below-knee serial casts were applied over two weeks with follow-up of daily stretching and wearing of customized night splints. Outcome measures were performed at baseline, 1, 3, 6, and 12 months post-casting. These included measures of calf length, leg strength, motor function, endurance, and spatio-temporal gait parameters. Both boys completed serial casting with gains in muscle length. No adverse effects on strength or motor function were observed over a 12-month follow-up period.

  17. A study on the strength of an armour-grade aluminum under high strain-rate loading

    Science.gov (United States)

    Appleby-Thomas, G. J.; Hazell, P. J.

    2010-06-01

    The aluminum alloy 5083 in tempers such as H32 and H131 is an established light-weight armour material. While its dynamic response under high strain-rates has been investigated elsewhere, little account of the effect of material orientation has been made. In addition, little information on its strength under such loadings is available in the literature. Here, both the longitudinal and lateral components of stress have been measured using embedded manganin stress gauges during plate-impact experiments on samples with the rolling direction aligned both orthogonal and parallel to the impact axis. The Hugoniot elastic limit, spall, and shear strengths were investigated for incident pressures in the range 1-8 GPa, providing an insight into the response of this alloy under shock loading. Further, the time dependence of lateral stress behind the shock front was investigated to give an indication of material response.

  18. INFLUENCE OF DIVIDING COVERINGS ON QUALITY OF CASTINGS AT MOLDING OF ALUMINUM ALLOYS UNDER PRESSURE

    Directory of Open Access Journals (Sweden)

    A. A. Pivovarchik

    2014-01-01

    Full Text Available The results of researches on influence of separating coverings on such properties of castings as corrosion resistance, roughness of cast surface, casting density are given in article.

  19. Microstructural evolution and mechanical properties of as-cast and T6-treated AA2195 DC cast alloy

    International Nuclear Information System (INIS)

    Hekmat-Ardakan, A.; Elgallad, E.M.; Ajersch, F.; Chen, X.-G.

    2012-01-01

    The use of direct chill (DC) cast ingot plates of AA2195 alloys has been recently extended for large mold applications in the plastics and automotive industries. The microstructural evolution of the as-cast AA2195 alloy was investigated using the Factsage thermodynamic software under both equilibrium and non-equilibrium conditions, and was compared with the results from differential scanning calorimetry (DSC) analysis and microstructural observations. The as-cast microstructure exhibited the presence of Al 2 CuMg, Al 2 Cu and Al 2 CuLi intermetallic phases formed at the aluminum dendrite boundaries, which can be completely dissolved in the α-Al matrix during the solution treatment. A significant improvement in the mechanical properties of the AA2195 cast alloy after the T6 heat treatment is attributed to the formation of nano-scale θ′ (Al 2 Cu) and T1 (Al 2 CuLi) precipitates. However, the non-uniform distribution of T1 precipitates together with the large size and low density indicate that the role of θ′ precipitates in strengthening the AA2195 cast alloy is more dominant than that of the T1 precipitates, in contrast with the strengthening mechanism of the pre-deformed AA2195-T8 rolled products.

  20. Reuse of Aluminum Dross as an Engineered Product

    Science.gov (United States)

    Dai, Chen; Apelian, Diran

    To prevent the leaching of landfilled aluminum dross waste and save the energy consumed by recovering metallic aluminum from dross, aluminum dross is reused as an engineering product directly rather than "refurbished" ineffectively. The concept is to reduce waste and to reuse. Two kinds of aluminum dross from industrial streams were selected and characterized. We have shown that dross can be applied directly, or accompanied with a simple conditioning process, to manufacture refractory components. Dross particles below 50 mesh are most effective. Mechanical property evaluations revealed the possibility for dross waste to be utilized as filler in concrete, resulting in up to 40% higher flexural strength and 10% higher compressive strength compared to pure cement, as well as cement with sand additions. The potential usage of aluminum dross as a raw material for such engineering applications is presented and discussed.

  1. Investigating aluminum alloy reinforced by graphene nanoflakes

    Energy Technology Data Exchange (ETDEWEB)

    Yan, S.J., E-mail: shaojiuyan@126.com [Beijing Institute of Aeronautical Materials, Beijing 100095 (China); Dai, S.L.; Zhang, X.Y.; Yang, C.; Hong, Q.H.; Chen, J.Z. [Beijing Institute of Aeronautical Materials, Beijing 100095 (China); Lin, Z.M. [Aviation Industry Corporation of China, Beijing 100022 (China)

    2014-08-26

    As one of the most important engineering materials, aluminum alloys have been widely applied in many fields. However, the requirement of enhancing their mechanical properties without sacrificing the ductility is always a challenge in the development of aluminum alloys. Thanks to the excellent physical and mechanical properties, graphene nanoflakes (GNFs) have been applied as promising reinforcing elements in various engineering materials, including polymers and ceramics. However, the investigation of GNFs as reinforcement phase in metals or alloys, especially in aluminum alloys, is still very limited. In this study, the aluminum alloy reinforced by GNFs was successfully prepared via powder metallurgy approach. The GNFs were mixed with aluminum alloy powders through ball milling and followed by hot isostatic pressing. The green body was then hot extruded to obtain the final GNFs reinforced aluminum alloy nanocomposite. The scanning electron microscopy and transmission electron microscope analysis show that GNFs were well dispersed in the aluminum alloy matrix and no chemical reactions were observed at the interfaces between the GNFs and aluminum alloy matrix. The mechanical properties' testing results show that with increasing filling content of GNFs, both tensile and yield strengths were remarkably increased without losing the ductility performance. These results not only provided a pathway to achieve the goal of preparing high strength aluminum alloys with excellent ductilitybut they also shed light on the development of other metal alloys reinforced by GNFs.

  2. Tensile-property characterization of thermally aged cast stainless steels

    International Nuclear Information System (INIS)

    Michaud, W.F.; Toben, P.T.; Soppet, W.K.; Chopra, O.K.

    1994-02-01

    The effect of thermal aging on tensile properties of cast stainless steels during service in light water reactors has been evaluated. Tensile data for several experimental and commercial heats of cast stainless steels are presented. Thermal aging increases the tensile strength of these steels. The high-C Mo-bearing CF-8M steels are more susceptible to thermal aging than the Mo-free CF-3 or CF-8 steels. A procedure and correlations are presented for predicting the change in tensile flow and yield stresses and engineering stress-vs.-strain curve of cast stainless steel as a function of time and temperature of service. The tensile properties of aged cast stainless steel are estimated from known material information, i.e., chemical composition and the initial tensile strength of the steel. The correlations described in this report may be used for assessing thermal embrittlement of cast stainless steel components

  3. Effect of Fe content, cooling rate and porosity on the tensile properties of cast 319 and 356 aluminum alloys

    International Nuclear Information System (INIS)

    Ma, Z.; Samuel, A.M.; Samuel, F.H.; Doty, H.W.; Valtierra, S.

    2002-01-01

    The present study was carried out to investigate the effects of Fe content, cooling rate and porosity on the tensile properties of cast 319 and 356 alloys. Both experimental and industrial 319 alloys (containing 0.1 and 0.4 wt% Mg) and industrial 356 alloys were used, with 200-300 ppm strontium additions to study the modification effect. The Fe content was varied from 0.2 to 0.8 wt% in the 319 alloys, and from 0.1 to 0.6 wt% in the 356 alloy in keeping with Fe levels observed in industry. An end-chilled mold was employed to obtain directionally solidified castings, where the cooling rate varied with the height of the casting. Tensile and microstructural samples were sectioned at heights corresponding to dendrite arm spacings of ∼23 to ∼83 μm. The microstructures were examined using optical- and scanning electron microscopy. The effect of Fe content and cooling rate was investigated through measurements of the β-Al 5 FeSi platelets, using image analysis. Porosity measurements were also made. Phase identification was done using EPMA, EDX and XRD. The results show that the β-Al 5 FeSi platelet size has a significant effect on ductility and tensile strength up to sizes of ∼100 μm in the 319 alloys and ∼70 μm in the 356 alloy, but has no significant effect on the yield strength. While tensile properties are interpreted by means of UTS vs. log Elongation plots (after the Quality index concept of Drouzy et al. (5)), in the present study, the properties for all sample conditions were best interpreted by means of log UTS vs. log Elongation plots, where the properties increased linearly within low cooling rate-high Fe and high cooling rate-low Fe condition extremities. The results are explained in terms of the β-Al 5 FeSi platelet size and porosity values obtained. (author)

  4. Comparative evaluation of cast aluminum alloys for automotive cylinder heads: Part I Microstructure evolution

    International Nuclear Information System (INIS)

    Roy, Shibayan; Allard, Lawrence Frederick Jr; Rodriguez, Andres; Watkins, Thomas R.; Shyam, Amit

    2017-01-01

    The present study stages a comparative evaluation of microstructure and associated mechanical and thermal response for common cast aluminum alloys that are used for manufacturing automotive cylinder heads. The systems considered are Al-Cu (206-T6), Al-Si-Cu (319-T7), and Al-Si (356-T6, A356-T6, and A356 + 0.5Cu-T6). The focus of the present manuscript is on the evaluation of microstructure at various length scales after aging, while the second manuscript will deal with the mechanical and thermal response of these alloys due to short-term (aging) and long-term (pre-conditioning) heat treatments. At the grain-scale, the Al-Cu alloy possessed an equiaxed microstructure as opposed to the dendritic structure for the Al-Si-Cu or Al-Si alloys which is related to the individual solidification conditions for these alloy systems. The composition and morphology of intermetallic precipitates within the grain and at the grain/dendritic boundary are dictated by the alloy chemistry, solidification, and heat treatment conditions. At the nanoscale, these alloys contain various metastable strengthening precipitates (GPI and θ''θ'' in Al-Cu alloy, θ'θ' in Al-Si-Cu alloy, and β'β' in Al-Si alloys) with varying size, morphology, coherency, and thermal stability.

  5. Esthetic modification of cast dental-ceramic restorations.

    Science.gov (United States)

    Campbell, S D

    1990-01-01

    The advantages and disadvantages of conventional opaque substructures (eg, metal ceramic restorations) used for creating esthetic complete crown restorations are reviewed, and the esthetic advantages of veneering a translucent crown (Dicor) are considered. An appropriate aluminous veneering porcelain was identified (Vitadur Veneer). This veneer porcelain was chosen to match the thermal coefficient of expansion of the cast glass-ceramic substructure. A flexural strength study was then completed and it showed no difference in the strength of the veneered and nonveneered translucent cast glass-ceramic specimens. Scanning electron microscopy revealed that the interface between the porcelain veneer and cast glass-ceramic substructure had no visible porosity and resulted in a continuous-appearing structure. Potential coping designs, as well as the clinical applications and ramifications of this modified crown, are discussed.

  6. Influence of processing factors over concrete strength.

    Science.gov (United States)

    Kara, K. A.; Dolzhenko, A. V.; Zharikov, I. S.

    2018-03-01

    Construction of facilities of cast in-situ reinforced concrete poses additional requirements to quality of material, peculiarities of the construction process may sometimes lead to appearance of lamination planes and inhomogeneity of concrete, which reduce strength of the material and structure as a whole. Technology compliance while working with cast in-situ concrete has a significant impact onto the concrete strength. Such process factors as concrete curing, vibration and compaction of the concrete mixture, temperature treatment, etc., when they are countered or inadequately followed lead to a significant reduction in concrete strength. Here, the authors experimentally quantitatively determine the loss of strength in in-situ cast concrete structures due to inadequate following of process requirements, in comparison with full compliance.

  7. The relationship of dislocation and vacancy cluster with yield strength in magnetic annealed UFG 1050 aluminum alloy

    Energy Technology Data Exchange (ETDEWEB)

    Cao, Yiheng [Key Lab of Electromagnetic Processing of Materials, Ministry of Education, Northeastern University, Shenyang 110819 (China); He, Lizi, E-mail: helizi@epm.neu.edu.cn [Key Lab of Electromagnetic Processing of Materials, Ministry of Education, Northeastern University, Shenyang 110819 (China); School of Materials Science and Engineering, Northeastern University, Shenyang 110819 (China); Cao, Xingzhong; Zhang, Peng; Wang, Baoyi [Key Laboratory of Nuclear Radiation and Nuclear Energy Technology, Institute of High Energy Physics, Chinese Academy of Sciences, Beijing 100049 (China); Zhou, Yizhou [Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China); Wang, Ping; Cui, Jianzhong [Key Lab of Electromagnetic Processing of Materials, Ministry of Education, Northeastern University, Shenyang 110819 (China); School of Materials Science and Engineering, Northeastern University, Shenyang 110819 (China)

    2017-01-02

    The evolutions of tensile properties and microstructures of ultrafine grained (UFG) 1050 aluminum alloy after annealing at 90–210 °C for 4 h without and with 12 T high magnetic field were investigated by tensile test, electron back scattering diffraction pattern (EBSD), transmission electron microscopy (TEM) and positron annihilation lifetime spectroscopy (PALS). When annealing temperature increases from 90 °C to 150 °C, the yield strength (YS) of UFG 1050 aluminum alloy increases, it is because that the increase in the density of vacancy clusters due to the activated monovacancies and the high angle boundaries (HABs) having more stable structures, both of them can act as effective barriers to dislocation motion during tensile deformation. When annealing at 210 °C, the YS of UFG 1050 aluminum alloy deceases, it is because that the decrease in the vacancy clusters density due to the thermally activated the vacancy clusters annihilating at sinks and the dislocation density decreases. The YS of magnetic annealed samples are lower at 90 °C and 150 °C due to the lower density of dislocations and vacancy clusters. The difference of YS between samples annealed without and with magnetic field disappears at 210 °C due to the sharply reduced strain hardening stage.

  8. Semi-solid rheocasting of grain refined aluminum alloy 7075

    CSIR Research Space (South Africa)

    Curle, UA

    2010-09-01

    Full Text Available mm×6 mm. Fig.1 shows the whole casting including the runner and the biscuit. A batch of the 7075 alloy was melted in a 20 kg tilting furnace and degassed with argon. A sample was poured and cooled to analyze the starting chemical composition... of the liquid metal by optical emission spectroscopy (Thermo Quantris OES). Thermodynamic properties of the starting alloy were then calculated (Scheil solidification model) with an aluminum thermodynamic database (ProCast 2009.1) using the OES composition...

  9. 3D characterization and modeling of low cycle fatigue damage mechanisms at high temperature in a cast aluminum alloy

    International Nuclear Information System (INIS)

    Dezecot, Sebastien; Maurel, Vincent; Buffiere, Jean-Yves; Szmytka, Fabien; Koster, Alain

    2017-01-01

    Synchrotron X-ray tomography was used to monitor damage evolution in three dimensions during in situ Low Cycle Fatigue (LCF) tests at high temperature (250 °C) for an industrial material. The studied material is an AlSi7Cu3Mg aluminum alloy (close to ASTM A319) produced by Lost Foam Casting (LFC), a process which generates coarse microstructures but is nevertheless used for engine parts by the automotive industry. The volume analysis (3D images) has shown that cracks are extremely sensitive to microstructural features: coarse pores and hard particles of the eutectic regions are critical regarding respectively the main crack initiation and the crack growth. Finite Elements (FE) simulations, performed on meshes directly generated from 3D volumes and containing only pores, have revealed that mechanical fields also play a major role on the crack behavior. Initiation sites corresponded to areas of maximum inelastic strain while the crack path was globally correlated to high stress triaxiality and inelastic strain fields.

  10. Strength of "Light" Ferritic and Austenitic Steels Based on the Fe - Mn - Al - C System

    Science.gov (United States)

    Kaputkina, L. M.; Svyazhin, A. G.; Smarygina, I. V.; Kindop, V. E.

    2017-01-01

    The phase composition, the hardness, the mechanical properties at room temperature, and the resistance to hot (950 - 1000°C) and warm (550°C) deformation are studied for cast deformable "light" ferritic and austenitic steels of the Fe - (12 - 25)% Mn - (0 - 15)% Al - (0 - 2)% C system alloyed additionally with about 5% Ni. The high-aluminum high-manganese low-carbon and carbonless ferritic steels at a temperature of about 0.5 T melt have a specific strength close to that of the austenitic steels and may be used as weldable scale-resistant and wear-resistant materials. The high-carbon Fe - (20 - 24)% Mn - (5 - 9)% Al - 5% Ni - 1.5% C austenitic steels may be applied as light high-strength materials operating at cryogenic temperatures after a solution treatment and as scale- and heat-resistant materials in an aged condition.

  11. Effects of environmental variables on the crack initiation stages of corrosion fatigue of high strength aluminum alloys

    Science.gov (United States)

    Poteat, L. E.

    1981-01-01

    Fatigue initiation in six aluminum alloys used in the aircraft industry was investigated. Cyclic loading superimposed on a constant stress was alternated with atmospheric corrosion. Tests made at different stress levels revealed that a residual stress as low as 39% of the yield strength caused stress corrosion cracking in some of the alloys. An atmospheric corrosion rate meter developed to measure the corrosivity of the atmosphere is described. An easily duplicated hole in the square test specimen with a self-induced residual stress was developed.

  12. Impact of as-cast structure on structure and properties of twin-roll cast AA8006 alloy

    Energy Technology Data Exchange (ETDEWEB)

    Slamova, M.; Ocenasek, V. [Vyzkumny Ustav Kovu, Panenske Brezany (Czechoslovakia); Juricek, Z.

    2000-07-01

    Sheet production by twin-roll casting (TRC) process is a well established practice in the aluminium industry because it offers several advantages in comparison with DC casting and hot rolling, esp. lower production and investment costs. Thin strips exhibiting a combination of good strength and high ductility are required for various applications and for this reason alloys with higher Fe and Mn content such as AA 8006 displace AA 1xxx or AA 8011 alloys. However, TRC of AA 8006 strips involves several problems, e.g. casting conditions and subsequent treatment procedures need fine tuning. The results of an investigation of the effect of casting conditions on structure and properties of AA 8006 strips are presented. The influence of casting speed, grain refiner addition, molten metal level in the tundish, tip setback and roll separating force was investigated. The impact of imperfect as-cast structure on structure and properties of thin strips in H22 and O tempers was evaluated and compared with strips from good as-cast material. (orig.)

  13. Energy Saving Melting and Revert Reduction Technology: Melting Efficiency in Die Casting Operations

    Energy Technology Data Exchange (ETDEWEB)

    David Schwam

    2012-12-15

    This project addressed multiple aspects of the aluminum melting and handling in die casting operations, with the objective of increasing the energy efficiency while improving the quality of the molten metal. The efficiency of melting has always played an important role in the profitability of aluminum die casting operations. Consequently, die casters need to make careful choices in selecting and operating melting equipment and procedures. The capital cost of new melting equipment with higher efficiency can sometimes be recovered relatively fast when it replaces old melting equipment with lower efficiency. Upgrades designed to improve energy efficiency of existing equipment may be well justified. Energy efficiency is however not the only factor in optimizing melting operations. Melt losses and metal quality are also very important. Selection of melting equipment has to take into consideration the specific conditions at the die casting shop such as availability of floor space, average quantity of metal used as well as the ability to supply more metal during peaks in demand. In all these cases, it is essential to make informed decisions based on the best available data.

  14. Investigation of Methods for Selectively Reinforcing Aluminum and Aluminum-Lithium Materials

    Science.gov (United States)

    Bird, R. Keith; Alexa, Joel A.; Messick, Peter L.; Domack, Marcia S.; Wagner, John A.

    2013-01-01

    Several studies have indicated that selective reinforcement offers the potential to significantly improve the performance of metallic structures for aerospace applications. Applying high-strength, high-stiffness fibers to the high-stress regions of aluminum-based structures can increase the structural load-carrying capability and inhibit fatigue crack initiation and growth. This paper discusses an investigation into potential methods for applying reinforcing fibers onto the surface of aluminum and aluminum-lithium plate. Commercially-available alumina-fiber reinforced aluminum alloy tapes were used as the reinforcing material. Vacuum hot pressing was used to bond the reinforcing tape to aluminum alloy 2219 and aluminum-lithium alloy 2195 base plates. Static and cyclic three-point bend testing and metallurgical analysis were used to evaluate the enhancement of mechanical performance and the integrity of the bond between the tape and the base plate. The tests demonstrated an increase in specific bending stiffness. In addition, no issues with debonding of the reinforcing tape from the base plate during bend testing were observed. The increase in specific stiffness indicates that selectively-reinforced structures could be designed with the same performance capabilities as a conventional unreinforced structure but with lower mass.

  15. Residual Strength Pressure Tests and Nonlinear Analyses of Stringer- and Frame-Stiffened Aluminum Fuselage Panels with Longitudinal Cracks

    Science.gov (United States)

    Young, Richard D.; Rouse, Marshall; Ambur, Damodar R.; Starnes, James H., Jr.

    1999-01-01

    The results of residual strength pressure tests and nonlinear analyses of stringer- and frame-stiffened aluminum fuselage panels with longitudinal cracks are presented. Two types of damage are considered: a longitudinal crack located midway between stringers, and a longitudinal crack adjacent to a stringer and along a row of fasteners in a lap joint that has multiple-site damage (MSD). In both cases, the longitudinal crack is centered on a severed frame. The panels are subjected to internal pressure plus axial tension loads. The axial tension loads are equivalent to a bulkhead pressure load. Nonlinear elastic-plastic residual strength analyses of the fuselage panels are conducted using a finite element program and the crack-tip-opening-angle (CTOA) fracture criterion. Predicted crack growth and residual strength results from nonlinear analyses of the stiffened fuselage panels are compared with experimental measurements and observations. Both the test and analysis results indicate that the presence of MSD affects crack growth stability and reduces the residual strength of stiffened fuselage shells with long cracks.

  16. Permeability of Aluminium Foams Produced by Replication Casting

    Directory of Open Access Journals (Sweden)

    Maxim L. Cherny

    2012-12-01

    Full Text Available The replication casting process is used for manufacturing open-pore aluminum foams with advanced performances, such as stability and repeatability of foam structure with porosity over 60%. A simple foam structure model based on the interaction between sodium chloride solid particles poorly wetted by melted aluminum, which leads to the formation of air pockets (or “air collars”, is proposed for the permeability of porous material. The equation for the minimum pore radius of replicated aluminum foam is derived. According to the proposed model, the main assumption of the permeability model consists in a concentration of flow resistance in a circular aperture of radius rmin. The permeability of aluminum open-pore foams is measured using transformer oil as the fluid, changing the fractions of initial sodium chloride. Measured values of minimum pore size are close to theoretically predicted ones regardless of the particle shape. The expression for the permeability of replicated aluminum foam derived on the basis of the “bottleneck” model of porous media agrees well with the experimental data. The obtained data can be applied for commercial filter cells and pneumatic silencers.

  17. Progress on high-performance rapid prototype aluminum mirrors

    Science.gov (United States)

    Woodard, Kenneth S.; Myrick, Bruce H.

    2017-05-01

    Near net shape parts can be produced using some very old processes (investment casting) and the relatively new direct metal laser sintering (DMLS) process. These processes have significant advantages for complex blank lightweighting and costs but are not inherently suited for producing high performance mirrors. The DMLS process can provide extremely complex lightweight structures but the high residual stresses left in the material results in unstable mirror figure retention. Although not to the extreme intricacy of DMLS, investment casting can also provide complex lightweight structures at considerably lower costs than DMLS and even conventional wrought mirror blanks but the less than 100% density for casting (and also DMLS) limits finishing quality. This paper will cover the progress that has been made to make both the DMLS and investment casting processes into viable near net shape blank options for high performance aluminum mirrors. Finish and figure results will be presented to show performance commensurate with existing conventional processes.

  18. Al based ultra-fine eutectic with high room temperature plasticity and elevated temperature strength

    Energy Technology Data Exchange (ETDEWEB)

    Tiwary, C.S., E-mail: cst311@gmail.com [Department of Materials Engineering, Indian Institute of Science, Bangalore 560012, Karnataka (India); Kashyap, S. [Department of Materials Engineering, Indian Institute of Science, Bangalore 560012, Karnataka (India); Kim, D.H. [Center for Non-Crystalline Materials, Department of Metallurgical Engineering, Yonsei University, Seoul 120-749 (Korea, Republic of); Chattopadhyay, K. [Department of Materials Engineering, Indian Institute of Science, Bangalore 560012, Karnataka (India)

    2015-07-15

    Developments of aluminum alloys that can retain strength at and above 250 °C present a significant challenge. In this paper we report an ultrafine scale Al–Fe–Ni eutectic alloy with less than 3.5 at% transition metals that exhibits room temperature ultimate tensile strength of ~400 MPa with a tensile ductility of 6–8%. The yield stress under compression at 300 °C was found to be 150 MPa. We attribute it to the refinement of the microstructure that is achieved by suction casting in copper mold. The characterization using scanning and transmission electron microscopy (SEM and TEM) reveals an unique composite structure that contains the Al–Al{sub 3}Ni rod eutectic with spacing of ~90 nm enveloped by a lamellar eutectic of Al–Al{sub 9}FeNi (~140 nm). Observation of subsurface deformation under Vickers indentation using bonded interface technique reveals the presence of extensive shear banding during deformation that is responsible for the origin of ductility. The dislocation configuration in Al–Al{sub 3}Ni eutectic colony indicates accommodation of plasticity in α-Al with dislocation accumulation at the α-Al/Al{sub 3}Ni interface boundaries. In contrast the dislocation activities in the intermetallic lamellae are limited and contain set of planner dislocations across the plates. We present a detailed analysis of the fracture surface to rationalize the origin of the high strength and ductility in this class of potentially promising cast alloy.

  19. Microstructure, tensile properties and fracture behavior of high temperature Al–Si–Mg–Cu cast alloys

    Energy Technology Data Exchange (ETDEWEB)

    Mohamed, A.M.A., E-mail: madel@uqac.ca [Center for Advanced Materials, Qatar University, Doha (Qatar); Department of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez Canal University, Box 43721, Suez (Egypt); Samuel, F.H. [Université du Québec à Chicoutimi, Chicoutimi, QC, Canada G7H 2B1 (Canada); Al Kahtani, Saleh [Industrial Engineering Program, Mechanical Engineering Department, College of Engineering, Salman bin Abdulaziz University, Al Kharj (Saudi Arabia)

    2013-08-10

    The high temperature tensile behavior of 354 aluminum cast alloy was investigated in the presence of Zr and Ni. The cast alloys were given a solutionizing treatment followed by artificial aging at 190 °C for 2 h. High temperature tensile tests were conducted at various temperatures from 25 °C to 300 °C. Optical microscopy and electron probe micro-analyzer were used to study the microstructure of different intermetallic phases formed. The fractographic observations of fracture surface were analyzed by scanning electron microscopy to understand the fracture mechanism. The results revealed that the intermetallics phases of (Al, Si){sub 3}(Zr, Ti), Al{sub 3}CuNi and Al{sub 9}NiFe are the main feature in the microstructures of alloys with Zr and Ni additions. The results also indicated that the tensile strength of alloy decreases with an increase in temperature. The combined addition of 0.2 wt% Zr and 0.2 wt% Ni leads to a 30% increase in the tensile properties at 300 °C compared to the base alloy. Zr and Ni bearing phases played a vital role in the fracture mechanism of the alloys studied.

  20. Microstructure, tensile properties and fracture behavior of high temperature Al–Si–Mg–Cu cast alloys

    International Nuclear Information System (INIS)

    Mohamed, A.M.A.; Samuel, F.H.; Al Kahtani, Saleh

    2013-01-01

    The high temperature tensile behavior of 354 aluminum cast alloy was investigated in the presence of Zr and Ni. The cast alloys were given a solutionizing treatment followed by artificial aging at 190 °C for 2 h. High temperature tensile tests were conducted at various temperatures from 25 °C to 300 °C. Optical microscopy and electron probe micro-analyzer were used to study the microstructure of different intermetallic phases formed. The fractographic observations of fracture surface were analyzed by scanning electron microscopy to understand the fracture mechanism. The results revealed that the intermetallics phases of (Al, Si) 3 (Zr, Ti), Al 3 CuNi and Al 9 NiFe are the main feature in the microstructures of alloys with Zr and Ni additions. The results also indicated that the tensile strength of alloy decreases with an increase in temperature. The combined addition of 0.2 wt% Zr and 0.2 wt% Ni leads to a 30% increase in the tensile properties at 300 °C compared to the base alloy. Zr and Ni bearing phases played a vital role in the fracture mechanism of the alloys studied

  1. Three-dimensional rigid multiphase networks providing high-temperature strength to cast AlSi10Cu5Ni1-2 piston alloys

    International Nuclear Information System (INIS)

    Asghar, Z.; Requena, G.; Boller, E.

    2011-01-01

    The three-dimensional (3-D) architecture of rigid multiphase networks present in AlSi10Cu5Ni1 and AlSi10Cu5Ni2 piston alloys in as-cast condition and after 4 h spheroidization treatment is characterized by synchrotron tomography in terms of the volume fraction of rigid phases, interconnectivity, contiguity and morphology. The architecture of both alloys consists of α-Al matrix and a rigid long-range 3-D network of Al 7 Cu 4 Ni, Al 4 Cu 2 Mg 8 Si 7 , Al 2 Cu, Al 15 Si 2 (FeMn) 3 and AlSiFeNiCu aluminides and Si. The investigated architectural parameters of both alloys studied are correlated with room-temperature and high-temperature (300 deg. C) strengths as a function of solution treatment time. The AlSi10Cu5Ni1 and AlSi10Cu5Ni2 alloys behave like metal matrix composites with 16 and 20 vol.% reinforcement, respectively. Both alloys have similar strengths in the as-cast condition, but the AlSi10Cu5Ni2 is able to retain ∼15% higher high temperature strength than the AlSi10Cu5Ni1 alloy after more than 4 h of spheroidization treatment. This is due to the preservation of the 3-D interconnectivity and the morphology of the rigid network, which is governed by the higher degree of contiguity between aluminides and Si.

  2. Optimization of Micro-Alloying Elements for Mechanical Properties in Normalized Cast Steel Using Taguchi Technique

    Directory of Open Access Journals (Sweden)

    Chokkalingam B.

    2017-06-01

    Full Text Available In this study, Taguchi method is used to find out the effect of micro alloying elements like vanadium, niobium and titanium on the hardness and tensile strength of the normalized cast steel. Based on this method, plan of experiments were made by using orthogonal arrays to acquire the data on hardness and tensile strength. The signal to noise ratio and analysis of variance (ANOVA are used to investigate the effect of these micro alloying elements on these two mechanical properties of the micro alloyed normalized cast steel. The results indicated that in the micro alloyed normalized cast steel both these properties increases when compared to non-micro-alloyed normalized cast steel. The effect of niobium addition was found to be significantly higher to obtain higher hardness and tensile strength when compared to other micro alloying elements. The maximum hardness of 200HV and the maximum tensile strength of 780 N/mm2 were obtained in 0.05%Nb addition micro alloyed normalized cast steel. Micro-alloyed with niobium normalized cast steel have the finest and uniform microstructure and fine pearlite colonies distributed uniformly in the ferrite. The optimum condition to obtain higher hardness and tensile strength were determined. The results were verified with experiments.

  3. Research of Mechanical Property Gradient Distribution of Al-Cu Alloy in Centrifugal Casting

    Science.gov (United States)

    Sun, Zhi; Sui, Yanwei; Liu, Aihui; Li, Bangsheng; Guo, Jingjie

    Al-Cu alloy castings are obtained using centrifugal casting. The regularity of mechanical property gradient distribution of Al-Cu alloy castings with the same centrifugal radius at different positions is investigated. The result shows that the tensile strength, yield strength, elongation and microscope hardness exhibit the following gradient distribution characteristic — high on both sides and low on the center. The trend of mechanical property gradient distribution of Al-Cu alloy increases with the increase in the rotation speed. Moreover, the mechanical properties of casting centerline two sides have asymmetry. The reason is that the grain size of casting centerline two sides and Al2Cu phase and Cu content change correspondingly.

  4. Reduction of surface erosion caused by helium blistering in sintered beryllium and sintered aluminum powder

    International Nuclear Information System (INIS)

    Das, S.K.; Kaminsky, M.

    1976-01-01

    Studies have been conducted to find materials with microstructures which minimize the formation of blisters. A promising class of materials appears to be sintered metal powder with small average grain sizes and low atomic number Z. Studies of the surface erosion of sintered aluminum powder (SAP 895) and of aluminum held at 400 0 C due to blistering by 100 keV helium ions have been conducted and the results are compared to those obtained earlier for room temperature irradiation. A significant reduction of the erosion rate in SAP 895 in comparison to annealed aluminum and SAP 930 is observed. In addition results on the blistering of sintered beryllium powder (type I) irradiated at room temperature and 600 0 C by 100 keV helium ions are given. These results will be compared with those reported recently for vacuum cast beryllium foil and a foil of sintered beryllium powder (type II) which was fabricated differently, than type I. For room temperature irradiation only a few blisters could be observed in sintered beryllium powder type I and type II and they are smaller in size and in number than in vacuum cast beryllium. For irradiation at 600 0 C large scale exfoliation of blisters was observed for vacuum cast beryllium but much less exfoliation was seen for sintered beryllium powder, type I, and type II. The results show a reduction in erosion rate cast beryllium, for both room temperature and 600 0 C

  5. Carbide coated fibers in graphite-aluminum composites

    Science.gov (United States)

    Imprescia, R. J.; Levinson, L. S.; Reiswig, R. D.; Wallace, T. C.; Williams, J. M.

    1975-01-01

    The NASA-supported program at the Los Alamos Scientific Laboratory (LASL) to develop carbon fiber-aluminum matrix composites is described. Chemical vapor deposition (CVD) was used to uniformly deposit thin, smooth, continuous coats of TiC on the fibers of graphite tows. Wet chemical coating of fibers, followed by high-temperature treatment, was also used, but showed little promise as an alternative coating method. Strength measurements on CVD coated fiber tows showed that thin carbide coats can add to fiber strength. The ability of aluminum alloys to wet TiC was successfully demonstrated using TiC-coated graphite surfaces. Pressure-infiltration of TiC- and ZrC-coated fiber tows with aluminum alloys was only partially successful. Experiments were performed to evaluate the effectiveness of carbide coats on carbon as barriers to prevent reaction between alluminum alloys and carbon. Initial results indicate that composites of aluminum and carbide-coated graphite are stable for long periods of time at temperatures near the alloy solidus.

  6. Seacoast stress corrosion cracking of aluminum alloys

    Science.gov (United States)

    Humphries, T. S.; Nelson, E. E.

    1981-01-01

    The stress corrosion cracking resistance of high strength, wrought aluminum alloys in a seacoast atmosphere was investigated and the results were compared with those obtained in laboratory tests. Round tensile specimens taken from the short transverse grain direction of aluminum plate and stressed up to 100 percent of their yield strengths were exposed to the seacoast and to alternate immersion in salt water and synthetic seawater. Maximum exposure periods of one year at the seacoast, 0.3 or 0.7 of a month for alternate immersion in salt water, and three months for synthetic seawater were indicated for aluminum alloys to avoid false indications of stress corrosion cracking failure resulting from pitting. Correlation of the results was very good among the three test media using the selected exposure periods. It is concluded that either of the laboratory test media is suitable for evaluating the stress corrosion cracking performance of aluminum alloys in seacoast atmosphere.

  7. Influence of heat treatment on the strength and fracture toughness of 7N01 aluminum alloy

    Energy Technology Data Exchange (ETDEWEB)

    Li, Bo [School of Materials Science and Engineering, Southwest Jiaotong University, Chengdu, 610031, Sichuan (China); Wang, Xiaomin, E-mail: xmwang991011@163.com [School of Life Science and Engineering, Southwest Jiaotong University, Chengdu, 610031, Sichuan (China); Chen, Hui; Hu, Jie [School of Materials Science and Engineering, Southwest Jiaotong University, Chengdu, 610031, Sichuan (China); Huang, Cui [School of Life Science and Engineering, Southwest Jiaotong University, Chengdu, 610031, Sichuan (China); Gou, Guoqing [School of Materials Science and Engineering, Southwest Jiaotong University, Chengdu, 610031, Sichuan (China)

    2016-09-05

    7N01 aluminum (Al) alloys are treated by five heat treatment methods as peak aging (T6), over aging (T74), high temperature and subsequently low temperature aging (HLA), retrogression and reaging (RRA) and double retrogression and reaging (DRRA). The strength and fracture toughness of the five samples are tested, and the microstructures are investigated by optical microscopy (OM), transmission electron microscopy (TEM), and scanning electron microscopy (SEM). The results show that 7N01 Al-alloy treated at T6 condition has high strength but low fracture toughness. Compared with T6 treatment, T74 and HLA treatments increase the fracture toughness by 67% and 90% respectively, while the strength decrease by 9% and 17%. RRA process is a proper treatment method for 7N01 which improves the fracture toughness without sacrificing strength. The fracture toughness of DRRA treated alloy is much lower than that of RRA. Quantitative analysis through TEM images shows that the heat treatment affects the mechanical properties of 7N01 Al-alloy highly through changing the precipitates in grains and on grain boundaries, which can be explained by the coherency strengthening mechanism and Orowan mechanism. - Highlights: • Five heat treatments which can change the properties of 7N01 Al alloy were designed. • Quantitative analysis of precipitates was employed to study the mechanism. • RRA treatment can make proper strength/toughness property balances for 7N01 Al alloy.

  8. Influence of heat treatment on the strength and fracture toughness of 7N01 aluminum alloy

    International Nuclear Information System (INIS)

    Li, Bo; Wang, Xiaomin; Chen, Hui; Hu, Jie; Huang, Cui; Gou, Guoqing

    2016-01-01

    7N01 aluminum (Al) alloys are treated by five heat treatment methods as peak aging (T6), over aging (T74), high temperature and subsequently low temperature aging (HLA), retrogression and reaging (RRA) and double retrogression and reaging (DRRA). The strength and fracture toughness of the five samples are tested, and the microstructures are investigated by optical microscopy (OM), transmission electron microscopy (TEM), and scanning electron microscopy (SEM). The results show that 7N01 Al-alloy treated at T6 condition has high strength but low fracture toughness. Compared with T6 treatment, T74 and HLA treatments increase the fracture toughness by 67% and 90% respectively, while the strength decrease by 9% and 17%. RRA process is a proper treatment method for 7N01 which improves the fracture toughness without sacrificing strength. The fracture toughness of DRRA treated alloy is much lower than that of RRA. Quantitative analysis through TEM images shows that the heat treatment affects the mechanical properties of 7N01 Al-alloy highly through changing the precipitates in grains and on grain boundaries, which can be explained by the coherency strengthening mechanism and Orowan mechanism. - Highlights: • Five heat treatments which can change the properties of 7N01 Al alloy were designed. • Quantitative analysis of precipitates was employed to study the mechanism. • RRA treatment can make proper strength/toughness property balances for 7N01 Al alloy.

  9. The comparative studies of ADI versus Hadfield cast steel wear resistance

    Directory of Open Access Journals (Sweden)

    Mieczysław Kaczorowski

    2011-04-01

    Full Text Available The results of comparative studies of wear resistance of ADI versus high manganese Hadfield cast steel are presented. For evaluation ofwear resistance three type of ADI were chosen. Two of them were of moderate strength ADI with 800 and 1000MPa tensile strength whilethe third was 1400MPa tensile strength ADI. The specimens were cut from ADI test YII type casting poured and heat treated in Institute ofFoundry in Krakow. The pin on disc method was used for wear resistance experiment. The specimens had a shape of 40mm long rod withdiameter 6mm. The load and speed were 100N and 0,54m/s respectively. It was concluded that the wear resistance of ADI is comparablewith high manganese cast steel and in case of low tensile grade ADI and is even better for high strength ADI than Hadfield steel.

  10. Relationship between casting distortion, mold filling, and interfacial heat transfer. Annual technical report, September 1997 - September 1998

    Energy Technology Data Exchange (ETDEWEB)

    Woodbury, K.A.; Parker, J.K.; Piwonka, T.S.; Owusu, Y.

    1998-10-22

    In the third year of this program, the final castings necessary to evaluate the effect of casting orientation and gating in silica sand lost foam were poured and measured using a CMM machine. Interfacial heat transfer and gap formation measurements continued. However, significant problems were encountered in making accurate measurements. No consistent evidence of gap formation was found in aluminum sand casting. Initial analysis yields heat transfer values below those previously reported in the literature. The program in continuing.

  11. Synthesis of new aluminum nano hybrid composite liner for energy saving in diesel engines

    International Nuclear Information System (INIS)

    Tiruvenkadam, N.; Thyla, P.R.; Senthilkumar, M.; Bharathiraja, M.; Murugesan, A.

    2015-01-01

    Highlights: • Nano hybrid composite cylinder liner (NL) was developed to replace cast iron liner. • NL improved engine performance, combustion and reduced emissions except NO x . • Teardown analysis provides the suitability of NL for diesel engine. • The developed aluminum NL saved 43.75% of weight than cast iron cylinder liner. - Abstract: This work aims to replace the conventional cast iron cylinder liner (CL) in diesel engine by introducing lightweight aluminum (Al) 6061 nano hybrid composite cylinder liner (NL) by analyzing the performance, combustion, and emission characteristics of an engine. NL was fabricated by bottom pouring stir casting technique with nano- and micro-reinforcement materials. Experimental results proved that the use of NL increased brake thermal efficiency, in-cylinder pressure, heat release rate, and reduced carbon monoxide, hydrocarbon, and smoke emission in comparison with CL. However, oxides of nitrogen slightly increased with the use of the new liner. No differences in wear or other issues were noted during the engine teardown after 1 year of operation and 2000 h of running. Thus, NL has been recommended to replace the CL to save the energy and to reap environmental benefits

  12. In situ formation of ZrB2 particulates and their influence on microstructure and tensile behavior of AA7075 aluminum matrix composites

    Directory of Open Access Journals (Sweden)

    J. David Raja Selvam

    2017-02-01

    Full Text Available In situ synthesis of aluminum matrix composites (AMCs has become a popular method due to several advantages over conventional stir casting method. In the present study, AA7075/ZrB2 AMCs reinforced with various content of ZrB2 particulates (0, 3, 6, 9 and 12 wt.% were synthesized by the in situ reaction of molten aluminum with inorganic salts K2ZrF6 and KBF4. The composites were characterized using XRD, OM, SEM, EBSD and TEM. The XRD patterns revealed the formation of ZrB2 particulates without the presence of any other compounds. The formation of ZrB2 particulates refined the grains of aluminum matrix extensively. Most of the ZrB2 particulates were located near the grain boundaries. The ZrB2 particulates exhibited various morphologies including spherical, cylindrical and hexagonal shapes. The size of the ZrB2 particulates was in the order of nano, sub micron and micron level. A good interfacial bonding was observed between the aluminum matrix and the ZrB2 particulates. The in situ formed ZrB2 particulates enhanced the mechanical properties such as microhardness and the ultimate tensile strength. Various strengthening mechanisms were identified.

  13. Effect of cerium addition on microstructure and mechanical properties of high-strength Fe85Cr4Mo8V2C1 cast steel

    Energy Technology Data Exchange (ETDEWEB)

    Hufenbach, J., E-mail: j.k.hufenbach@ifw-dresden.de [IFW Dresden, Institute for Complex Materials, P.O. Box 270116, D-01171 Dresden (Germany); Helth, A. [IFW Dresden, Institute for Complex Materials, P.O. Box 270116, D-01171 Dresden (Germany); Lee, M.-H. [Korea Institute of Industrial Technology, Gaetbeol-ro 156, Yeonsu-gu, Incheon 406-840 (Korea, Republic of); Wendrock, H.; Giebeler, L. [IFW Dresden, Institute for Complex Materials, P.O. Box 270116, D-01171 Dresden (Germany); Choe, C.-Y.; Kim, K.-H. [Korea Institute of Industrial Technology, Gaetbeol-ro 156, Yeonsu-gu, Incheon 406-840 (Korea, Republic of); Kühn, U. [IFW Dresden, Institute for Complex Materials, P.O. Box 270116, D-01171 Dresden (Germany); Kim, T.-S. [Korea Institute of Industrial Technology, Gaetbeol-ro 156, Yeonsu-gu, Incheon 406-840 (Korea, Republic of); Eckert, J. [IFW Dresden, Institute for Complex Materials, P.O. Box 270116, D-01171 Dresden (Germany); TU Dresden, Institute of Materials Science, D-01062 Dresden (Germany)

    2016-09-30

    This work presents an investigation on the influence of rare earth additions (Ce) on the microstructure and mechanical properties of a cast Fe85Cr4Mo8V2C1 (element contents in wt%) tool steel. The applied relatively high solidification rate during the casting process promotes the formation of non-equilibrium phases such as martensite, retained austenite as well as a fine network-like structure of complex carbides. This combination of phases and their morphology results in excellent mechanical properties already in the as-cast state. Cerium additions induce a change in phase formation and resulting mechanical properties. Besides morphological and quantitative changes of the main constituent phases, novel carbo-oxide and carbide phases are formed. To investigate this microstructural phenomenon, X-ray diffraction (XRD), transmission electron microscopy (TEM) and scanning electron microscopy (SEM) combined with energy dispersive X-ray spectroscopy (EDX) were applied. Altogether, the addition of small amounts of the rare earth element cerium together with a tailored casting process results in enhanced mechanical properties compared to the Fe85Cr4Mo8V2C1 alloy and offers new possibilities to obtain high-strength and simultaneously adequate ductile cast steels for advanced tool design.

  14. Analysis of the Causes of Cracks in a Thick-Walled Bush Made of Die-Cast Aluminum Bronze

    Directory of Open Access Journals (Sweden)

    Pisarek B.P.

    2016-12-01

    Full Text Available For the die casting conditions of aluminium bronzes assumed based on the literature data, a thick-walled bush was cast, made of complex aluminium bronze (Cu-Al-Fe-Ni-Cr. After the cast was removed from the mould, cracks were observed inside it. In order to identify the stage in the technological production process at which, potentially, the formation of stresses damaging the continuity of the microstructure created in the cast was possible (hot cracking and/or cold cracking, a computer simulation was performed. The article presents the results of the computer simulation of the process of casting the material into the gravity die as well as solidifying and cooling of the cast in the shape of a thick-walled bush. The simulation was performed with the use of the MAGMA5 program and by application of the CuAl10Ni5,5Fe4,5 alloy from the MAGMA5 program database. The results were compared with the location of the defects identified in the actual cast. As a result of the simulation of the die-casting process of this bush, potential regions were identified where significant principal stresses accumulate, which can cause local hot and cold cracking. Until now, no research has been made of die-cast aluminium bronzes with a Cr addition. Correlating the results of the computer simulation validated by the analysis of the actual cast made it possible to clearly determine the critical regions in the cast exposed to cracking and point to the causes of its occurrence. Proposals of changes in the bush die casting process were elaborated, in order to avoid hot tearing and cold cracking. The article discusses the results of preliminary tests being a prologue to the optimization of the die-casting process parameters of complex aluminium bronze thick-walled bushs.

  15. Characterization of Ni-Cr alloys using different casting techniques and molds.

    Science.gov (United States)

    Chen, Wen-Cheng; Teng, Fu-Yuan; Hung, Chun-Cheng

    2014-02-01

    This study differentiated the mechanical properties of nickel-chromium (Ni-Cr) alloys under various casting techniques (different casting molds and casting atmospheres). These techniques were sampled by a sand mold using a centrifugal machine in ambient air (group I) and electromagnetic induction in an automatic argon castimatic casting machine (group II). The specimen casting used a graphite mold by a castimatic casting machine (group III). The characteristics of the Ni-Cr alloys, yield and ultimate tensile strength, bending modulus, microhardness, diffraction phase, grindability, ability to spring back, as well as ground microstructure and pattern under different casting conditions were evaluated. The group III specimens exhibited the highest values in terms of strength, modulus, hardness, and grindability at a grind rate of 500 rpm. Moreover, group III alloys exhibited smaller grain sizes, higher ability to spring back, and greater ductility than those casted by sand investment (groups I and II). The main factor, "casting mold," significantly influenced all mechanical properties. The graphite mold casting of the Ni-Cr dental alloys in a controlled atmosphere argon casting system provided an excellent combination of high mechanical properties and good ability to spring back, and preserved the ductile properties for application in Ni-Cr porcelain-fused system. The results can offer recommendations to assist a prosthetic technician in selecting the appropriate casting techniques to obtain the desired alloy properties. Copyright © 2013 Elsevier B.V. All rights reserved.

  16. Statistical model for predicting correct amount of deoxidizer of Al-killed grade casted at slab continuous caster of Pakistan steel

    International Nuclear Information System (INIS)

    Siddiqui, A.R.; Khan, M.M.A.; Ismail, B.M.

    1999-01-01

    Oxygen is blown in Converter process to oxidize hot metal. This introduces dissolved oxygen in the metal, which may cause embrittlement, voids, inclusion and other undesirable properties in steel. The steel bath at the time of tapping contains 400 to 800 ppm oxygen. Deoxidation is carried out during tapping by adding into the tap ladle appropriate amounts of ferromanganese, ferrosilicon and/or aluminum or other special deoxidizers. In the research aluminum killed grade steel which are casted at the slab caster of Pakistan Steel were investigated. Amount of aluminum added is very critical because if we add lesser amount of aluminum then the required quantity then there will be an incomplete killing of oxygen which results uncleanness in steel. Addition of larger amount of aluminum not only increases the cost of the production but also results as higher amount of alumina, which results in nozzle clogging and increase, loses. The purpose of the research is to develop a statistical model which would predict correct amount of aluminum addition for complete deoxidation of aluminum killed grade casted at slab continuous caster of Pakistan Steel. In the model aluminum added is taken as dependent variable while tapping temperature, turn down carbon composition, turndown manganese composition and oxygen content in steel would be the independent variable. This work is based on operational practice on 130 tons Basic Oxygen furnace. (author)

  17. Updated Life-Cycle Assessment of Aluminum Production and Semi-fabrication for the GREET Model

    Energy Technology Data Exchange (ETDEWEB)

    Dai, Qiang [Argonne National Lab. (ANL), Argonne, IL (United States); Kelly, Jarod C. [Argonne National Lab. (ANL), Argonne, IL (United States); Burnham, Andrew [Argonne National Lab. (ANL), Argonne, IL (United States); Elgowainy, Amgad [Argonne National Lab. (ANL), Argonne, IL (United States)

    2015-09-01

    This report serves as an update for the life-cycle analysis (LCA) of aluminum production based on the most recent data representing the state-of-the-art of the industry in North America. The 2013 Aluminum Association (AA) LCA report on the environmental footprint of semifinished aluminum products in North America provides the basis for the update (The Aluminum Association, 2013). The scope of this study covers primary aluminum production, secondary aluminum production, as well as aluminum semi-fabrication processes including hot rolling, cold rolling, extrusion and shape casting. This report focuses on energy consumptions, material inputs and criteria air pollutant emissions for each process from the cradle-to-gate of aluminum, which starts from bauxite extraction, and ends with manufacturing of semi-fabricated aluminum products. The life-cycle inventory (LCI) tables compiled are to be incorporated into the vehicle cycle model of Argonne National Laboratory’s Greenhouse Gases, Regulated Emissions, and Energy Use in Transportation (GREET) Model for the release of its 2015 version.

  18. Microstructure and Properties of Selected Magnesium-Aluminum Alloys Prepared for SPD Processing Technology

    Directory of Open Access Journals (Sweden)

    Cizek L.

    2017-12-01

    Full Text Available A growing interest in wrought magnesium alloys has been noticed recently, mainly due to development of various SPD (severe plastic deformation methods that enable significant refinement of the microstructure and – as a result – improvement of various functional properties of products. However, forming as-cast magnesium alloys with the increased aluminum content at room temperature is almost impossible. Therefore, application of heat treatment before forming or forming at elevated temperature is recommended for these alloys. The paper presents the influence of selected heat treatment conditions on the microstructure and the mechanical properties of the as-cast AZ91 alloy. Deformation behaviour of the as-cast AZ61 alloy at elevated temperatures was analysed as well. The microstructure analysis was performed by means of both light microscopy and SEM. The latter one was used also for fracture analysis. Moreover, the effect of chemical composition modification by lithium addition on the microstructure of the AZ31-based alloy is presented. The test results can be helpful in preparation of the magnesium-aluminum alloys for further processing by means of SPD methods.

  19. Relationships Between Solidification Parameters in A319 Aluminum Alloy

    Science.gov (United States)

    Vandersluis, E.; Ravindran, C.

    2018-03-01

    The design of high-performance materials depends on a comprehensive understanding of the alloy-specific relationships between solidification and properties. However, the inconsistent use of a particular solidification parameter for presenting materials characterization in the literature impedes inter-study comparability and the interpretation of findings. Therefore, there is a need for accurate expressions relating the solidification parameters for each alloy. In this study, A319 aluminum alloy castings were produced in a permanent mold with various preheating temperatures in order to control metal cooling. Analysis of the cooling curve for each casting enabled the identification of its liquidus, Al-Si eutectic, and solidus temperatures and times. These values led to the calculation of the primary solidification rate, total solidification rate, primary solidification time, and local solidification time for each casting, which were related to each other as well as to the average casting SDAS and material hardness. Expressions for each of their correlations have been presented with high coefficients of determination, which will aid in microstructural prediction and casting design.

  20. Wear-resistance of Aluminum Matrix Microcomposite Materials

    Directory of Open Access Journals (Sweden)

    M. Kandeva

    2011-03-01

    Full Text Available A procedure is developed for the study of wear of aluminum alloys AlSi7 obtained by casting, reinforced by TiC microparticles, before and after heat treatment. Tribological study is realized under conditions of friction on counterbody with fixed abrasive. Experimental results were obtained for mass wear, wear rate, wear intensity and wear-resistance of the alloys with different wt% of microparticles.

  1. Effect of quenching rate on precipitation kinetics in AA2219 DC cast alloy

    Energy Technology Data Exchange (ETDEWEB)

    Elgallad, E.M., E-mail: eelgalla@uqac.ca; Zhang, Z.; Chen, X.-G.

    2017-06-01

    Slow quenching of direct chill (DC) cast aluminum ingot plates used in large mold applications is often used to decrease quench-induced residual stresses, which can deteriorate the machining performance of these plates. Slow quenching may negatively affect the mechanical properties of the cast plates when using highly quench-sensitive aluminum alloys because of its negative effect on the precipitation hardening behavior of such alloys. The effect of the quenching rate on precipitation kinetics in AA2219 DC cast alloy was systematically studied under water and air quenching conditions using differential scanning calorimetry (DSC) technique. Transmission electron microscopy (TEM) was also used to characterize the precipitate microstructure. The results showed that the precipitation kinetics of the θ′ phase in the air-quenched condition was mostly slower than that in the water-quenched one. Air quenching continuously increased the precipitation kinetics of the θ phase compared to water quenching. These results revealed the contributions of the inadequate precipitation of the strengthening θ′ phase and the increased precipitation of the equilibrium θ phase to the deterioration of the mechanical properties of air-quenched AA2219 DC cast plates. The preexisting GP zones and quenched-in dislocations affected the kinetics of the θ′ phase, whereas the preceding precipitation of the θ′ phase affected the kinetics of the θ phase by controlling its precipitation mechanism.

  2. The influence of surface topography on the forming friction of automotive aluminum sheet

    Energy Technology Data Exchange (ETDEWEB)

    Kramer, Pamela Ann [Univ. of California, Berkeley, CA (United States). Dept. of Materials Science and Mineral Engineering

    1998-05-01

    Interest in utilizing aluminum alloys in automobiles has increased in recent years as a result of the desire to lower automobile weight and, consequently, increase fuel economy. While aluminum alloy use in cast parts has increased, outer body panel applications are still being investigated. The industry is interested in improving the formability of these sheet alloys by a combination of alloy design and processing. A different avenue of improving the formability of these alloys may be through patterning of the sheet surface. Surface patterns hold the lubricant during the forming process, with a resulting decrease in the sheet-die surface contact. While it has been speculated that an optimum surface pattern would consist of discrete cavities, detailed investigation into the reduction of forming friction by utilizing discrete patterns is lacking. A series of discrete patterns were investigated to determine the dependence of the forming friction of automotive aluminum alloys on pattern lubricant carrying capacity and on material strength. Automotive aluminum alloys used in outer body panel applications were rolled on experimental rolls that had been prepared with a variety of discrete patterns. All patterns for each alloy were characterized before and after testing both optically and, to determine pattern lubricant capacity, using three dimensional laser profilometry. A draw bead simulation (DBS) friction tester was designed and fabricated to determine the forming friction of the patterned sheets. Tensile testing and frictionless DBS testing were performed to ascertain the material properties of each sheet. The most striking result of this work was the inversely linear dependence of forming friction on the lubricant carrying capacity of the discrete patterns.

  3. Mechanical properties and grindability of dental cast Ti-Nb alloys.

    Science.gov (United States)

    Kikuchi, Masafumi; Takahashi, Masatoshi; Okuno, Osamu

    2003-09-01

    Aiming at developing a dental titanium alloy with better mechanical properties and machinability than unalloyed titanium, a series of Ti-Nb alloys with Nb concentrations up to 30% was made. They were cast into magnesia-based molds using a dental casting machine and the mechanical properties and grindability of the castings were examined. The hardness of the alloys with Nb concentrations of 5% and above was significantly higher than that of titanium. The yield strength and tensile strength of the alloys with Nb concentrations of 10% and above were significantly higher than those of titanium, while the elongation was significantly lower. A small addition of niobium to titanium did not contribute to improving the grindability of titanium. The Ti-30% Nb alloy exhibited significantly better grindability at low grinding speed with higher hardness, strength, and Young's modulus than titanium, presumably due to precipitation of the omega phase in the beta matrix.

  4. Detection and removal of molten salts from molten aluminum alloys

    Energy Technology Data Exchange (ETDEWEB)

    K. Butcher; D. Smith; C. L. Lin; L. Aubrey

    1999-08-02

    Molten salts are one source of inclusions and defects in aluminum ingots and cast shapes. A selective adsorption media was used to remove these inclusions and a device for detection of molten salts was tested. This set of experiments is described and the results are presented and analyzed.

  5. A Tri-modal 2024 Al -B4C composites with super-high strength and ductility: Effect of coarse-grained aluminum fraction on mechanical behavior

    Directory of Open Access Journals (Sweden)

    Alireza Abdollahi

    2014-12-01

    Full Text Available In this study, ultrafine grained 2024 Al alloy based B4C particles reinforced composite was produced by mechanical milling and hot extrusion. Mechanical milling was used to synthesize the nanostructured Al2024 in attrition mill under argon atmosphere up to 50h. A similar process was used to produce Al2024-5%wt. B4C composite powder. To produce trimodal composites, milled powders were combined with coarse grained aluminum in 30 and 50 wt% and then were exposed to hot extrusion at 570°C. The microstructure of hot extruded samples were studied by optical microscope, Transmission electron microscope (TEM and scanning electron microscope (SEM equipped with EDS spectroscopy. The mechanical properties of samples were compared by using tensile, compression and hardness tests. The results showed that the strength, after 50 h milling and addition of 5wt% B4C, increased from 340 to 582 MPa and the hardness increased from 87 HBN to 173 HBN, but the elongation decreased from 14 to 0.5%. By adding the coarse-grained aluminum powder, the strength and hardness decreased slightly, but the increases in return. Ductility increase is the result of increase in dislocation movements and strength increase is the result of restriction in plastic deformation by nanostructured regions. Furthermore, the strength and hardness of trimodal composites were higher, but their ductility was lower.

  6. The effects of microstructural stability on the compressive response of two cast aluminum alloys up to 300 °C

    International Nuclear Information System (INIS)

    Shower, Patrick T.; Technology Division; University of Tennessee, Knoxville, TN; Roy, Shibayan; Technology Division; Indian Institute of Technology; Hawkins, Charles Shane; Technology Division)

    2017-01-01

    Here in this study, the high temperature compressive response of cast aluminum alloys 319 and RR350 is compared in light of their microstructures. The 319 alloy is widely used in thermally critical automotive applications and provides a baseline for comparison with the RR350 alloy, whose microstructural stability at high homologous temperatures was recently reported. Cylindrical compression samples from each alloy were tested at four temperatures up to 300 °C at a constant true strain rate that was varied over four orders of magnitude. Although both alloys are strengthened by metastable precipitates (nominally Al 2 Cu) in the as-aged condition, their mechanical response diverges at temperatures greater than 250 °C as the strengthening precipitates evolve in the 319 alloy and retain their as-aged morphology in the RR350 alloy. Deformation mechanisms of each alloy are examined using microstructural analysis and empirical activation energy calculations. The stability of the θ' phase in the RR350 alloy leads to effective precipitation hardening at homologous temperatures up to 0.6 and an extensive regime of grain boundary controlled deformation.

  7. Stress Corrosion Cracking of Certain Aluminum Alloys

    Science.gov (United States)

    Hasse, K. R.; Dorward, R. C.

    1983-01-01

    SC resistance of new high-strength alloys tested. Research report describes progress in continuing investigation of stress corrosion (SC) cracking of some aluminum alloys. Objective of program is comparing SC behavior of newer high-strength alloys with established SC-resistant alloy.

  8. Influence of Casting Defects on S- N Fatigue Behavior of Ni-Al Bronze

    Science.gov (United States)

    Sarkar, Aritra; Chakrabarti, Abhishek; Nagesha, A.; Saravanan, T.; Arunmuthu, K.; Sandhya, R.; Philip, John; Mathew, M. D.; Jayakumar, T.

    2015-02-01

    Nickel-aluminum bronze (NAB) alloys have been used extensively in marine applications such as propellers, couplings, pump casings, and pump impellers due to their good mechanical properties such as tensile strength, creep resistance, and corrosion resistance. However, there have been several instances of in-service failure of the alloy due to high cycle fatigue (HCF). The present paper aims at characterizing the casting defects in this alloy through X-ray radiography and X-ray computed tomography into distinct defect groups having particular defect size and location. HCF tests were carried out on each defect group of as-cast NAB at room temperature by varying the mean stress. A significant decrease in the HCF life was observed with an increase in the tensile mean stress, irrespective of the defect size. Further, a considerable drop in the HCF life was observed with an increase in the size of defects and proximity of the defects to the surface. However, the surface proximity indicated by location of the defect in the sample was seen to override the influence of defect size and maximum cyclic stress. This leads to huge scatter in S- N curve. For a detailed quantitative analysis of defect size and location, an empirical model is developed which was able to minimize the scatter to a significant extent. Further, a concept of critical distance is proposed, beyond which the defect would not have a deleterious consequence on the fatigue behavior. Such an approach was found to be suitable for generating S- N curves for cast NAB.

  9. Hydroxyapatite scaffolds processed using a TBA-based freeze-gel casting/polymer sponge technique.

    Science.gov (United States)

    Yang, Tae Young; Lee, Jung Min; Yoon, Seog Young; Park, Hong Chae

    2010-05-01

    A novel freeze-gel casting/polymer sponge technique has been introduced to fabricate porous hydroxyapatite scaffolds with controlled "designer" pore structures and improved compressive strength for bone tissue engineering applications. Tertiary-butyl alcohol (TBA) was used as a solvent in this work. The merits of each production process, freeze casting, gel casting, and polymer sponge route were characterized by the sintered microstructure and mechanical strength. A reticulated structure with large pore size of 180-360 microm, which formed on burn-out of polyurethane foam, consisted of the strut with highly interconnected, unidirectional, long pore channels (approximately 4.5 microm in dia.) by evaporation of frozen TBA produced in freeze casting together with the dense inner walls with a few, isolated fine pores (<2 microm) by gel casting. The sintered porosity and pore size generally behaved in an opposite manner to the solid loading, i.e., a high solid loading gave low porosity and small pore size, and a thickening of the strut cross section, thus leading to higher compressive strengths.

  10. Study on the Optimum Cutting Parameters of an Aluminum Mold for Effective Bonding Strength of a PDMS Microfluidic Device

    Directory of Open Access Journals (Sweden)

    Caffiyar Mohamed Yousuff

    2017-08-01

    Full Text Available Master mold fabricated using micro milling is an easy way to develop the polydimethylsiloxane (PDMS based microfluidic device. Achieving high-quality micro-milled surface is important for excellent bonding strength between PDMS and glass slide. The aim of our experiment is to study the optimal cutting parameters for micro milling an aluminum mold insert for the production of a fine resolution microstructure with the minimum surface roughness using conventional computer numerical control (CNC machine systems; we also aim to measure the bonding strength of PDMS with different surface roughnesses. Response surface methodology was employed to optimize the cutting parameters in order to obtain high surface smoothness. The cutting parameters were demonstrated with the following combinations: 20,000 rpm spindle speed, 50 mm/min feed rate, depth of cut 5 µm with tool size 200 µm or less; this gives a fine resolution microstructure with the minimum surface roughness and strong bonding strength between PDMS–PDMS and PDMS–glass.

  11. Fractography of STIR casted Al-ZrO2 composites

    International Nuclear Information System (INIS)

    Baghchesara, M. A.; Abdizadeh, H.; Baharvandi, H. R.

    2009-01-01

    In this study, Al-ZrO 2 composites were produced by Vortex method using ZrO 2 powder with 1 micron average diameter as reinforce particles and Al-356 as the matrix metal. The melt composites were stirred for 13 minutes, then casted into a metallic mold. Different samples of 5, 10 and 15 volume percent of ZrO 2 , in different casting temperatures of 750, 850 and 950 d eg C were produced. The latter 2 casting temperatures are not a common practice but were chosen to enhance fluidity. Effects of volume percent of ZrO 2 particles and casting temperature on tensile strength, microstructure, and fracture surfaces of Al-ZrO 2 composites have been investigated. The highest tensile strength was achieved in the specimen containing 15 vol. % ZrO 2 produced at 750 d eg C which shows an increase of 60% in comparison to the Al-356 non-reinforced alloy. Microscopic investigations of fracture surfaces revealed that fracture in a brittle manner with little or no necking happening. By increasing ZrO 2 content and casting temperature, the composites fracture goes in a more severely brittle manner.

  12. Properties of welded joints in laser welding of aeronautic aluminum-lithium alloys

    Science.gov (United States)

    Malikov, A. G.; Orishich, A. M.

    2017-01-01

    The work presents the experimental investigation of the laser welding of the aluminum-lithium alloys (system Al-Mg-Li) and aluminum alloy (system Al-Cu-Li) doped with Sc. The influence of the nano-structuring of the surface layer welded joint by the cold plastic deformation method on the strength properties of the welded joint is determined. It is founded that, regarding the deformation degree over the thickness, the varying value of the welded joint strength is different for these aluminum alloys.

  13. Influence of Orientation and Radiative Heat Transfer on Aluminum Foams in Buoyancy-Induced Convection

    Science.gov (United States)

    Billiet, Marijn; De Schampheleire, Sven; Huisseune, Henk; De Paepe, Michel

    2015-01-01

    Two differently-produced open-cell aluminum foams were compared to a commercially available finned heat sink. Further, an aluminum plate and block were tested as a reference. All heat sinks have the same base plate dimensions of four by six inches. The first foam was made by investment casting of a polyurethane preform and has a porosity of 0.946 and a pore density of 10 pores per linear inch. The second foam is manufactured by casting over a solvable core and has a porosity of 0.85 and a pore density of 2.5 pores per linear inch. The effects of orientation and radiative heat transfer are experimentally investigated. The heat sinks are tested in a vertical and horizontal orientation. The effect of radiative heat transfer is investigated by comparing a painted/anodized heat sink with an untreated one. The heat flux through the heat sink for a certain temperature difference between the environment and the heat sink’s base plate is used as the performance indicator. For temperature differences larger than 30 ∘C, the finned heat sink outperforms the in-house-made aluminum foam heat sink on average by 17%. Furthermore, the in-house-made aluminum foam dissipates on average 12% less heat than the other aluminum foam for a temperature difference larger than 40 ∘C. By painting/anodizing the heat sinks, the heat transfer rate increased on average by 10% to 50%. Finally, the thermal performance of the horizontal in-house-made aluminum foam heat sink is up to 18% larger than the one of the vertical aluminum foam heat sink. PMID:28793601

  14. Influence of Orientation and Radiative Heat Transfer on Aluminum Foams in Buoyancy-Induced Convection

    Directory of Open Access Journals (Sweden)

    Marijn Billiet

    2015-10-01

    Full Text Available Two differently-produced open-cell aluminum foams were compared to a commercially available finned heat sink. Further, an aluminum plate and block were tested as a reference. All heat sinks have the same base plate dimensions of four by six inches. The first foam was made by investment casting of a polyurethane preform and has a porosity of 0.946 and a pore density of 10 pores per linear inch. The second foam is manufactured by casting over a solvable core and has a porosity of 0.85 and a pore density of 2.5 pores per linear inch. The effects of orientation and radiative heat transfer are experimentally investigated. The heat sinks are tested in a vertical and horizontal orientation. The effect of radiative heat transfer is investigated by comparing a painted/anodized heat sink with an untreated one. The heat flux through the heat sink for a certain temperature difference between the environment and the heat sink’s base plate is used as the performance indicator. For temperature differences larger than 30 °C, the finned heat sink outperforms the in-house-made aluminum foam heat sink on average by 17%. Furthermore, the in-house-made aluminum foam dissipates on average 12% less heat than the other aluminum foam for a temperature difference larger than 40 °C. By painting/anodizing the heat sinks, the heat transfer rate increased on average by 10% to 50%. Finally, the thermal performance of the horizontal in-house-made aluminum foam heat sink is up to 18% larger than the one of the vertical aluminum foam heat sink.

  15. Higher Strength, Lighter Weight Aluminum Spacecraft Structures, Phase I

    Data.gov (United States)

    National Aeronautics and Space Administration — This SBIR Phase I program proposes to develop a bulk processing technology for producing ultra fine grain (UFG) aluminum alloy structures. The goal is to demonstrate...

  16. Crystallization characteristics of cast aluminum alloys during a unidirectional solidification process

    Energy Technology Data Exchange (ETDEWEB)

    Okayasu, Mitsuhiro, E-mail: mitsuhiro.okayasu@utoronto.ca; Takeuchi, Shuhei

    2015-05-01

    The crystal orientation characteristics of cast Al–Si, Al–Cu and Al–Mg alloys produced by a unidirectional solidification process are examined. Two distinct crystal orientation patterns are observed: uniform and random formation. A uniform crystal orientation is created by columnar growth of α-Al dendrites in the alloys with low proportions of alloying element, e.g., the Al–Si alloy (with Si <12.6%) and the Al–Cu and Al–Mg alloys (with Cu and Mg <2%). A uniformly organized crystal orientation with [100] direction is created by columnar growth of α-Al dendrites. With increasing proportion of alloying element (>2% Cu or Mg), the uniform crystal orientations collapse in the Al–Cu and Al–Mg alloys, owing to interruption of the columnar α-Al dendrite growth as a result of different dynamics of the alloying atoms and the creation of a core for the eutectic phases. For the hypo-eutectic Al–Si alloys, a uniform crystal orientation is obtained. In contrast, a random orientation can be detected in the hyper-eutectic Al–Si alloy (15% Si), which results from interruption of the growth of the α-Al dendrites due to precipitation of primary Si particles. There is no clear effect of crystal formation on ultimate tensile strength (UTS), whereas crystal orientation does influence the material ductility, with the alloys with a uniform crystal orientation being elongated beyond their UTS points and with necking occurring in the test specimens. In contrast, the alloys with a nonuniform crystal orientation are not elongated beyond their UTS points.

  17. Crystallization characteristics of cast aluminum alloys during a unidirectional solidification process

    International Nuclear Information System (INIS)

    Okayasu, Mitsuhiro; Takeuchi, Shuhei

    2015-01-01

    The crystal orientation characteristics of cast Al–Si, Al–Cu and Al–Mg alloys produced by a unidirectional solidification process are examined. Two distinct crystal orientation patterns are observed: uniform and random formation. A uniform crystal orientation is created by columnar growth of α-Al dendrites in the alloys with low proportions of alloying element, e.g., the Al–Si alloy (with Si <12.6%) and the Al–Cu and Al–Mg alloys (with Cu and Mg <2%). A uniformly organized crystal orientation with [100] direction is created by columnar growth of α-Al dendrites. With increasing proportion of alloying element (>2% Cu or Mg), the uniform crystal orientations collapse in the Al–Cu and Al–Mg alloys, owing to interruption of the columnar α-Al dendrite growth as a result of different dynamics of the alloying atoms and the creation of a core for the eutectic phases. For the hypo-eutectic Al–Si alloys, a uniform crystal orientation is obtained. In contrast, a random orientation can be detected in the hyper-eutectic Al–Si alloy (15% Si), which results from interruption of the growth of the α-Al dendrites due to precipitation of primary Si particles. There is no clear effect of crystal formation on ultimate tensile strength (UTS), whereas crystal orientation does influence the material ductility, with the alloys with a uniform crystal orientation being elongated beyond their UTS points and with necking occurring in the test specimens. In contrast, the alloys with a nonuniform crystal orientation are not elongated beyond their UTS points

  18. Modeling and sensitivity analysis on the transport of aluminum oxide nanoparticles in saturated sand: effects of ionic strength, flow rate, and nanoparticle concentration.

    Science.gov (United States)

    Rahman, Tanzina; Millwater, Harry; Shipley, Heather J

    2014-11-15

    Aluminum oxide nanoparticles have been widely used in various consumer products and there are growing concerns regarding their exposure in the environment. This study deals with the modeling, sensitivity analysis and uncertainty quantification of one-dimensional transport of nano-sized (~82 nm) aluminum oxide particles in saturated sand. The transport of aluminum oxide nanoparticles was modeled using a two-kinetic-site model with a blocking function. The modeling was done at different ionic strengths, flow rates, and nanoparticle concentrations. The two sites representing fast and slow attachments along with a blocking term yielded good agreement with the experimental results from the column studies of aluminum oxide nanoparticles. The same model was used to simulate breakthrough curves under different conditions using experimental data and calculated 95% confidence bounds of the generated breakthroughs. The sensitivity analysis results showed that slow attachment was the most sensitive parameter for high influent concentrations (e.g. 150 mg/L Al2O3) and the maximum solid phase retention capacity (related to blocking function) was the most sensitive parameter for low concentrations (e.g. 50 mg/L Al2O3). Copyright © 2014 Elsevier B.V. All rights reserved.

  19. Modeling of high temperature- and diffusion-controlled die soldering in aluminum high pressure die casting

    DEFF Research Database (Denmark)

    Domkin, Konstantin; Hattel, Jesper Henri; Thorborg, Jesper

    2009-01-01

    of the die lifetime based on a quantitative analysis of die soldering in the framework of the numerical simulations of the die-casting process. Full 3D simulations of the process, including the filling. solidification, and the die cooling, are carried out using the casting simulation software MAGMAsoft....... The resulting transient temperature fields on the die surface and in the casting are then post-processed to estimate the die soldering. The present work deals only with the metallurgical/chemical kind of soldering which occurs at high temperatures and involves formation and growth of intermetallic layers...

  20. Computation material science of structural-phase transformation in casting aluminium alloys

    Science.gov (United States)

    Golod, V. M.; Dobosh, L. Yu

    2017-04-01

    Successive stages of computer simulation the formation of the casting microstructure under non-equilibrium conditions of crystallization of multicomponent aluminum alloys are presented. On the basis of computer thermodynamics and heat transfer during solidification of macroscale shaped castings are specified the boundary conditions of local heat exchange at mesoscale modeling of non-equilibrium formation the solid phase and of the component redistribution between phases during coalescence of secondary dendrite branches. Computer analysis of structural - phase transitions based on the principle of additive physico-chemical effect of the alloy components in the process of diffusional - capillary morphological evolution of the dendrite structure and the o of local dendrite heterogeneity which stochastic nature and extent are revealed under metallographic study and modeling by the Monte Carlo method. The integrated computational materials science tools at researches of alloys are focused and implemented on analysis the multiple-factor system of casting processes and prediction of casting microstructure.

  1. Performance of casting aluminum-silicon alloy condensing heating exchanger for gas-fired boiler

    Science.gov (United States)

    Cao, Weixue; Liu, Fengguo; You, Xue-yi

    2018-01-01

    Condensing gas boilers are widely used due to their high heat efficiency, which comes from their ability to use the recoverable sensible heat and latent heat in flue gas. The condensed water of the boiler exhaust has strong corrosion effect on the heat exchanger, which restricts the further application of the condensing gas boiler. In recent years, a casting aluminum-silicon alloy (CASA), which boasts good anti-corrosion properties, has been introduced to condensing hot water boilers. In this paper, the heat transfer performance, CO and NOx emission concentrations and CASA corrosion resistance of a heat exchanger are studied by an efficiency bench test of the gas-fired boiler. The experimental results are compared with heat exchangers produced by Honeywell and Beka. The results show that the excess air coefficient has a significant effect on the heat efficiency and CO and NOx emission of the CASA water heater. When the excess air coefficient of the CASA gas boiler is 1.3, the CO and NOx emission concentration of the flue gas satisfies the design requirements, and the heat efficiency of water heater is 90.8%. In addition, with the increase of heat load rate, the heat transfer coefficient of the heat exchanger and the heat efficiency of the water heater are increased. However, when the heat load rate is at 90%, the NOx emission in the exhaust gas is the highest. Furthermore, when the temperature of flue gas is below 57 °C, the condensation of water vapor occurs, and the pH of condensed water is in the 2.5 5.5 range. The study shows that CASA water heater has good corrosion resistance and a high heat efficiency of 88%. Compared with the heat exchangers produced by Honeywell and Beka, there is still much work to do in optimizing and improving the water heater.

  2. Grain size effect on yield strength of titanium alloy implanted with aluminum ions

    Energy Technology Data Exchange (ETDEWEB)

    Popova, Natalya, E-mail: natalya-popova-44@mail.ru [Tomsk State University of Architecture and Building, 2, Solyanaya Sq., 634003, Tomsk (Russian Federation); Institute of Strength Physics and Materials Science, SB RAS, 2/4, Akademicheskii Ave., 634021, Tomsk (Russian Federation); Nikonenko, Elena, E-mail: vilatomsk@mail.ru [Tomsk State University of Architecture and Building, 2, Solyanaya Sq., 634003, Tomsk (Russian Federation); National Research Tomsk Polytechnic University, 30, Lenin Str., 634050, Tomsk (Russian Federation); Yurev, Ivan, E-mail: yiywork@mail.ru [Tomsk State University of Architecture and Building, 2, Solyanaya Sq., 634003, Tomsk (Russian Federation); Kalashnikov, Mark, E-mail: kmp1980@mail.ru [Institute of Strength Physics and Materials Science, SB RAS, 2/4, Akademicheskii Ave., 634021, Tomsk (Russian Federation); Kurzina, Irina, E-mail: kurzina99@mail.ru [National Research Tomsk State University, 36, Lenin Str., 634050, Tomsk (Russian Federation)

    2016-01-15

    The paper presents a transmission electron microscopy (TEM) study of the microstructure and phase state of commercially pure titanium VT1-0 implanted by aluminum ions. This study has been carried out before and after the ion implantation for different grain size, i.e. 0.3 µm (ultra-fine grain condition), 1.5 µm (fine grain condition), and 17 µm (polycrystalline condition). This paper presents details of calculations and analysis of strength components of the yield stress. It is shown that the ion implantation results in a considerable hardening of the entire thickness of the implanted layer in the both grain types. The grain size has, however, a different effect on the yield stress. So, both before and after the ion implantation, the increase of the grain size leads to the decrease of the alloy hardening. Thus, hardening in ultra-fine and fine grain alloys increased by four times, while in polycrystalline alloy it increased by over six times.

  3. In-situ reactions in hybrid aluminum alloy composites during incorporating silica sand in aluminum alloy melts

    Directory of Open Access Journals (Sweden)

    Benjamin F. Schultz

    2016-07-01

    Full Text Available In order to gain a better understanding of the reactions and strengthening behavior in cast aluminum alloy/silica composites synthesized by stir mixing, experiments were conducted to incorporate low cost foundry silica sand into aluminum composites with the use of Mg as a wetting agent. SEM and XRD results show the conversion of SiO2 to MgAl2O4 and some Al2O3 with an accompanying increase in matrix Si content. A three-stage reaction mechanism proposed to account for these changes indicates that properties can be controlled by controlling the base Alloy/SiO2/Mg chemistry and reaction times. Experimental data on changes of composite density with increasing reaction time and SiO2 content support the three-stage reaction model. The change in mechanical properties with composition and time is also described.

  4. Cast iron repair method of stitching pin

    International Nuclear Information System (INIS)

    Yun, In Sik; Yu, Yeong Chul; Kim, Steve S.; Reed, Gary J.

    2003-01-01

    Many cast iron parts are welded and suffer from improper pre-heating and poor welding skills which destroy the castings due to new cracks, deformations etc. This is due mainly to the lack of understanding of the properties of cast iron. Welding, however impractical, was the only alternative for many years. Locks are used to add strength across a crack. Special drilling jigs are used to create a precise hole pattern that locks are driven into. Our locks have a unique ability to pull the sides of a crack together. Bottom locks are stacked or laminated to a depth of 80% of the casting thickness. Thicker surface locks finish off lock installation, allowing repairs in irregular shapes and contours. Installing products can be done quickly with pneumatic tools. Up to one inch of repair can be done in 5 minutes in 1/4 inch thick cast iron.

  5. Refining processes in the copper casting technology

    OpenAIRE

    Rzadkosz, S.; Kranc, M.; Garbacz-Klempka, A.; Kozana, J.; Piękoś, M.

    2015-01-01

    The paper presents the analysis of technology of copper and alloyed copper destined for power engineering casts. The casts quality was assessed based on microstructure, chemical content analysis and strength properties tests. Characteristic deoxidising (Logas, Cup) and modifying (ODM2, Kupmod2) formulas were used for the copper where high electrical conductivity was required. Chosen examples of alloyed copper with varied Cr and Zr content were studied, and the optimal heat treatment parameter...

  6. Cast-concrete products made with FBC ash and wet-collected coal-ash

    Energy Technology Data Exchange (ETDEWEB)

    Naik, T.R.; Kraus, R.N.; Chun, Y.M.; Botha, F.D. [University of Wisconsin, Milwaukee, WI (United States)

    2005-12-01

    Cast-concrete hollow blocks, solid blocks, and paving stones were produced at a manufacturing plant by replacing up to 45% (by mass) of portland cement with fluidized bed combustion (FBC) coal ash and up to 9% of natural aggregates with wet-collected, low-lime, coarse coal-ash (WA). Cast-concrete product specimens of all three types exceeded the compressive strength requirements of ASTM from early ages, with the exception of one paving-stone mixture, which fell short of the requirement by less than 10%. The cast-concrete products made by replacing up to 40% of cement with FBC ash were equivalent in strength (89-113% of control) to the products without ash. The abrasion resistance of paving stones was equivalent for up to 34% FBC ash content. Partial replacement of aggregates with WA decreased strength of the products. The resistance of hollow blocks and paving stones to freezing and thawing decreased appreciably with increasing ash contents. The cast-concrete products could be used indoors in regions where freezing and thawing is a concern, and outdoors in a moderate climate.

  7. Numerical simulation and optimization of Al alloy cylinder body by low pressure die casting

    Directory of Open Access Journals (Sweden)

    Mi Guofa

    2008-05-01

    Full Text Available Shrinkage defects can be formed easily at Critical location during low pressure die casting (LPDC of aluminum alloy cylinder body. It has harmful effect on the products. Mold fi lling and solidifi cation process of a cylinder body was simulated by using of Z-CAST software. The casting method was improved based on the simulation results. In order to create effective feeding passage, the structure of casting was modifi ed by changing the location of strengthening ribs at the bottom, without causing any adverse effect on the part’s performance. Inserting copper billet at suitable location of the die is a valid way to create suitable solidifi cation sequence that is benefi cial to the feeding. Using these methods, the shrinkage defect was completely eliminated at the critical location.

  8. Cross accumulative roll bonding—A novel mechanical technique for significant improvement of stir-cast Al/Al2O3 nanocomposite properties

    International Nuclear Information System (INIS)

    Ardakani, Mohammad Reza Kamali; Amirkhanlou, Sajjad; Khorsand, Shohreh

    2014-01-01

    Lightweight metal-matrix nanocomposites (MMNCs—metal matrix with nanosized ceramic particles) can be of significance for automobile, aerospace, and numerous other applications. There are some problems in obtaining suitable mechanical properties of MMNCs, including weak bonding between reinforcement and matrix, non-uniformity of reinforcement nanoparticles and high porosity content. In this study, aluminum/alumina nanocomposite was fabricated by stircasting method. Subsequently, cross accumulative roll bonding (CARB) process was used as an effective method for refinement of microstructure and improvement of mechanical properties. The microstructural evolution and the mechanical properties of the nanocomposites during various CARB cycles were examined by the Archimedes method, X-ray defractometer, scanning electron microscopy and tensile testing. The results showed that the microstructure of the nanocomposite after eight cycles of CARB had an excellent distribution of alumina nanoparticles in aluminum matrix without any remarkable porosity. The X-ray diffraction results showed that the crystallite size of the nanocomposite was 71 nm by employing eight cycles of CARB technique. Mechanical experiment also indicated that the ultimate tensile strength and the elongation of the nanocomposite increased as the number of CARB cycles increased. After eight CARB cycles, ultimate tensile strength and the elongation values reached 344 MPa and 6.4%, which were 3.13 and 3.05 times greater than those of as-cast nanocomposites, respectively

  9. Fatigue strength of nodular cast iron with regard to heavy-wall applications

    Energy Technology Data Exchange (ETDEWEB)

    Bleicher, Christoph; Wagener, Rainer; Kaufmann, Heinz [Fraunhofer-Institut fuer Betriebsfestigkeit und Systemzuverlaessigkeit LBF, Darmstadt (Germany); Melz, Tobias [Fraunhofer-Institut fuer Betriebsfestigkeit und Systemzuverlaessigkeit LBF, Darmstadt (Germany); TU Darmstadt (Germany). Faculty of Mechanical Engineering

    2015-11-01

    For a proper estimation of the fatigue life of a heavy-walled cast component made of nodular cast iron, sufficient knowledge regarding the cyclic properties of the material is necessary. Based on the material parameters at hand for component design, different fatigue analysis procedures can be used. Elastic and elastic-plastic approaches can be adopted, with the latter being reserved only for local approaches. The present publication summarizes the cyclic material parameters gained during a research project by extensive material tests under stress and strain controlled cyclic loading at different load ratios for three nodular cast iron grades. In addition to an improved knowledge of the cyclic material behavior, the notch, the size effects and the mean stress sensitivity were of special concern during the investigations in order to provide an entire overview of the tested materials and thus input information for both stress and strain based design approaches. Tests were performed for specimens taken from large cast blocks of the nodular cast iron grades EN-GJS-400-18U-LT and EN-GJS-450-18, both with ferritic matrices, and EN-GJS-700-2 with a pearlitic matrix. For some of these materials, mean stress sensitivities above 0.5 were obtained during the investigations. These values are not covered by the common standards, which calculate lower values for the mean stress sensitivity. Cyclic material parameters for stress and strain controlled tests are given in this paper as well as values for the size effect, based on the concept of the highly stressed volume. The effect of different specimen sizes could be shown not only by stress but also by strain controlled tests.

  10. Microstructure, hardness and tensile properties of A380 aluminum alloy with and without Li additions

    International Nuclear Information System (INIS)

    Karamouz, Mostafa; Azarbarmas, Mortaza; Emamy, Masoud; Alipour, Mohammad

    2013-01-01

    In this work, the effects of lithium (Li) on the microstructure, hardness and mechanical properties of A380 aluminum alloy have been investigated. The alloy was produced by conventional casting. Microstructures of the samples were investigated using the optical and scanning electron microscopy. The results showed that with increase of Li content up to 0.1%, the morphology of β-Al 5 FeSi and eutectic Si phases changed from intersected and branched coarse platelets into fine and independent ones. Li decreased hardness values of the alloy. Also, it was revealed from tensile tests that with addition of 0.6% Li, the ultimate tensile strength (UTS) and elongation values increased from 274 to 300 MPa and 3.8% to 6%, respectively. Fractographic examination of the fracture surfaces indicated that the alloys with Li addition had more ductile dimple and fewer brittle cleavage surfaces

  11. Effects of erbium modification on the microstructure and mechanical properties of A356 aluminum alloys

    Energy Technology Data Exchange (ETDEWEB)

    Shi, Z.M., E-mail: shizm@imut.edu.cn; Wang, Q.; Zhao, G.; Zhang, R.Y.

    2015-02-25

    The effects of erbium (Er) modification on the microstructure and mechanical properties of A356 aluminum alloys were investigated using optical microscope, X-ray diffraction, scanning electronic microscope and mechanical testing. Experimental results show that additions of Er refined the α-Al grains and eutectic Si phases in its as-cast state; the addition of 0.3 wt% of Er has the best effects on them. The Fe-containing Al{sub 3}Er phases were introduced by the modifications; by a T6 treatment, the eutectic Si phases were further sphereodized; the large Al{sub 3}Er and β-Al{sub 5}FeSi phases were changed into fine particles and short rods; which enhanced the hardness of the alloys. The highest strength and elongation were obtained for the 0.3 wt% of Er-modified and T6-treated A356 alloy.

  12. Improvement of Strength and Energy Absorption Properties of Porous Aluminum Alloy with Aligned Unidirectional Pores Using Equal-Channel Angular Extrusion

    Science.gov (United States)

    Yoshida, Tomonori; Muto, Daiki; Tamai, Tomoya; Suzuki, Shinsuke

    2018-06-01

    Porous aluminum alloy with aligned unidirectional pores was fabricated by dipping A1050 tubes into A6061 semi-solid slurry. The porous aluminum alloy was processed through Equal-channel Angular Extrusion (ECAE) while preventing cracking and maintaining both the pore size and porosity by setting the insert material and loading back pressure. The specific compressive yield strength of the sample aged after 13 passes of ECAE was approximately 2.5 times higher than that of the solid-solutionized sample without ECAE. Both the energy absorption E V and energy absorption efficiency η V after four passes of ECAE were approximately 1.2 times higher than that of the solid-solutionized sample without ECAE. The specific yield strength was improved via work hardening and precipitation following dynamic aging during ECAE. E V was improved by the application of high compressive stress at the beginning of the compression owing to work hardening via ECAE. η V was improved by a steep increase of stress at low compressive strain and by a gradual increase of stress in the range up to 50 pct of compressive strain. The gradual increase of stress was caused by continuous shear fracture in the metallic part, which was due to the high dislocation density and existence of unidirectional pores parallel to the compressive direction in the structure.

  13. Improvement of Strength and Energy Absorption Properties of Porous Aluminum Alloy with Aligned Unidirectional Pores Using Equal-Channel Angular Extrusion

    Science.gov (United States)

    Yoshida, Tomonori; Muto, Daiki; Tamai, Tomoya; Suzuki, Shinsuke

    2018-04-01

    Porous aluminum alloy with aligned unidirectional pores was fabricated by dipping A1050 tubes into A6061 semi-solid slurry. The porous aluminum alloy was processed through Equal-channel Angular Extrusion (ECAE) while preventing cracking and maintaining both the pore size and porosity by setting the insert material and loading back pressure. The specific compressive yield strength of the sample aged after 13 passes of ECAE was approximately 2.5 times higher than that of the solid-solutionized sample without ECAE. Both the energy absorption E V and energy absorption efficiency η V after four passes of ECAE were approximately 1.2 times higher than that of the solid-solutionized sample without ECAE. The specific yield strength was improved via work hardening and precipitation following dynamic aging during ECAE. E V was improved by the application of high compressive stress at the beginning of the compression owing to work hardening via ECAE. η V was improved by a steep increase of stress at low compressive strain and by a gradual increase of stress in the range up to 50 pct of compressive strain. The gradual increase of stress was caused by continuous shear fracture in the metallic part, which was due to the high dislocation density and existence of unidirectional pores parallel to the compressive direction in the structure.

  14. Characterization of Ti6Al4V for integral transition structures in FRP-aluminum compounds

    Energy Technology Data Exchange (ETDEWEB)

    Schimanski, Kai; Schumacher, Jens; Von Hehl, Axel; Zoch, Hans-Werner [Stiftung Institut fuer Werkstofftechnik, Bremen (Germany); Wottschel, Vitalij; Vollertsen, Frank [Bremer Institut fuer Angewandte Strahltechnik, Bremen (Germany)

    2012-08-15

    Components in hybrid design become more and more important in terms of their lightweight potential. In this context, the demand for weight saving in aerospace industry leads to increase numbers of applications of fiber reinforced composites for primary structural components. In consequence, the use of FRP-metal compounds is necessary. In the context of the investigations of the researcher group named ''Black-Silver'' (''Schwarz Silber'', FOR 1224) founded by the DFG (German Research Foundation) material optimized interface structures for advanced carbon fiber reinforced plastic (CFRP)-aluminum compounds are currently being studied. Within their work the researcher group focussed on three concepts realizing the transition structures: the usage of wires (titanium), foils (titanium), and fibers (glass fiber) as transition elements between CFRP and aluminum. For the connection of the aluminum sheet and the transition element die-casting and laser beam welding are basically used. The paper concentrates on the characterization of suitable materials for transition structures. Due to their high strength and low density (in comparison to steel) and the resulting potential in view on light-weight design Ti-alloys were investigated. Because of the increased availability of Ti-wires compared to Ti-foils in suitable thickness the former were used for the basic investigations on Ti-alloys which are suitable for integral transition structures. (Copyright copyright 2012 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

  15. Static and Dynamic Behavior of High Modulus Hybrid Boron/Glass/Aluminum Fiber Metal Laminates

    Science.gov (United States)

    Yeh, Po-Ching

    2011-12-01

    This dissertation presents the investigation of a newly developed hybrid fiber metal laminates (FMLs) which contains commingled boron fibers, glass fibers, and 2024-T3 aluminum sheets. Two types of hybrid boron/glass/aluminum FMLs are developed. The first, type I hybrid FMLs, contained a layer of boron fiber prepreg in between two layers of S2-glass fiber prepreg, sandwiched by two aluminum alloy 2024-T3 sheets. The second, type II hybrid FMLs, contained three layer of commingled hybrid boron/glass fiber prepreg layers, sandwiched by two aluminum alloy 2024-T3 sheets. The mechanical behavior and deformation characteristics including blunt notch strength, bearing strength and fatigue behavior of these two types of hybrid boron/glass/aluminum FMLs were investigated. Compared to traditional S2-glass fiber reinforced aluminum laminates (GLARE), the newly developed hybrid boron/glass/aluminum fiber metal laminates possess high modulus, high yielding stress, and good blunt notch properties. From the bearing test result, the hybrid boron/glass/aluminum fiber metal laminates showed outstanding bearing strength. The high fiber volume fraction of boron fibers in type II laminates lead to a higher bearing strength compared to both type I laminates and traditional GLARE. Both types of hybrid FMLs have improved fatigue crack initiation lives and excellent fatigue crack propagation resistance compared to traditional GLARE. The incorporation of the boron fibers improved the Young's modulus of the composite layer in FMLs, which in turn, improved the fatigue crack initiation life and crack propagation rates of the aluminum sheets. Moreover, a finite element model was established to predict and verify the properties of hybrid boron/glass/aluminum FMLs. The simulated results showed good agreement with the experimental results.

  16. Some properties of aluminum-uranium alloys in the cast, rolled and annealed conditions

    International Nuclear Information System (INIS)

    Jones, T.I.; McGee, I.J.; Norlock, L.R.

    1960-06-01

    The metallographic and hardness changes associated with the rolling and subsequent. annealing of aluminum alloys containing up to 30-wt.% uranium have been described. The alloys possessed good rolling properties. However the richer alloys were unusual in that after an initial reduction,, further cold rolling caused softening. In the alloy range examined, increasing uranium contents caused reduced preferred orientation. Qualitative explanations have been proposed to account for the observations on roll softening and preferred orientation. Heat-treating and ageing experiments confirmed that the solid solubility of uranium in aluminum is negligible. (author)

  17. Improved Interfacial Bonding in Magnesium/Aluminum Overcasting Systems by Aluminum Surface Treatments

    Science.gov (United States)

    Zhang, Hui; Chen, Yiqing; Luo, Alan A.

    2014-12-01

    "Overcasting" technique is used to produce bimetallic magnesium/aluminum (Mg/Al) structures where lightweight Mg can be cast onto solid Al substrates. An inherent difficulty in creating strong Mg/Al interfacial bonding is the natural oxide film on the solid Al surfaces, which reduces the wettability between molten Mg and Al substrates during the casting process. In the paper, an "electropolishing + anodizing" surface treatment has been developed to disrupt the oxide film on a dilute Al-0.08 wt pct Ga alloy, improving the metallurgical bonding between molten Mg and Al substrates in the bimetallic experiments carried out in a high-vacuum test apparatus. The test results provided valuable information of the interfacial phenomena of the Mg/Al bimetallic samples. The results show significantly improved metallurgical bonding in the bimetallic samples with "electropolishing + anodizing" surface treatment and Ga alloying. It is recommended to adjust the pre-heating temperature and time of the Al substrates and the Mg melt temperature to control the interfacial reactions for optimum interfacial properties in the actual overcasting processes.

  18. Fabrication of silk fibroin film using centrifugal casting technique for corneal tissue engineering.

    Science.gov (United States)

    Lee, Min Chae; Kim, Dong-Kyu; Lee, Ok Joo; Kim, Jung-Ho; Ju, Hyung Woo; Lee, Jung Min; Moon, Bo Mi; Park, Hyun Jung; Kim, Dong Wook; Kim, Su Hyeon; Park, Chan Hum

    2016-04-01

    Films prepared from silk fibroin have shown potential as biomaterials in tissue engineering applications for the eye. Here, we present a novel process for fabrication of silk fibroin films for corneal application. In this work, fabrication of silk fibroin films was simply achieved by centrifugal force. In contrast to the conventional dry casting method, we carried out the new process in a centrifuge with a rotating speed of 4000 rpm, where centrifugal force was imposed on an aluminum tube containing silk fibroin solution. In the present study, we also compared the surface roughness, mechanical properties, transparency, and cell proliferation between centrifugal and dry casting method. In terms of surface morphology, films fabricated by the centrifugal casting have less surface roughness than those by the dry casting. For elasticity and transparency, silk fibroin films obtained from the centrifugal casting had favorable results compared with those prepared by dry casting. Furthermore, primary human corneal keratocytes grew better in films prepared by the centrifugal casting. Therefore, our results suggest that this new fabrication process for silk fibroin films offers important potential benefits for corneal tissue regeneration. © 2015 Wiley Periodicals, Inc.

  19. Process for optimizing titanium and zirconium additions to aluminum welding consumables

    International Nuclear Information System (INIS)

    Dvornak, M.J.; Frost, R.H.

    1992-01-01

    This patent describes a process for manufacturing an aluminum welding consumable. It comprises: creating an aluminum melt; adding to the aluminum melt solid pieces of a master alloy, comprising aluminum and a weld-enhancing additive to form a mixture, wherein the weld-enhancing additive being a material selected from the group consisting of titanium and zirconium, so that the weld-enhancing additive exists in the alloy prior to addition to the melt in the form of intermetallic particles relatively large in size and small in number, and after addition to the melt the weld-enhancing additive exists in the form of fractured intermetallic particles of refined size having dissolved fractured interfaces, casting the mixture into a chill mold to form an ingot; reducing the ingot to rods of rough wire dimension by cold rolling; annealing the reduced rods; and drawing the rods into wire

  20. Aluminum fin-stock alloys

    International Nuclear Information System (INIS)

    Gul, R.M.; Mutasher, F.

    2007-01-01

    Aluminum alloys have long been used in the production of heat exchanger fins. The comparative properties of the different alloys used for this purpose has not been an issue in the past, because of the significant thickness of the finstock material. However, in order to make fins lighter in weight, there is a growing demand for thinner finstock materials, which has emphasized the need for improved mechanical properties, thermal conductivity and corrosion resistance. The objective of this project is to determine the effect of iron, silicon and manganese percentage increment on the required mechanical properties for this application by analyzing four different aluminum alloys. The four selected aluminum alloys are 1100, 8011, 8079 and 8150, which are wrought non-heat treatable alloys with different amount of the above elements. Aluminum alloy 1100 serve as a control specimen, as it is commercially pure aluminum. The study also reports the effect of different annealing cycles on the mechanical properties of the selected alloys. Metallographic examination was also preformed to study the effect of annealing on the precipitate phases and the distribution of these phases for each alloy. The microstructure analysis of the aluminum alloys studied indicates that the precipitated phase in the case of aluminum alloys 1100 and 8079 is beta-FeAI3, while in 8011 it is a-alfa AIFeSi, and the aluminum alloy 8150 contains AI6(Mn,Fe) phase. The comparison of aluminum alloys 8011 and 8079 with aluminum alloy 1100 show that the addition of iron and silicon improves the percent elongation and reduces strength. The manganese addition increases the stability of mechanical properties along the annealing range as shown by the comparison of aluminum alloy 8150 with aluminum alloy 1100. Alloy 8150 show superior properties over the other alloys due to the reaction of iron and manganese, resulting in a preferable response to thermal treatment and improved mechanical properties. (author)

  1. Energy and resource efficiency in aluminium die casting

    CERN Document Server

    Heinemann, Tim

    2016-01-01

    This monograph provides a field-proven approach to analyze industrial production with a cross-company scope as well as regarding all hierarchical system levels of manufacturing enterprises. The book exemplifies this approach in the context of aluminum  die casting, and presents a set of measures which allow a 30 percent energy reduction along the value chain. The target audience primarily comprises researchers and experts in the field but the book may also be beneficial for graduate students.

  2. Application of optical scanning for measurements of castings and cores

    Directory of Open Access Journals (Sweden)

    M. Wieczorowski

    2010-01-01

    Full Text Available In the paper application of non destructive method for dimensional control of elements in initial phase of car manufacturing, at Volks-wagen Poznań foundry was presented. VW foundry in Poznań is responsible of series production of chill and dies castings made of light alloys using contemporary technologies. Castings have a complex shape: they are die castings of housings for steering columns and gravity chill castings of cylinder heads, for which cores are manufactured using both hot box and cold box method. Manufacturing capabilities of VW foundry in Poznań reach 26.000 tons of aluminum castings per year. Optical system ATOS at Volkswagen Poznań foundry is used to digitize object and determination of all dimensions and shapes of inspected object. This technology is applied in car industry, reverse engineering, quality analysis and control and to solve many similar tasks. System is based on triangulation: sensor head projects different fringes patterns onto a measured object while scanner observes their trajectories using two cameras. Basing on optical transform equations a processing unit automatically and with a great accuracy calculates 3D coordinates for every pixel of camera. Depending on camera reso-lution as an effect of such a scan we obtain a cloud of up to 4 million points for every single measurement. In the paper examples of di-mensional analysis regarding castings and cores were presented.

  3. Evaluation of the Mechanical Properties of Gray Cast Iron Using Electrical Resistivity Measurement

    Directory of Open Access Journals (Sweden)

    Bieroński M.

    2016-12-01

    Full Text Available In this paper an attempt to determine the relationship between the electrical resistivity and the tensile strength and hardness of cast iron of carbon equivalent in the range from 3.93% to 4.48%. Tests were performed on the gray cast iron for 12 different melts with different chemical composition. From one melt poured 6 samples. Based on the study of mechanical and electro-resistive determined variation characteristics of tensile strength, hardness and resistivity as a function of the carbon equivalent. Then, regression equations were developed as power functions describing the relationship between the resistivity of castings and their tensile strength and hardness. It was found a high level of regression equations to measuring points, particularly with regard to the relationship Rm=f(ρ. The obtained preliminary results indicate the possibility of application of the method of the resistance to rapid diagnostic casts on the production line, when we are dealing with repeatable production, in this case non variable geometry of the product for which it has been determinated before a regression equation.

  4. Modeling of TiAl Alloy Grating by Investment Casting

    Directory of Open Access Journals (Sweden)

    Yi Jia

    2015-12-01

    Full Text Available The investment casting of TiAl alloys has become the most promising cost-effective technique for manufacturing TiAl components. This study aimed to investigate a series of problems associated with the investment casting of TiAl alloys. The mold filling and solidification of this casting model were numerically simulated using ProCAST. Shrinkage porosity was quantitatively predicted by a built-in feeding criterion. The results obtained from the numerical simulations were compared with experiments, which were carried out on Vacuum Skull Furnace using an investment block mold. The investment casting of TiAl grating was conducted for verifying the correctness and feasibility of the proposed method. The tensile test results indicated that, at room temperature, the tensile strength and elongation were approximately 675 MPa and 1.7%, respectively. The microstructure and mechanical property of the investment cast TiAl alloy were discussed.

  5. Alloy Design and Development of Cast Cr-W-V Ferritic Steels for Improved High-Temperature Strength for Power Generation Applications

    Energy Technology Data Exchange (ETDEWEB)

    Klueh, R L; Maziasz, P J; Vitek, J M; Evans, N D; Hashimoto, N

    2006-09-23

    Economic and environmental concerns demand that the power-generation industry seek increased efficiency for gas turbines. Higher efficiency requires higher operating temperatures, with the objective temperature for the hottest sections of new systems {approx} 593 C, and increasing to {approx} 650 C. Because of their good thermal properties, Cr-Mo-V cast ferritic steels are currently used for components such as rotors, casings, pipes, etc., but new steels are required for the new operating conditions. The Oak Ridge National Laboratory (ORNL) has developed new wrought Cr-W-V steels with 3-9% Cr, 2-3% W, 0.25% V (compositions are in wt.%), and minor amounts of additional elements. These steels have the strength and toughness required for turbine applications. Since cast alloys are expected to behave differently from wrought material, work was pursued to develop new cast steels based on the ORNL wrought compositions. Nine casting test blocks with 3, 9, and 11% Cr were obtained. Eight were Cr-W-V-Ta-type steels based on the ORNL wrought steels; the ninth was COST CB2, a 9Cr-Mo-Co-V-Nb cast steel, which was the most promising cast steel developed in a European alloy-development program. The COST CB2 was used as a control to which the new compositions were compared, and this also provided a comparison between Cr-W-V-Ta and Cr-Mo-V-Nb compositions. Heat treatment studies were carried out on the nine castings to determine normalizing-and-tempering treatments. Microstructures were characterized by both optical and transmission electron microscopy (TEM). Tensile, impact, and creep tests were conducted. Test results on the first nine cast steel compositions indicated that properties of the 9Cr-Mo-Co-V-Nb composition of COST CB2 were better than those of the 3Cr-, 9Cr-, and 11Cr-W-V-Ta steels. Analysis of the results of this first iteration using computational thermodynamics raised the question of the effectiveness in cast steels of the Cr-W-V-Ta combination versus the Cr

  6. Effects of silicon, copper and iron on static and dynamic properties of alloy 206 (aluminum-copper) in semi-solids produced by the SEED process

    Science.gov (United States)

    Lemieux, Alain

    The advantages of producing metal parts by rheocasting are generally recognised for common foundry alloys of Al-Si. However, other more performing alloys in terms of mechanical properties could have a great interest in specialized applications in the automotive industry, while remaining competitive in the forming. Indeed, the growing demand for more competitive products requires the development of new alloys better suited to semi-solid processes. Among others, Al-Cu alloys of the 2XX series are known for their superior mechanical strength. However, in the past, 2XX alloys were never candidates for pressure die casting. The main reason is their propensity to hot tearing. Semi-solid processes provide better conditions for molding with the rheological behavior of dough and molding temperatures lower reducing this type of defect. In the initial phase, this research has studied factors that reduce hot tearing susceptibility of castings produced by semi-solid SEED of alloy 206. Subsequently, a comparative study on the tensile properties and fatigue was performed on four variants of the alloy 206. The results of tensile strength and fatigue were compared with the specifications for applications in the automotive industry and also to other competing processes and alloys. During this study, several metallurgical aspects were analyzed. The following main points have been validated: i) the main effects of compositional variations of silicon, iron and copper alloy Al-Cu (206) on the mechanical properties, and ii) certain relationships between the mechanism of hot cracking and the solidification rate in semi-solid. Parts produced from the semi-solid paste coming from the SEED process combined with modified 206 alloys have been successfully molded and achieved superior mechanical properties than the requirements of the automotive industry. The fatigue properties of the two best modified 206 alloys were higher than those of A357 alloy castings and are close to those of the

  7. Scanning Probe Investigation of Pitting Corrosion on Aluminum 5083 H131

    Science.gov (United States)

    2014-05-01

    245–254. 10. Dolic, N.; Malina, J.; Begic Hadzipasic, A. Pit Nucleation on As-Cast Aluminum Alloy AW-5083 in 0.01M NaCl. Journal of Mining and...R. A.; Stratmann, M. Application of a Kelvin Microprobe to the Corrosion in Humid Atmospheres. J. Electrochem Soc. 1991, 138 (1), 55–61. 15

  8. Properties Improvement of Cast Stone Produced Using Recycled Glass Waste and Lightweight Aggregates

    Directory of Open Access Journals (Sweden)

    Elham Abd AL-Majeed

    2018-01-01

    Full Text Available Cast stone (CS is a form of pre-cast concrete widely, used in architectural applications for decorating and building face in place of natural stone due its superior features. The present study was an attempt in using of local lightweight aggregate materials (LWAM as an alternative to percentage of coarse aggregate, and glass wastes as alternatives to percentages of fine aggregate in cast stone normal mixtures with white cement and plasticizer admixture. The CS products were cured after 24 hrs using of two different processes: water curing (at 23 C° for 3 days and steam curing (at 60 C° for 14 hrs. Then the products were characterized by tests of compressive strength, design, absorption, flexure strength and liner drying shrinkage. The addition of alternative materials was done by trial mixes (M0-M3 through 3 groups (A, B, and C according to standards. Group A: design of reference mixtures of CS with compressive strength of 46.3 MPa and the absorption of 6.19%, Group B: design of mixtures containing 50% LWA were 16% lighter than those of Group A with compressive strength of 43.6 MPa and 11% improvement in the absorption, Group C: design of mixtures containing (50 and 75% glass waste with compressive strength of (47.5-44.3 MPa and the absorption of (5.3-4.7%, respectively. The modified steam curing process (curing after 24 hrs casting done in this study could prove its effectiveness in the achievement of the required compressive strength in comparison with the normal process (direct curing after casting due to the effect of such new process in providing the more uniform distribution of the cement gel with good physical properties. Results from the flexural strength test could prove the achievement of the required levels (6.9 – 6.3 at 50 – 75% glass waste addition recorded in the standard.

  9. Influence of ceramic particulate type on microstructure and tensile strength of aluminum matrix composites produced using friction stir processing

    Directory of Open Access Journals (Sweden)

    I. Dinaharan

    2016-06-01

    Full Text Available Friction stir processing (FSP was applied to produce aluminum matrix composites (AMCs. Aluminum alloy AA6082 was used as the matrix material. Various ceramic particles, such as SiC, Al2O3, TiC, B4C and WC, were used as reinforcement particle. AA6082 AMCs were produced using a set of optimized process parameters. The microstructure was studied using optical microscopy, filed emission scanning electron microscopy and electron back scattered diagram. The results indicated that the type of ceramic particle did not considerably vary the microstructure and ultimate tensile strength (UTS. Each type of ceramic particle provided a homogeneous dispersion in the stir zone irrespective of the location and good interfacial bonding. Nevertheless, AA6082/TiC AMC exhibited superior hardness and wear resistance compared to other AMCs produced in this work under the same set of experimental conditions. The strengthening mechanisms and the variation in the properties are correlated to the observed microstructure. The details of fracture mode are further presented.

  10. Search for chameleons with CAST

    DEFF Research Database (Denmark)

    Anastassopoulos, V.; Arik, M.; Aune, S.

    2015-01-01

    In this work we present a search for (solar) chameleons with the CERN Axion Solar Telescope (CAST). This novel experimental technique, in the field of dark energy research, exploits both the chameleon coupling to matter (βm) and to photons (βΥ) via the Primako eect. By reducing the X-ray detection...... energy threshold used for axions from 1 keV to 400 eV CAST became sensitive to the converted solar chameleon spectrum which peaks around 600 eV. Even though we have not observed any excess above background, we can provide a 95% C.L. limit for the coupling strength of chameleons to photons of βΥ≤1011...

  11. Effect of low frequency electromagnetic field on microstructures and macrosegregation of horizontal direct chill casting aluminum alloy

    Institute of Scientific and Technical Information of China (English)

    赵志浩; 崔建忠; 董杰; 张海涛; 张北江

    2004-01-01

    The influences of low frequency electromagnetic field on cast surface, microstructures and macrosegregation in horizontal direct chill(HDC) casting process were investigated experimentally. The cast surfaces, microstructures and macrosegregation of the ingots manufactured by conventional HDC and low frequency electromagnetic HDC casting were compared. The results show that low frequency electromagnetic field significantly improves the surface quality, refines the microstructures and reduces macrosegregation. Further more, increasing electromagnetic intensity or decreasing frequency is beneficial to the improvement. In the range of ampere-turns and frequency employed in the experiments, the optimum ampere-turns is found to be 10 000 A · turn and the frequency to be 30 Hz.

  12. Micro-structure and Air-tightness of Squeeze Casting Motor housing for New Energy Vehicle

    Science.gov (United States)

    Jiang, Y. F.; Kang, Z. Q.; Jiang, W. F.; Wang, K. W.; Sha, D. L.; Li, M. L.; Sun, J.

    2018-05-01

    In order to improve the performance of automobile parts, the influence of squeeze casting process parameters on casting defects, material structure and air-tightness of aluminum alloy motor housing for new energy vehicle was studied. The results show that the density of the castings increases with the increase in pressure and mold temperature. With increase in pouring temperature, it increases first and then decreases. Pressure has the greatest influence on the density of the castings. Under a certain pressure, with moderate increase in casting temperature and mold temperature, the grain growth begins to increase; the dendrites become less, the new α - Al grains are spherical and granular, the micro-structure is uniform. Also, with increase in pressure, this effect is more pronounced, the air-tightness of castings improve. In conclusion, when the pressure is 110MPa, pouring temperature is 680° C, mold temperature is 280° C, pressure holding for 30s, and punch speed of 0.1m/s, there is no clear shrinkage in the casting, the structure is uniform, the qualified rate of air-tightness of production reaches 86%, and the performance is excellent.

  13. Cast iron - a predictable material

    Directory of Open Access Journals (Sweden)

    Jorg C. Sturm

    2011-02-01

    Full Text Available High strength compacted graphite iron (CGI or alloyed cast iron components are substituting previously used non-ferrous castings in automotive power train applications. The mechanical engineering industry has recognized the value in substituting forged or welded structures with stiff and light-weight cast iron castings. New products such as wind turbines have opened new markets for an entire suite of highly reliable ductile iron cast components. During the last 20 years, casting process simulation has developed from predicting hot spots and solidification to an integral assessment tool for foundries for the entire manufacturing route of castings. The support of the feeding related layout of the casting is still one of the most important duties for casting process simulation. Depending on the alloy poured, different feeding behaviors and self-feeding capabilities need to be considered to provide a defect free casting. Therefore, it is not enough to base the prediction of shrinkage defects solely on hot spots derived from temperature fields. To be able to quantitatively predict these defects, solidification simulation had to be combined with density and mass transport calculations, in order to evaluate the impact of the solidification morphology on the feeding behavior as well as to consider alloy dependent feeding ranges. For cast iron foundries, the use of casting process simulation has become an important instrument to predict the robustness and reliability of their processes, especially since the influence of alloying elements, melting practice and metallurgy need to be considered to quantify the special shrinkage and solidification behavior of cast iron. This allows the prediction of local structures, phases and ultimately the local mechanical properties of cast irons, to asses casting quality in the foundry but also to make use of this quantitative information during design of the casting. Casting quality issues related to thermally driven

  14. ON THE REACTIONS IN ILMENITE, ALUMINUM AND GRAPHITE SYSTEM

    Directory of Open Access Journals (Sweden)

    R. Khoshhal

    2016-03-01

    Full Text Available Al2O3/TiC composites are used as cutting tools for machining gray cast iron and steels. The addition of iron improves the toughness of Al2O3/TiC composites. Ilmenite, aluminum and graphite can be used to produce in-situ Al2O3/TiC–Fe composites. However, the formation mechanism and reaction sequences of this system are not clear enough. Therefore, the present research is designed to determine the reactions mechanism of the first step of reactions that may be occurred between raw materials. In this research, pure ilmenite was synthesized to eliminate the effects of impurities available in the natural ilmenite in the system. The milled and pressed samples, prepared from the synthesized ilmenite, aluminum and graphite mixture with a molar ratio of 1:2:1, were heat treated at 720°C for 48h. In addition, two samples one containing ilmenite and aluminum with a molar ratio of 1:2 and ilmenite and graphite with a molar ratio of 1:1 were heat treated at 720°C for 48h. The final products were analyzed with XRD. It was found that at 720°C, aluminum reacts with FeTiO3, forming Fe, TiO2 and Al2O3. Since the aluminum content used in the mixture was more than the stoichiometry for reaction of ilmenite and aluminum, some unreacted aluminum remains. Therefore, the residual aluminum reacts with the reduced Fe to form Fe2Al5.

  15. Influence of multi-step heat treatments in creep age forming of 7075 aluminum alloy: Optimization for springback, strength and exfoliation corrosion

    Energy Technology Data Exchange (ETDEWEB)

    Arabi Jeshvaghani, R.; Zohdi, H. [Department of Materials Engineering, Tarbiat Modares University, P.O. Box 14115-143, Tehran (Iran, Islamic Republic of); Shahverdi, H.R., E-mail: shahverdi@modares.ac.ir [Department of Materials Engineering, Tarbiat Modares University, P.O. Box 14115-143, Tehran (Iran, Islamic Republic of); Bozorg, M. [Department of Materials Engineering, Tarbiat Modares University, P.O. Box 14115-143, Tehran (Iran, Islamic Republic of); Hadavi, S.M.M. [School of Materials Science and Engineering, MA University of Technology, P.O. Box 16765-3197, Tehran (Iran, Islamic Republic of)

    2012-11-15

    Multi-step heat treatments comprise of high temperature forming (150 Degree-Sign C/24 h plus 190 Degree-Sign C for several minutes) and subsequent low temperature forming (120 Degree-Sign C for 24 h) is developed in creep age forming of 7075 aluminum alloy to decrease springback and exfoliation corrosion susceptibility without reduction in tensile properties. The results show that the multi-step heat treatment gives the low springback and the best combination of exfoliation corrosion resistance and tensile strength. The lower springback is attributed to the dislocation recovery and more stress relaxation at higher temperature. Transmission electron microscopy observations show that corrosion resistance is improved due to the enlargement in the size and the inter-particle distance of the grain boundaries precipitates. Furthermore, the achievement of the high strength is related to the uniform distribution of ultrafine {eta} Prime precipitates within grains. - Highlights: Black-Right-Pointing-Pointer Creep age forming developed for manufacturing of aircraft wing panels by aluminum alloy. Black-Right-Pointing-Pointer A good combination of properties with minimal springback is required in this component. Black-Right-Pointing-Pointer This requirement can be improved through the appropriate heat treatments. Black-Right-Pointing-Pointer Multi-step cycles developed in creep age forming of AA7075 for improving of springback and properties. Black-Right-Pointing-Pointer Results indicate simultaneous enhancing the properties and shape accuracy (lower springback).

  16. Study of aluminum-doped silicon clusters

    International Nuclear Information System (INIS)

    Zhan Shichang; Li Baoxing; Yang Jiansong

    2007-01-01

    Using full-muffin-tin-orbital molecular-dynamics (FP-LMTO-MD) method, we have investigated the effect of aluminum heteroatoms on the geometric structures and bond characteristics of Si n (n=5-10) clusters in detail. It is found that the geometric framework of the ground state structures for Si n (n=5-10) clusters change to some extent upon the substitution of Al atoms in some Si atoms. The effect of aluminum doping on the silicon clusters depends on the geometric structures of Si n (n=5-10) clusters. In particular, the calculations suggest that the aluminum doping would improve the bond strength of some Si-Si bonds in the mixed Si n - m Al m clusters

  17. Microstructure, hardness and tensile properties of A380 aluminum alloy with and without Li additions

    Energy Technology Data Exchange (ETDEWEB)

    Karamouz, Mostafa [Research Center of Materials engineering, University of Kerman Industrial Graduate, Kerman (Iran, Islamic Republic of); Research Center of Materials engineering, University of Kerman Industrial Graduate, Kerman (Iran, Islamic Republic of); Azarbarmas, Mortaza, E-mail: mazarbarmas@ut.ac.ir [Faculty of Mechanical Engineering, K.N. Toosi University of Technology, Tehran (Iran, Islamic Republic of); Faculty of Materials Engineering, Sahand University of Technology, Tabriz (Iran, Islamic Republic of); Emamy, Masoud [School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of); Alipour, Mohammad [School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of); Department of Materials Engineering, Faculty of Mechanical Engineering, University of Tabriz, Tabriz (Iran, Islamic Republic of)

    2013-10-10

    In this work, the effects of lithium (Li) on the microstructure, hardness and mechanical properties of A380 aluminum alloy have been investigated. The alloy was produced by conventional casting. Microstructures of the samples were investigated using the optical and scanning electron microscopy. The results showed that with increase of Li content up to 0.1%, the morphology of β-Al{sub 5}FeSi and eutectic Si phases changed from intersected and branched coarse platelets into fine and independent ones. Li decreased hardness values of the alloy. Also, it was revealed from tensile tests that with addition of 0.6% Li, the ultimate tensile strength (UTS) and elongation values increased from 274 to 300 MPa and 3.8% to 6%, respectively. Fractographic examination of the fracture surfaces indicated that the alloys with Li addition had more ductile dimple and fewer brittle cleavage surfaces.

  18. The Strength of Moulding Sand Consisting of a Mixture of Bentonite, Tapioca Flour, and Sago Flour as a New Binder Formula to Improve the Quality of Al-Si Cast Alloy

    Directory of Open Access Journals (Sweden)

    Andoko Andoko

    2017-08-01

    Full Text Available The major factors determining the quality of sand casting products are the base sand and the composition of the sand mould and the binding material. In the foundry industry, the most commonly used binder for creating sand moulds is bentonite. However, the price of bentonite is likely to keep rising. This study aimed at discovering a new binder formula associated with the effect of binder composition i.e. bentonite, tapioca flour, and sago flour on the basis of its mechanical and physical properties. The new formula was expected to be a better binder in the production of sand moulds, resulting in high-quality casting products with minimal defects. Moreover, it is probable to be much more economical than bentonite. This research focused on testing the moulding sand composition with a number of different binders, i.e. bentonite, tapioca flour, and sago flour, each in a different proportion. The mixture of the moulding sand with each of the three binders will be tested in terms of its mechanical properties including compressive, shear, and tensile strength. Based on the test results, sago flour has the highest dry compressive strength of 28.6 N/cm2, whereas bentonite has the highest wet compressive strength, i.e. 11.83 N/cm2 and the highest wet shear strength i.e. 3.16 N/cm2. The binder with the highest dry shear strength is tapioca flour with 18.16 N/cm2. Regarding the tensile strength value, bentonite has the highest wet tensile strength of 0.85 N/cm2, while sago flour has the highest dry tensile strength of 1.73 N/cm2.

  19. Surface Hardening of Composite Material by the Centrifugal-Casting Method

    Science.gov (United States)

    Eidelman, E. D.; Durnev, M. A.

    2018-04-01

    The effect of rotation flow emerging under centrifugal casting on the first-order phase transition, i.e., crystallization, has been studied using the example of producing a gradient composite material of AK12 aluminum alloy in a mixture with basalt fibers. It has been shown that a material with a hardened surface can be created. Distribution of admixtures in the main material when there is macroscopic motion has been found.

  20. Constitutive behaviour of an as-cast AA7050 alloy in the sub-solidus temperature range

    International Nuclear Information System (INIS)

    Subroto, T A S; Miroux, A G; Eskin, D G; Katgerman, L

    2012-01-01

    Aluminum alloy 7050 is of interest for aerospace industries due to its superior mechanical properties. However, its inherent solidification behaviour may augment the accumulation of residual stresses due to uneven cooling conditions upon direct-chill (DC) casting. This can increase the propensity of cold cracking (CC), which is a potentially catastrophic phenomenon in casting ingots. To predict the outcome of the aluminum casting process, ALSIM software is utilised. This software has the capability to predict CC susceptibility during the casting process. However, at the moment, ALSIM lacks the information regarding material constitutive behaviour in the sub-solidus temperature range, which is considered important for studying CC phenomenon. At the moment, ALSIM only has a partial constitutive database for AA7050 and misses data, especially in the vicinity of non-equilibrium solidus (NES) point. The present work presents measurements of tensile constitutive parameters in the temperature range between 400 °C and NES, which is for this alloy defined as 465 °C. The mechanical behaviour is tested in a Gleeble 3800 thermo-mechanical simulator. Constitutive parameters such as stress-strain curves, strain-rate sensitivity and ductility of the alloy have been measured at different test temperatures. With these constitutive data, we expect to improve the accuracy of ALSIM simulations in terms of CC prediction, and gain more insight into the evolution of mechanical properties of AA7050 in the temperature nearby the NES.

  1. Principles of Structure and Phase Composition Formation in Composite Master Alloys of the Al-Ti-B/B4c Systems Used for Aluminum Alloy Modification

    Science.gov (United States)

    Zhukov, I. A.; Promakhov, V. V.; Matveev, A. E.; Platov, V. V.; Khrustalev, A. P.; Dubkova, Ya. A.; Vorozhtsov, S. A.; Potekaev, A. I.

    2018-03-01

    The principles of formation of structure and properties of materials produced by self-propagating hightemperature synthesis (SHS) from the Al-Ti-B/B4C powder systems are identified. It is shown that the SHSmaterials produced from the Al-Ti-B powder systems consist of a TiAl intermetallic matrix with inclusions of titanium diboride particles. It is found out that an introduction of 1 wt.% of TiB2 particles into the melt of the AD35 aluminum alloy allows reducing the grain size from 620 to 220 μm and gives rise to an increase in the ultimate tensile strength of as-cast specimens from 100 to 145 MPa and in the plasticity from 7 to 9%.

  2. Ultrasonic Real-Time Quality Monitoring Of Aluminum Spot Weld Process

    Science.gov (United States)

    Perez Regalado, Waldo Josue

    The real-time ultrasonic spot weld monitoring system, introduced by our research group, has been designed for the unsupervised quality characterization of the spot welding process. It comprises the ultrasonic transducer (probe) built into one of the welding electrodes and an electronics hardware unit which gathers information from the transducer, performs real-time weld quality characterization and communicates with the robot programmable logic controller (PLC). The system has been fully developed for the inspection of spot welds manufactured in steel alloys, and has been mainly applied in the automotive industry. In recent years, a variety of materials have been introduced to the automotive industry. These include high strength steels, magnesium alloys, and aluminum alloys. Aluminum alloys have been of particular interest due to their high strength-to-weight ratio. Resistance spot welding requirements for aluminum vary greatly from those of steel. Additionally, the oxide film formed on the aluminum surface increases the heat generation between the copper electrodes and the aluminum plates leading to accelerated electrode deterioration. Preliminary studies showed that the real-time quality inspection system was not able to monitor spot welds manufactured with aluminum. The extensive experimental research, finite element modelling of the aluminum welding process and finite difference modeling of the acoustic wave propagation through the aluminum spot welds presented in this dissertation, revealed that the thermodynamics and hence the acoustic wave propagation through an aluminum and a steel spot weld differ significantly. For this reason, the hardware requirements and the algorithms developed to determine the welds quality from the ultrasonic data used on steel, no longer apply on aluminum spot welds. After updating the system and designing the required algorithms, parameters such as liquid nugget penetration and nugget diameter were available in the ultrasonic data

  3. Mechanical and microstructural characterization of aluminum reinforced with carbon-coated silver nanoparticles

    International Nuclear Information System (INIS)

    Martinez-Sanchez, R.; Reyes-Gasga, J.; Caudillo, R.; Garcia-Gutierrez, D.I.; Marquez-Lucero, A.; Estrada-Guel, I.; Mendoza-Ruiz, D.C.; Jose Yacaman, M.

    2007-01-01

    Composites of pure aluminum with carbon-coated silver nanoparticles (Ag-C NP) of 10 nm in size were prepared by the mechanical milling process. Transmission electron microscopy showed that the Ag-C NP are homogeneously dispersed into the Al matrix, silver nanoparticles do not coalesce, grow or dissolve in the aluminum matrix due the carbon shell. The values of yield strength (σ y ), maximum strength (σ max ) and micro-hardness Vickers (HVN) of the composites were evaluated and reported as a function of Ag-C NP content. It has been found that the introduction of this type of particles in aluminum strengthen it, increasing all the previous parameters

  4. Modeling of solidification of MMC composites during gravity casting process

    Directory of Open Access Journals (Sweden)

    R. Zagórski

    2013-04-01

    Full Text Available The paper deals with computer simulation of gravity casting of the metal matrix composites reinforced with ceramics (MMC into sand mold. The subject of our interest is aluminum matrix composite (AlMMC reinforced with ceramic particles i.e. silicon carbide SiC and glass carbon Cg. The created model describes the process taking into account solidification and its influence on the distribution of reinforcement particles. The computer calculation has been carried out in 2D system with the use of Navier-Stokes equations using ANSYS FLUENT 13. The Volume of Fluid approach (VOF and enthalpy method have been used to model the air-fluid free surface (and also volume fraction of particular continuous phases and the solidification of the cast, respectively.

  5. An Influence of Ageing on the Structure, Corrosion Resistance and Hardness of High Aluminum ZnAl40Cu3 Alloy

    Directory of Open Access Journals (Sweden)

    Michalik R.

    2016-03-01

    Full Text Available Zn-Al-Cu alloys are used primarily because of their tribological properties as an alternative material for bronze, cast iron and aluminum alloy bearings and as a construction material. Particularly interesting are high aluminum zinc alloys. Monoeutectic zinc and aluminum alloys are characterized by the highest hardness, tensile strength and wear resistance of all of the zinc alloys. A significant problem with the use of the Zn-Al-Cu alloys is their insufficient resistance to electrochemical corrosion. Properties of Zn-Al-Cu alloys can be improved by heat treatment. The purpose of examination was to determine the effect of heat treatment (aging at various temperatures on the microstructure and corrosion resistance of the ZnAl40Cu3 alloy. The scope of the examination included: structural examinations, determination of hardness using Brinell’s method and corrosion resistance examinations. Ageing at higher temperatures causes a creation of areas where is an eutectoid mixture. The study showed that ageing causes a decrease in hardness of ZnAl40Cu3 alloy. This decrease is even greater, when the temperature of ageing is lower. The studies have shown a significant influence of ageing on the corrosion resistance of the alloy ZnAl40Cu3. Maximum corrosion resistance were characterized by the sample after ageing at higher temperatures.

  6. Modeling and Analysis of The Pressure Die Casting Using Response Surface Methodology

    International Nuclear Information System (INIS)

    Kittur, Jayant K.; Herwadkar, T. V.; Parappagoudar, M. B.

    2010-01-01

    Pressure die casting is successfully used in the manufacture of Aluminum alloys components for automobile and many other industries. Die casting is a process involving many process parameters having complex relationship with the quality of the cast product. Though various process parameters have influence on the quality of die cast component, major influence is seen by the die casting machine parameters and their proper settings. In the present work, non-linear regression models have been developed for making predictions and analyzing the effect of die casting machine parameters on the performance characteristics of die casting process. Design of Experiments (DOE) with Response Surface Methodology (RSM) has been used to analyze the effect of effect of input parameters and their interaction on the response and further used to develop nonlinear input-output relationships. Die casting machine parameters, namely, fast shot velocity, slow shot to fast shot change over point, intensification pressure and holding time have been considered as the input variables. The quality characteristics of the cast product were determined by porosity, hardness and surface rough roughness (output/responses). Design of experiments has been used to plan the experiments and analyze the impact of variables on the quality of casting. On the other-hand Response Surface Methodology (Central Composite Design) is utilized to develop non-linear input-output relationships (regression models). The developed regression models have been tested for their statistical adequacy through ANOVA test. The practical usefulness of these models has been tested with some test cases. These models can be used to make the predictions about different quality characteristics, for the known set of die casting machine parameters, without conducting the experiments.

  7. Does the casting mode influence microstructure, fracture and properties of different metal ceramic alloys?

    Science.gov (United States)

    Bauer, José Roberto de Oliveira; Grande, Rosa Helena Miranda; Rodrigues-Filho, Leonardo Eloy; Pinto, Marcelo Mendes; Loguercio, Alessandro Dourado

    2012-01-01

    The aim of the present study was to evaluate the tensile strength, elongation, microhardness, microstructure and fracture pattern of various metal ceramic alloys cast under different casting conditions. Two Ni-Cr alloys, Co-Cr and Pd-Ag were used. The casting conditions were as follows: electromagnetic induction under argon atmosphere, vacuum, using blowtorch without atmosphere control. For each condition, 16 specimens, each measuring 25 mm long and 2.5 mm in diameter, were obtained. Ultimate tensile strength (UTS) and elongation (EL) tests were performed using a Kratos machine. Vickers Microhardness (VM), fracture mode and microstructure were analyzed by SEM. UTS, EL and VM data were statistically analyzed using ANOVA. For UTS, alloy composition had a direct influence on casting condition of alloys (Wiron 99 and Remanium CD), with higher values shown when cast with Flame/Air (p casting condition" influenced the EL and VM results, generally presenting opposite results, i.e., alloy with high elongation value had lower hardness (Wiron 99), and casting condition with the lowest EL values had the highest VM values (blowtorch). Both factors had significant influence on the properties evaluated, and prosthetic laboratories should select the appropriate casting method for each alloy composition to obtain the desired property.

  8. The role of aluminum distribution on the local corrosion resistance of the microstructure in a sand-cast AM50 alloy

    International Nuclear Information System (INIS)

    Danaie, Mohsen; Asmussen, Robert Matthew; Jakupi, Pellumb; Shoesmith, David W.; Botton, Gianluigi A.

    2013-01-01

    Highlights: •Site-specific analytical electron microscopy was performed on corroded AM50. •Areas close to eutectic microstructure show less corrosion damage. •Eutectic Mg grains develop an Al-rich layer between the alloy and corrosion product. •We demonstrate, using low-loss EELS, that the Al-rich layer is metallic in character. •Primary α-Mg grains, with lower Al content, do not develop the Al-rich layer and corrode severely. -- Abstract: Site-specific analytical electron microscopy was performed on a corroded sand-cast AM50 alloy. Areas close to partially divorced eutectic were the regions with less corrosion damage. The corrosion product layer in these areas consisted of a columnar section of predominantly amorphous MgO. At the alloy interface, an aluminum-rich layer was identified. Electron energy-loss spectroscopy suggests this layer is metallic in character. The corrosion product film on the primary α-Mg grains possessed a bi-layer morphology: a thin columnar film and a thicker, porous sub-layer. The formation of the Al-rich layer depends on the Al content in solid solution at a specific location

  9. A new technique for the strengthening of aluminum tungsten inert gas weld metals: using carbon nanotube/aluminum composite as a filler metal.

    Science.gov (United States)

    Fattahi, M; Nabhani, N; Rashidkhani, E; Fattahi, Y; Akhavan, S; Arabian, N

    2013-01-01

    The effect of multi-walled carbon nanotube (MWCNT) on the mechanical properties of aluminum multipass weld metal prepared by the tungsten inert gas (TIG) welding process was investigated. High energy ball milling was used to disperse MWCNT in the aluminum powder. Carbon nanotube/aluminum composite filler metal was fabricated for the first time by hot extrusion of ball-milled powders. After welding, the tensile strength, microhardness and MWCNT distribution in the weld metal were investigated. The test results showed that the tensile strength and microhardness of weld metal was greatly increased when using the filler metal containing 1.5 wt.% MWCNT. Therefore, according to the results presented in this paper, it can be concluded that the filler metal containing MWCNT can serve as a super filler metal to improve the mechanical properties of TIG welds of Al and its alloys. Copyright © 2013 Elsevier Ltd. All rights reserved.

  10. The nucleation of austenite in ferritic ductile cast iron

    International Nuclear Information System (INIS)

    Chou, J.M.; Hon, M.H.; Lee, J.L.

    1992-01-01

    Austempered ductile cast iron has recently been receiving increasing attention because of its excellent combination of strength and ductility. Since the austenitization process has a significant influence on the mechanical properties of austempered ductile cast iron, several investigations on the nucleation sites of austenite and diffusion paths of carbon from spheroidal graphite have been reported in ferritic ductile cast iron. However, agreement on this subject has not ben reached. The purpose of this paper is to study the preferential nucleation sites of austenite during austenitization at two austenitizing temperatures in ferritic ductile cast iron. An attempt was made to understand the reasons which give rise to preferential austenite nucleation sites. The carbon diffusion paths from spheroidal graphite were also investigated

  11. Corrosion of aluminum components and remedial measures

    International Nuclear Information System (INIS)

    Sheikh, S.T.; Khalique, A.; Malik, F.A.

    2006-01-01

    Aluminum has versatile physical properties, mechanical strength, corrosion resistance, and is used in special applications like aerospace, automobiles and other strategic industries. The outdoor exposed structural components of aluminum have very good corrosion resistance due to the thick oxide layer (0.2 -0.4 micro). This study involves the corrosion of aluminum based components, though aluminum is protected by an oxide layer but due to extreme weather and environmental conditions the oxide layer was damaged. The corroded product was removed, pits or cavities formed due to the material removal were filled with epoxy resins and acrylic-based compounds containing fibreglass as reinforcement. Optimum results were obtained with epoxy resins incorporated with 5% glass fibers. The inner surface of the components was provided further protection with a cellulose nitrate compound. (author)

  12. Casting and stress-strain simulations of a cast ductile iron component using microstructure based mechanical behavior

    International Nuclear Information System (INIS)

    Olofsson, Jakob; Svensson, Ingvar L

    2012-01-01

    The industrial demand for increased component performance with concurrent reductions in component weight, development times and verifications using physical prototypes drives the need to use the full potential of casting and Finite Element Method (FEM) simulations to correctly predict the mechanical behavior of cast components in service. The mechanical behavior of the component is determined by the casting process, and factors as component geometry and casting process parameters are known to affect solidification and microstructure formation throughout the component and cause local variations in mechanical behavior as well as residual stresses. Though residual stresses are known to be an important factor in the mechanical behavior of the component, the importance of local mechanical behavior is not well established and the material is typically considered homogeneous throughout the component. This paper deals with the influence of solidification and solid state transformation on microstructure formation and the effect of local microstructure variations on the mechanical behavior of the cast component in service. The current work aims to investigate the coupling between simulation of solidification, microstructure and local variations in mechanical behavior and stress-strain simulation. This is done by performing several simulations of a ductile iron component using a recently developed simulation strategy, a closed chain of simulations for cast components, able to predict and describe the local variations in not only elastic but also plastic behavior throughout the component by using microstructural parameters determined by simulations of microstructural evolution in the component during the casting process. In addition the residual stresses are considered. The results show that the FEM simulation results are significantly affected by including microstructure based mechanical behavior. When the applied load is low and the component is subjected to stress levels

  13. The Application of the Method of Continuous Casting for Manufacturing of Welding Wire AMg6

    International Nuclear Information System (INIS)

    Azhazha, V.M.; Sverdlov, V.Ya.; Kondratov, A.A.; Rudycheva, T.Yu.

    2007-01-01

    The method of manufacturing semifinished item of high alloyed of aluminum, silver and copper alloys has been investigated on the basis of the continuous casting method. The sample of aluminum alloy AMg6 consist of small grains with the vios-cut dimension ∼ 15 mkm and which are stretched in the direction of longitudinal axis of the sample Such microstructure is favourable for plastic deformation of the sample. Welding wire which meets the demands of standards of commercial welding wires of this brand has been produced by the drawing from the sample

  14. ''Heat Transfer at the Mold-Metal Interface in Permanent Mold Casting of Aluminum Alloys'' Final Project Report; FINAL

    International Nuclear Information System (INIS)

    Pehlke, R. D.; Cookson, John M.; Shouwei Hao; Prasad Krishna; Bilkey, Kevin T.

    2001-01-01

    This project on heat transfer coefficients in metal permanent mold casting has been conducted in three areas. They are the theoretical study at the University of Michigan, the experimental investigation of squeeze casting at CMI-Tech Center (Now Hayes-Lemmerz Technical Center) and the experimental investigation of low pressure permanent mold casting at Amcast Automotive

  15. Interplay among solidification, microstructure, residual strain and hot tearing in B206 aluminum alloy

    Energy Technology Data Exchange (ETDEWEB)

    D’Elia, F., E-mail: f.delia10@gmail.com [Centre for Near-net-shape Processing of Materials, Ryerson University, 101 Gerrard St. East, Toronto, Ontario, Canada M5B 2K3 (Canada); Ravindran, C. [Centre for Near-net-shape Processing of Materials, Ryerson University, 101 Gerrard St. East, Toronto, Ontario, Canada M5B 2K3 (Canada); Sediako, D. [Canadian Neutron Beam Centre, Chalk River Laboratories, Chalk River, Ontario, Canada K0J 1J0 (Canada)

    2015-01-29

    Hot tearing is a complex phenomenon attributed to alloy solidification, microstructure and stress/strain development within a casting. In this research, the conditions associated with the formation of hot tears in B206 aluminum alloy were investigated. Neutron diffraction strain mapping was carried out on three B206 castings with varying levels of titanium (i.e. unrefined, 0.02 and 0.05 wt%). Titanium additions effectively reduced grain size and transformed grain morphology from coarse dendrites to fine globular grains. Further, thermal analysis suggested that grain refinement delayed the onset of dendrite coherency in B206 and therefore enhanced the duration of bulk liquid metal feeding for the refined casting conditions. As a result, the interactive effects of such factors resulted in a more uniform distribution of strain, and subsequent higher resistance to hot tearing for the grain refined castings.

  16. Strong, corrosion-resistant aluminum tubing

    Science.gov (United States)

    Reed, M. W.; Adams, F. F.

    1980-01-01

    When aluminum tubing having good corrosion resistance and postweld strength is needed, type 5083 alloy should be considered. Chemical composition is carefully controlled and can be drawn into thin-wall tubing with excellent mechanical properties. Uses of tubing are in aircraft, boats, docks, and process equipment.

  17. Investigation of smooth specimen scc test procedures; variations in environment, specimen size, stressing frame, and stress state. [for high strength aluminum alloys

    Science.gov (United States)

    Lifka, B. W.; Sprowls, D. O.; Kelsey, R. A.

    1975-01-01

    The variables studied in the stress-corrosion cracking performance of high strength aluminum alloys were: (1) corrosiveness of the environment, (2) specimen size and stiffness of the stressing system, (3) interpretation of transgranular cracking, and (4) interaction of the state of stress and specimen orientation in a product with an anisotropic grain structure. It was shown that the probability of failure and time to fracture for a specimen loaded in direct tension are influenced by corrosion pattern, the stressing assembly stiffness, and the notch tensile strength of the alloy. Results demonstrate that the combination of a normal tension stress and a shear stress acting on the plane of maximum susceptibility in a product with a highly directional grain cause the greatest tendency for stress-corrosion cracking.

  18. Search for chameleons with CAST

    Directory of Open Access Journals (Sweden)

    V. Anastassopoulos

    2015-10-01

    Full Text Available In this work we present a search for (solar chameleons with the CERN Axion Solar Telescope (CAST. This novel experimental technique, in the field of dark energy research, exploits both the chameleon coupling to matter (βm and to photons (βγ via the Primakoff effect. By reducing the X-ray detection energy threshold used for axions from 1 keV to 400 eV CAST became sensitive to the converted solar chameleon spectrum which peaks around 600 eV. Even though we have not observed any excess above background, we can provide a 95% C.L. limit for the coupling strength of chameleons to photons of βγ≲1011 for 1<βm<106.

  19. Energy Saving Melting and Revert Reduction Technology (E-SMARRT): Development of Surface Engineered Coating Systems for Aluminum Pressure Die Casting Dies: Towards a 'Smart' Die Coating

    Energy Technology Data Exchange (ETDEWEB)

    Dr. John J. Moore; Dr. Jianliang Lin,

    2012-07-31

    The main objective of this research program was to design and develop an optimal coating system that extends die life by minimizing premature die failure. In high-pressure aluminum die-casting, the die, core pins and inserts must withstand severe processing conditions. Many of the dies and tools in the industry are being coated to improve wear-resistance and decrease down-time for maintenance. However, thermal fatigue in metal itself can still be a major problem, especially since it often leads to catastrophic failure (i.e. die breakage) as opposed to a wear-based failure (parts begin to go out of tolerance). Tooling costs remain the largest portion of production costs for many of these parts, so the ability prevent catastrophic failures would be transformative for the manufacturing industry.The technology offers energy savings through reduced energy use in the die casting process from several factors, including increased life of the tools and dies, reuse of the dies and die components, reduction/elimination of lubricants, and reduced machine down time, and reduction of Al solder sticking on the die. The use of the optimized die coating system will also reduce environmental wastes and scrap parts. Current (2012) annual energy saving estimates, based on initial dissemination to the casting industry in 2010 and market penetration of 80% by 2020, is 3.1 trillion BTU's/year. The average annual estimate of CO2 reduction per year through 2020 is 0.63 Million Metric Tons of Carbon Equivalent (MM TCE).

  20. Advanced powder metallurgy aluminum alloys via rapid solidification technology, phase 2

    Science.gov (United States)

    Ray, Ranjan; Jha, Sunil C.

    1987-01-01

    Marko's rapid solidification technology was applied to processing high strength aluminum alloys. Four classes of alloys, namely, Al-Li based (class 1), 2124 type (class 2), high temperature Al-Fe-Mo (class 3), and PM X7091 type (class 4) alloy, were produced as melt-spun ribbons. The ribbons were pulverized, cold compacted, hot-degassed, and consolidated through single or double stage extrusion. The mechanical properties of all four classes of alloys were measured at room and elevated temperatures and their microstructures were investigated optically and through electron microscopy. The microstructure of class 1 Al-Li-Mg alloy was predominantly unrecrystallized due to Zr addition. Yield strengths to the order of 50 Ksi were obtained, but tensile elongation in most cases remained below 2 percent. The class 2 alloys were modified composition of 2124 aluminum alloy, through addition of 0.6 weight percent Zr and 1 weight percent Ni. Nickel addition gave rise to a fine dispersion of intermetallic particles resisting coarsening during elevated temperature exposure. The class 2 alloy showed good combination of tensile strength and ductility and retained high strength after 1000 hour exposure at 177 C. The class 3 Al-Fe-Mo alloy showed high strength and good ductility both at room and high temperatures. The yield and tensile strength of class 4 alloy exceeded those of the commercial 7075 aluminum alloy.

  1. Structure/property relations of aluminum under varying rates and stress states

    Energy Technology Data Exchange (ETDEWEB)

    Tucker, Matthew T [Los Alamos National Laboratory; Horstemeyer, Mark F [MISSISSIPPI STATE UNIV; Whittington, Wilburn R [MISSISSIPPI STATE UNIV; Solanki, Kiran N [MISSISSIPPI STATE UNIV.

    2010-11-19

    In this work we analyze the plasticity, damage, and fracture characteristics of three different processed aluminum alloys (rolled 5083-H13, cast A356-T6, and extruded 6061-T6) under varying stress states (tension, compression, and torsion) and strain rates (0.001/, 1/s., and 1000/s). The stress state difference had more of a flow stress effect than the applied strain rates for those given in this study (0.001/sec up to 1000/sec). The stress state and strain rate also had a profound effect on the damage evolution of each aluminum alloy. Tension and torsional straining gave much greater damage nucleation rates than compression. Although the damage of all three alloys was found to be void nucleation dominated, the A356-T6 and 5083-H131 aluminum alloys incurred void damage via micron scale particles where the 6061-T6 aluminum alloy incurred void damage from two scales, micron-scale particles and nanoscale precipitates. Having two length scales of particles that participated in the damage evolution made the 6061-T6 incur a strain rate sensitive damage rate that was different than the other two aluminum alloys. Under tension, as the strain rate increased, the 6061-T6 aluminum alloy's void nucleation rate decreased, but the A356-T6 and 5083-H131 aluminum alloys void nucleation rate increased.

  2. Application of a grain refiner and modifier to an Al-12 Si cast alloy

    International Nuclear Information System (INIS)

    Haro R, Sergio; Goytia R, Rafael E; Santos B, Audel; Dwivedi, D.K

    2008-01-01

    The refining and modification of an alloy of cast aluminum Al-12Si was studied, using sample alloys of Al-5Ti-1B as a refiner and Al-10Sr as a modifier. Two levels of each one were tested and added separately. The results show that the addition of titanium as well as of strontium favored the improvement of the tension properties of the cast Al-12Si alloy, by modifying the microstructure. But the addition of 0.06% Sr in the form of a master alloy produced a more adequate microstructure and presented the best combination of mechanical properties (au)

  3. High-Strength Aluminium Alloys and Their Use in Foundry Industry of Nickel Superalloys

    Directory of Open Access Journals (Sweden)

    Pysz S.

    2014-08-01

    Full Text Available Of great importance in the selection of materials for cast structures is keeping a proper balance between the mechanical and plastic properties, while preserving the relevant casting properties. This study has been devoted to an analysis of the choice and application of high-strength aluminium-based alloys maintaining sufficient level of casting properties. The high level of tensile strength (Rm > 500 MPa matched with satisfactory elongation (A > 3% is important because materials of this type are used for cast parts operating in the aerospace, automotive, and military industries. These beneficial relationships between the high tensile strength and toughness are relatively easy to obtain in the Al-Zn-Mg-Cu alloys subjected to plastic forming and proper heat treatment. In gravity cast products, on the other hand, whether poured into sand moulds or metal moulds (dies, obtaining this favourable combination of properties poses a number of research problems (mostly resulting from the alloy chemical composition as well as technical and technological difficulties.

  4. Friction stir welding of T joints of dissimilar aluminum alloy: A review

    Science.gov (United States)

    Thakare, Shrikant B.; Kalyankar, Vivek D.

    2018-04-01

    Aluminum alloys are preferred in the mechanical design due to their advantages like high strength, good corrosion resistance, low density and good weldability. In various industrial applications T joints configuration of aluminum alloys are used. In different fields, T joints having skin (horizontal sheet) strengthen by stringers (vertical sheets) were used to increase the strength of structure without increasing the weight. T joints are usually carried out by fusion welding which has limitations in joining of aluminum alloy due to significant distortion and metallurgical defects. Some aluminum alloys are even non weldable by fusion welding. The friction stir welding (FSW) has an excellent replacement of conventional fusion welding for T joints. In this article, FSW of T joints is reviewed by considering aluminum alloy and various joint geometries for defect analysis. The previous experiments carried out on T joints shows the factors such as tool geometry, fixturing device and joint configurations plays significant role in defect free joints. It is essential to investigate the material flow during FSW to know joining mechanism and the formation of joint. In this study the defect occurred in the FSW are studied for various joint configurations and parameters. Also the effect of the parameters and defects occurs on the tensile strength are studied. It is concluded that the T-joints of different joint configurations can be pretended successfully. Comparing to base metal some loss in tensile strength was observed in the weldments as well as overall reduction of the hardness in the thermos mechanically affected zone also observed.

  5. Joining of parts via magnetic heating of metal aluminum powders

    Science.gov (United States)

    Baker, Ian

    2013-05-21

    A method of joining at least two parts includes steps of dispersing a joining material comprising a multi-phase magnetic metal-aluminum powder at an interface between the at least two parts to be joined and applying an alternating magnetic field (AMF). The AMF has a magnetic field strength and frequency suitable for inducing magnetic hysteresis losses in the metal-aluminum powder and is applied for a period that raises temperature of the metal-aluminum powder to an exothermic transformation temperature. At the exothermic transformation temperature, the metal-aluminum powder melts and resolidifies as a metal aluminide solid having a non-magnetic configuration.

  6. Microstructural and mechanical properties characterization of heat treated and overaged cast A354 alloy with various SDAS at room and elevated temperature

    Energy Technology Data Exchange (ETDEWEB)

    Ceschini, Lorella; Morri, Alessandro [Department of Industrial Engineering (DIN), Alma Mater Studiorum – University of Bologna, Viale Risorgimento 4, 40136 Bologna (Italy); Industrial Research Centre for Advanced Mechanics and Materials (CIRI-MAM) Alma Mater Studiorum – University of Bologna, Viale Risorgimento 4, 40136 Bologna (Italy); Toschi, Stefania, E-mail: stefania.toschi3@unibo.it [Department of Industrial Engineering (DIN), Alma Mater Studiorum – University of Bologna, Viale Risorgimento 4, 40136 Bologna (Italy); Johansson, Sten [Department of Management & Engineering, Division of Engineering Materials, Linköping University, SE-581 83 Linköping (Sweden); Seifeddine, Salem [Department of Materials and Manufacturing, School of Engineering – Jönköping University (Sweden)

    2015-11-11

    The aim of the present study was to carry out a microstructural and mechanical characterization of the A354 (Al–Si–Cu–Mg) cast aluminum alloy. The effect of microstructure on the tensile behavior was evaluated by testing samples with different Secondary Dendrite Arm Spacing, (SDAS) values (20–25 μm and 50–70 μm for fine and coarse microstructure, respectively), which were produced through controlled casting conditions. The tensile behavior of the alloy was evaluated both at room and elevated temperature (200 °C), in the heat treated and overaged (exposure at 210 °C for 41 h, after heat treatment) conditions. Optical, scanning electron microscopy (SEM) and scanning transmission electron microscopy (STEM) were used for microstructural investigations. Experimental data confirmed the significant role of microstructural coarseness on the tensile behavior of A354 alloy. Ultimate tensile strength and elongation to failure strongly increased with the decrease of SDAS. Moreover, solidification rate influenced other microstructural features, such as the eutectic silicon morphology as well as the size of the intermetallic phases, which in turn also influenced elongation to failure. Coarsening of the strengthening precipitates was induced by overaging, as observed by STEM analyses, thus leading to a strong reduction of the tensile strength of the alloy, regardless of SDAS. Tensile properties of the alloy sensibly decrease at elevated temperature (200 °C) in all the investigated heat treatment conditions.

  7. Spray rolling aluminum alloy strip

    Energy Technology Data Exchange (ETDEWEB)

    McHugh, Kevin M.; Delplanque, J.-P.; Johnson, S.B.; Lavernia, E.J.; Zhou, Y.; Lin, Y

    2004-10-10

    Spray rolling combines spray forming with twin-roll casting to process metal flat products. It consists of atomizing molten metal with a high velocity inert gas, cooling the resultant droplets in flight and directing the spray between mill rolls. In-flight convection heat transfer from atomized droplets teams with conductive cooling at the rolls to rapidly remove the alloy's latent heat. Hot deformation of the semi-solid material in the rolls results in fully consolidated, rapidly solidified product. While similar in some ways to twin-roll casting, spray rolling has the advantage of being able to process alloys with broad freezing ranges at high production rates. This paper describes the process and summarizes microstructure and tensile properties of spray-rolled 2124 and 7050 aluminum alloy strips. A Lagrangian/Eulerian poly-dispersed spray flight and deposition model is described that provides some insight into the development of the spray rolling process. This spray model follows droplets during flight toward the rolls, through impact and spreading, and includes oxide film formation and breakup when relevant.

  8. Fiscal 1991-1993 summary report on R and D on new forming technology of composite materials; Fukugo zairyo shinseikei gijutsu no kenkyu kaihatsu 1991 nendo - 1993 nendo sokatsu hokokusho

    Energy Technology Data Exchange (ETDEWEB)

    NONE

    1994-09-01

    Developed were the materials which can be easily formed by manifesting superplasticity simultaneously with high toughness and high strength through selection of material composition and micronizing of the structure, in regard to composite materials answering to high strength and resistance to high temperature suitable for engines or the like. Developed for ceramic matrix composite materials were composite technology of silicon nitride matrix composites by a casting method, composite technology of Al{sub 2}O{sub 3}/TiC matrix composites by a material preparation method using aqueous slurry, and superplastic forming technology of yttria stabilized zirconia/alumina matrix composites; developed for metallic matrix composite materials were composite technology of reinforced ceramics particulate aluminum alloy matrix composites by a voltex method, composite technology of ceramic short fibers reinforced aluminum alloy composites by a high pressure casting method under reduced pressure, composite technology of titanium matrix composites by a mechanical alloying method, and composite technology of aluminum alloy composites by ceramics particles, superplastic forming technology of SiC whisker reinforced aluminum alloy reinforced composites, and superplastic forming technology of aluminum alloy matrix reinforced composites reinforced by SiC particles. (NEDO)

  9. Development of thermophysical calculator for stainless steel casting alloys by using CALPHAD approach

    Directory of Open Access Journals (Sweden)

    In-Sung Cho

    2017-11-01

    Full Text Available The calculation of thermophysical properties of stainless steel castings and its application to casting simulation is discussed. It is considered that accurate thermophysical properties of the casting alloys are necessary for the valid simulation of the casting processes. Although previous thermophysical calculation software requires a specific knowledge of thermodynamics, the calculation method proposed in the present study does not require any special knowledge of thermodynamics, but only the information of compositions of the alloy. The proposed calculator is based on the CALPHAD approach for modeling of multi-component alloys, especially in stainless steels. The calculator proposed in the present study can calculate thermophysical properties of eight-component systems on an iron base alloy (Fe-C-Si-Cr-Mn-Ni-Cu-Mo, and several Korean standard stainless steel alloys were calculated and discussed. The calculator can evaluate the thermophysical properties of the alloys such as density, heat capacity, enthalpy, latent heat, etc, based on full Gibbs energy for each phase. It is expected the proposed method can help casting experts to devise the casting design and its process easily in the field of not only stainless steels but also other alloy systems such as aluminum, copper, zinc, etc.

  10. Development of High-Performance Cast Crankshafts. Final Technical Report

    Energy Technology Data Exchange (ETDEWEB)

    Bauer, Mark E [General Motors, Detroit, MI (United States)

    2017-03-31

    The objective of this project was to develop technologies that would enable the production of cast crankshafts that can replace high performance forged steel crankshafts. To achieve this, the Ultimate Tensile Strength (UTS) of the new material needs to be 850 MPa with a desired minimum Yield Strength (YS; 0.2% offset) of 615 MPa and at least 10% elongation. Perhaps more challenging, the cast material needs to be able to achieve sufficient local fatigue properties to satisfy the durability requirements in today’s high performance gasoline and diesel engine applications. The project team focused on the development of cast steel alloys for application in crankshafts to take advantage of the higher stiffness over other potential material choices. The material and process developed should be able to produce high-performance crankshafts at no more than 110% of the cost of current production cast units, perhaps the most difficult objective to achieve. To minimize costs, the primary alloy design strategy was to design compositions that can achieve the required properties with minimal alloying and post-casting heat treatments. An Integrated Computational Materials Engineering (ICME) based approach was utilized, rather than relying only on traditional trial-and-error methods, which has been proven to accelerate alloy development time. Prototype melt chemistries designed using ICME were cast as test specimens and characterized iteratively to develop an alloy design within a stage-gate process. Standard characterization and material testing was done to validate the alloy performance against design targets and provide feedback to material design and manufacturing process models. Finally, the project called for Caterpillar and General Motors (GM) to develop optimized crankshaft designs using the final material and manufacturing processing path developed. A multi-disciplinary effort was to integrate finite element analyses by engine designers and geometry-specific casting

  11. Section thickness-dependent tensile properties of squeeze cast magnesium alloy AM60

    Directory of Open Access Journals (Sweden)

    Xuezhi Zhang

    2012-05-01

    Full Text Available The development of alternative casting processes is essential for the high demand of light weight magnesium components to be used in the automotive industry, which often contain different section thicknesses. Squeeze casting with its inherent advantages has been approved for the capability of minimizing the gas porosity in magnesium alloys. For advanced engineering design of light magnesium automotive applications, it is critical to understand the effect of section thickness on mechanical properties of squeeze cast magnesium alloys. In this study, magnesium alloy AM60 with different section thicknesses of 6, 10 and 20 mm squeeze cast under an applied pressure of 30 MPa was investigated. The prepared squeeze cast AM60 specimens were tensile tested at room termperature. The results indicate that the mechanical properties including yield strength (YS, ultimate tensile strength (UTS and elongation (A decrease with an increase in section thickness of squeeze cast AM60. The microstructure analysis shows that the improvement in the tensile behavior of squeeze cast AM60 is primarily attributed to the low-gas porosity level and fine grain strucuture which result from the variation of cooling rate of different section thickness. The numerical simulation (Magmasoft? was employed to determine the solidification rates of each step, and the simulated results show that the solidification rate of the alloy decreases with an increase in the section thickness. The computed solidification rates support the experimental observation on grain structural development.

  12. The effect of thermohydrogen treatment on the structure and properties of casts obtained from titanium alloys

    International Nuclear Information System (INIS)

    Il'in, A.A.; Skvortsova, S.V.; Mamonov, A.M.; Permyakova, G.V.; Kurnikov, D.A.

    2002-01-01

    The method based on the combination of high temperature gas-static and thermal hydrogen treatments is suggested to increase mechanical properties of cast pseudo-α and (α+β)-titanium alloys. The study is carried out using alloys VT20L, VT23L and alloy Ti-6%Al-2%Mo-4%Zr-2%Sn. It is shown that the method proposed provides the change in a cast structure, an increase in density of castings, an increase of strength properties by 10-20% and fatigue by a factor of 1.5-2 at satisfactory ductility and impact strength [ru

  13. Cast Stone Formulation At Higher Sodium Concentrations

    International Nuclear Information System (INIS)

    Fox, K. M.; Edwards, T. A.; Roberts, K. B.

    2013-01-01

    concentration in the salt solution reduced the time to peak heat flow, and reducing the amount of slag in the premix increased the time to peak heat flow. These observations may help to describe some of the cured properties of the samples, in particular the differences in compressive strength observed after 28 and 90 days of curing. Samples were cured for at least 28 days at ambient temperature in the laboratory prior to cured properties analyses. The low activity waste form for disposal at the Hanford Site is required to have a compressive strength of at least 500 psi. After 28 days of curing, several of the test mixes had mean compressive strengths that were below the 500 psi requirement. Higher sodium concentrations and higher water to premix ratios led to reduced compressive strength. Higher fly ash concentrations decreased the compressive strength after 28 days of curing. This may be explained in that the cementitious phases matured more quickly in the mixes with higher concentrations of slag, as evidenced by the data for the time to peak heat generation. All of the test mixes exhibited higher mean compressive strengths after 90 days of curing, with only one composition having a mean compressive strength of less than 500 psi. Leach indices were determined for the test mixes for contaminants of interest. The leaching performance of the mixes evaluated in this study was not particularly sensitive to the factors used in the experimental design. This may be beneficial in demonstrating that the performance of the waste form is robust with respect to changes in the mix composition. The results of this study demonstrate the potential to achieve significantly higher waste loadings in Cast Stone and other low temperature, cementitious waste forms. Additional work is needed to elucidate the hydration mechanisms occurring in Cast Stone formulated with highly concentrated salt solutions since these reactions are responsible for determining the performance of the cured waste form. The

  14. Cast Stone Formulation At Higher Sodium Concentrations

    International Nuclear Information System (INIS)

    Fox, K. M.; Roberts, K. A.; Edwards, T. B.

    2014-01-01

    concentration in the salt solution reduced the time to peak heat flow, and reducing the amount of slag in the premix increased the time to peak heat flow. These observations may help to describe some of the cured properties of the samples, in particular the differences in compressive strength observed after 28 and 90 days of curing. Samples were cured for at least 28 days at ambient temperature in the laboratory prior to cured properties analyses. The low activity waste form for disposal at the Hanford Site is required to have a compressive strength of at least 500 psi. After 28 days of curing, several of the test mixes had mean compressive strengths that were below the 500 psi requirement. Higher sodium concentrations and higher water to premix ratios led to reduced compressive strength. Higher fly ash concentrations decreased the compressive strength after 28 days of curing. This may be explained in that the cementitious phases matured more quickly in the mixes with higher concentrations of slag, as evidenced by the data for the time to peak heat generation. All of the test mixes exhibited higher mean compressive strengths after 90 days of curing, with only one composition having a mean compressive strength of less than 500 psi. Leachability indices were determined for the test mixes for contaminants of interest. The leaching performance of the mixes evaluated in this study was not particularly sensitive to the factors used in the experimental design. This may be beneficial in demonstrating that the performance of the waste form is robust with respect to changes in the mix composition. The results of this study demonstrate the potential to achieve significantly higher waste loadings in Cast Stone and other low temperature, cementitious waste forms. Additional work is needed to elucidate the hydration mechanisms occurring in Cast Stone formulated with highly concentrated salt solutions since these reactions are responsible for determining the performance of the cured waste

  15. Cast Stone Formulation At Higher Sodium Concentrations

    Energy Technology Data Exchange (ETDEWEB)

    Fox, K. M. [Savannah River Site (SRS), Aiken, SC (United States). Savannah River National Lab. (SRNL); Roberts, K. A. [Savannah River Site (SRS), Aiken, SC (United States). Savannah River National Lab. (SRNL); Edwards, T. B. [Savannah River Site (SRS), Aiken, SC (United States). Savannah River National Lab. (SRNL)

    2014-02-28

    concentration in the salt solution reduced the time to peak heat flow, and reducing the amount of slag in the premix increased the time to peak heat flow. These observations may help to describe some of the cured properties of the samples, in particular the differences in compressive strength observed after 28 and 90 days of curing. Samples were cured for at least 28 days at ambient temperature in the laboratory prior to cured properties analyses. The low activity waste form for disposal at the Hanford Site is required to have a compressive strength of at least 500 psi. After 28 days of curing, several of the test mixes had mean compressive strengths that were below the 500 psi requirement. Higher sodium concentrations and higher water to premix ratios led to reduced compressive strength. Higher fly ash concentrations decreased the compressive strength after 28 days of curing. This may be explained in that the cementitious phases matured more quickly in the mixes with higher concentrations of slag, as evidenced by the data for the time to peak heat generation. All of the test mixes exhibited higher mean compressive strengths after 90 days of curing, with only one composition having a mean compressive strength of less than 500 psi. Leachability indices were determined for the test mixes for contaminants of interest. The leaching performance of the mixes evaluated in this study was not particularly sensitive to the factors used in the experimental design. This may be beneficial in demonstrating that the performance of the waste form is robust with respect to changes in the mix composition. The results of this study demonstrate the potential to achieve significantly higher waste loadings in Cast Stone and other low temperature, cementitious waste forms. Additional work is needed to elucidate the hydration mechanisms occurring in Cast Stone formulated with highly concentrated salt solutions since these reactions are responsible for determining the performance of the cured waste

  16. Cast Stone Formulation At Higher Sodium Concentrations

    Energy Technology Data Exchange (ETDEWEB)

    Fox, K. M.; Edwards, T. A.; Roberts, K. B.

    2013-10-02

    concentration in the salt solution reduced the time to peak heat flow, and reducing the amount of slag in the premix increased the time to peak heat flow. These observations may help to describe some of the cured properties of the samples, in particular the differences in compressive strength observed after 28 and 90 days of curing. Samples were cured for at least 28 days at ambient temperature in the laboratory prior to cured properties analyses. The low activity waste form for disposal at the Hanford Site is required to have a compressive strength of at least 500 psi. After 28 days of curing, several of the test mixes had mean compressive strengths that were below the 500 psi requirement. Higher sodium concentrations and higher water to premix ratios led to reduced compressive strength. Higher fly ash concentrations decreased the compressive strength after 28 days of curing. This may be explained in that the cementitious phases matured more quickly in the mixes with higher concentrations of slag, as evidenced by the data for the time to peak heat generation. All of the test mixes exhibited higher mean compressive strengths after 90 days of curing, with only one composition having a mean compressive strength of less than 500 psi. Leach indices were determined for the test mixes for contaminants of interest. The leaching performance of the mixes evaluated in this study was not particularly sensitive to the factors used in the experimental design. This may be beneficial in demonstrating that the performance of the waste form is robust with respect to changes in the mix composition. The results of this study demonstrate the potential to achieve significantly higher waste loadings in Cast Stone and other low temperature, cementitious waste forms. Additional work is needed to elucidate the hydration mechanisms occurring in Cast Stone formulated with highly concentrated salt solutions since these reactions are responsible for determining the performance of the cured waste form. The

  17. Cast Stone Formulation At Higher Sodium Concentrations

    Energy Technology Data Exchange (ETDEWEB)

    Fox, K. M.; Roberts, K. A.; Edwards, T. B.

    2013-09-17

    concentration in the salt solution reduced the time to peak heat flow, and reducing the amount of slag in the premix increased the time to peak heat flow. These observations may help to describe some of the cured properties of the samples, in particular the differences in compressive strength observed after 28 and 90 days of curing. Samples were cured for at least 28 days at ambient temperature in the laboratory prior to cured properties analyses. The low activity waste form for disposal at the Hanford Site is required to have a compressive strength of at least 500 psi. After 28 days of curing, several of the test mixes had mean compressive strengths that were below the 500 psi requirement. Higher sodium concentrations and higher water to premix ratios led to reduced compressive strength. Higher fly ash concentrations decreased the compressive strength after 28 days of curing. This may be explained in that the cementitious phases matured more quickly in the mixes with higher concentrations of slag, as evidenced by the data for the time to peak heat generation. All of the test mixes exhibited higher mean compressive strengths after 90 days of curing, with only one composition having a mean compressive strength of less than 500 psi. Leach indices were determined for the test mixes for contaminants of interest. The leaching performance of the mixes evaluated in this study was not particularly sensitive to the factors used in the experimental design. This may be beneficial in demonstrating that the performance of the waste form is robust with respect to changes in the mix composition. The results of this study demonstrate the potential to achieve significantly higher waste loadings in Cast Stone and other low temperature, cementitious waste forms. Additional work is needed to elucidate the hydration mechanisms occurring in Cast Stone formulated with highly concentrated salt solutions since these reactions are responsible for determining the performance of the cured waste form. The

  18. Investment casting of beta titanium alloys for aerospace applications

    International Nuclear Information System (INIS)

    Wheeler, D.A.; Cianci, M.S.; Vogt, R.G.

    1993-01-01

    The process of investment casting offers the ability to produce complex titanium components with minimal finish machining, thereby reducing their overall manufacturing cost. While aerospace applications for cast titanium have focused primarily on alpha+beta alloys, recent interest in higher strength beta alloys has prompted an examination of their suitability for investment casting. In this paper, the processing characteristics and mechanical proper-ties of Ti-1 5V-3Cr-3Al-3Sn, Ti-3Al-8V-6Cr-4Mo-4Zr, and Ti-15Mo-3Nb-3Al-0.2Si (wt.%) will be discussed. It will be shown that all three alloy compositions are readily processed using only slight modifications from current Ti-6Al-4V (wt.%) production operations. In addition, the mechanical properties of the cast product form can be manipulated through heat treatment and compare quite favorably with typical properties obtained in wrought beta titanium products. Finally, several demonstration castings are reviewed which illustrate the shape-making capabilities of the investment casting approach for beta titanium alloys

  19. Interface strength and degradation of adhesively bonded porous aluminum oxides

    NARCIS (Netherlands)

    Abrahami, S.T.; de Kok, John M.M.; Gudla, Visweswara C.; Ambat, Rajan; Terryn, H.A.; Mol, J.M.C.

    2017-01-01

    For more than six decades, chromic acid anodizing has been the main step in the surface treatment of aluminum for adhesively bonded aircraft structures. Soon this process, known for producing a readily adherent oxide with an excellent corrosion resistance, will be banned by strict international

  20. Design and strength evaluation of structural joint made by electro-magnetic forming (EMF)

    International Nuclear Information System (INIS)

    Park, Young-Bae; Oh, Soo-Ik; Kim, Heon-Young

    2004-01-01

    Recently, weight reduction of vehicles has been of great interest, and consequently, the use of low-density materials in the automotive industry is increasing every year. Materials should not be substituted such a way that material of component parts is simply changed because there is a problem in achieving stiffness and strength. To achieve these requirements, the automobile should be redesigned totally. Aluminum spaceframe is rapidly being adopted as a body structure for accommodating lightness, stiffness and strength requirement. In aluminum spaceframe manufacturing, it is often required to join aluminum tube. But there are few suitable methods for joining aluminum tube, so that much interest has been focused on testing suitable joining methods. Joining by electromagnetic forming(EMF) can be useful method in joining aluminum tube, which offers some advantages compared with the conventional joining method. In this paper, joining by EMF was investigated as a pre-study for applying an automotive spaceframe. Finite element simulations and strength tests were performed to analyze the influence of geometric parameters on joint strength. Based on these results, configurations of axial joint and torque joint were suggested and guidelines for designing EMF joint were established

  1. Multi-Objective Optimization of Squeeze Casting Process using Genetic Algorithm and Particle Swarm Optimization

    Directory of Open Access Journals (Sweden)

    Patel G.C.M.

    2016-09-01

    Full Text Available The near net shaped manufacturing ability of squeeze casting process requiresto set the process variable combinations at their optimal levels to obtain both aesthetic appearance and internal soundness of the cast parts. The aesthetic and internal soundness of cast parts deal with surface roughness and tensile strength those can readily put the part in service without the requirement of costly secondary manufacturing processes (like polishing, shot blasting, plating, hear treatment etc.. It is difficult to determine the levels of the process variable (that is, pressure duration, squeeze pressure, pouring temperature and die temperature combinations for extreme values of the responses (that is, surface roughness, yield strength and ultimate tensile strength due to conflicting requirements. In the present manuscript, three population based search and optimization methods, namely genetic algorithm (GA, particle swarm optimization (PSO and multi-objective particle swarm optimization based on crowding distance (MOPSO-CD methods have been used to optimize multiple outputs simultaneously. Further, validation test has been conducted for the optimal casting conditions suggested by GA, PSO and MOPSO-CD. The results showed that PSO outperformed GA with regard to computation time.

  2. Refinement and fracture mechanisms of as-cast QT700-6 alloy by alloying method

    Directory of Open Access Journals (Sweden)

    Min-qiang Gao

    2017-01-01

    Full Text Available The as-cast QT700-6 alloy was synthesized with addition of a certain amount of copper, nickel, niobium and stannum elements by alloying method in a medium frequency induction furnace, aiming at improving its strength and toughness. Microstructures of the as-cast QT700-6 alloy were observed using a scanning-electron microscope (SEM and the mechanical properties were investigated using a universal tensile test machine. Results indicate that the ratio of pearlite/ferrite is about 9:1 and the graphite size is less than 40 μm in diameter in the as-cast QT700-6 alloy. The predominant refinement mechanism is attributed to the formation of niobium carbides, which increases the heterogeneous nucleus and hinders the growth of graphite. Meanwhile, niobium carbides also exist around the grain boundaries, which improve the strength of the ductile iron. The tensile strength and elongation of the as-cast QT700-6 alloy reach over 700 MPa and 6%, respectively, when the addition amount of niobium is 0.8%. The addition of copper and nickel elements contributed to the decrease of eutectoid transformation temperature, resulting in the decrease of pearlite lamellar spacing (about 248 nm, which is also beneficial to enhancing the tensile strength. The main fracture mechanism is cleavage fracture with the appearance of a small amount of dimples.

  3. Wide Panel Testing Technique for Evaluating Repair Weld Strengths

    Science.gov (United States)

    Rogers, Patrick R.; Bynum, Julian E.; Shah, Sandeep R.

    1998-01-01

    This paper describes a new tensile testing technique for evaluating the overall effect of a repair weld on the strength of a welded joint. Previously, repair weld strengths have been evaluated using one-inch width tensile specimens, but this technique does not capture all of the effects that result from a repair. The new technique involves testing of "wide panel" tensile specimens which contain the full length of a repair weld within a longer initial weld, allowing the specimen to capture the combined effects of residual stresses, local strength degradation, and load redistribution around a repair. The development of strains in the repair area of standard aluminum alloy specimens and new high-performance aluminum-lithium alloy specimens was observed and evaluated using photoelastic material. The results of this evaluation show an increased sensitivity to repair welding residual stresses in the aluminum-lithium alloy specimens.

  4. Search for chameleons with CAST

    CERN Document Server

    Anastassopoulos, V; Aune, S; Barth, K; Belov, A; Bräuninger, H; Cantatore, G; Carmona, J M; Cetin, S A; Christensen, F; Collar, J I; Dafni, T; Davenport, M; Desch, K; Dermenev, A; Eleftheriadis, C; Fanourakis, G; Ferrer-Ribas, E; Friedrich, P; Galán, J; García, J A; Gardikiotis, A; Garza, J G; Gazis, E N; Geralis, T; Giomataris, I; Hailey, C; Haug, F; Hasinoff, M D; Hofmann, D H H; Iguaz, F J; Irastorza, I G; Jacoby, J; Jakobsen, A; Jakovčić, K; Kaminski, J; Karuza, M; Kavuk, M; Krčmar, M; Krieger, C; Krüger, A; Lakić, B; Laurent, J M; Liolios, A; Ljubičić, A; Luzón, G; Neff, S; Ortega, I; Papaevangelou, T; Pivovarov, M J; Raffelt, G; Riege, H; Rosu, M; Ruz, J; Savvidis, I; Solanki, S K; Vafeiadis, T; Villar, J A; Vogel, J K; Yildiz, S C; Zioutas, K; Brax, P; Lavrentyev, I; Upadhye, A

    2015-01-01

    In this work we present a search for (solar) chameleons with the CERN Axion Solar Telescope (CAST). This novel experimental technique, in the field of dark energy research, exploits both the chameleon coupling to matter ($\\beta_{\\rm m}$) and to photons ($\\beta_{\\gamma}$) via the Primakoff effect. By reducing the X-ray detection energy threshold used for axions from 1$\\,$keV to 400$\\,$eV CAST became sensitive to the converted solar chameleon spectrum which peaks around 600$\\,$eV. Even though we have not observed any excess above background, we can provide a 95% C.L. limit for the coupling strength of chameleons to photons of $\\beta_{\\gamma}\\!\\lesssim\\!10^{11}$ for $1<\\beta_{\\rm m}<10^6$.

  5. Evaluation and Comparison of the Effects of RRA, T73 and T6 Heat Treatments on Hardness, Tensile and Bending Strengths of 7075 Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    M. Assadi

    2016-09-01

    20 min and in the third stage aging process was repeated like T6 treatment. Evaluation of the microstructures and fractured surfaces were performed with optical microscopes (OM and scanning electron microscopes (SEM. Energy dispersive spectroscopy (EDS was used to study the chemical composition of precipitates. Hardness, tensile and bending strength were evaluated according to ASTM E384-11e1, ASTM B557-06 and DIN 50121 standards. RRA treatment increased tensile strength from 466 to 485 MPa and hardness from 110 to 165 Vickers. After T6 treatment, tensile strength increased from 466 to 505 MPa and hardness from 110 to 160 Vickers. In T73 process, the tensile strength remained almost constant (465 MPa but yield strength increased from 394 to 410 MPa and hardness decreased from 110 to 84 Vickers. The bending strength increased from 797 to 844, 920 and 1030 MPa in T73, RRA and T6 processes, respectively. By applying RRA process in optimized temperature and time, hardness, tensile and bending strengths of 7075 aluminum alloy were enhanced from 5 to 15% compared to that of T6 and T73 processes.

  6. A computational study of low-head direct chill slab casting of aluminum alloy AA2024

    Science.gov (United States)

    Hasan, Mainul; Begum, Latifa

    2016-04-01

    The steady state casting of an industrial-sized AA2024 slab has been modeled for a vertical low-head direct chill caster. The previously verified 3-D CFD code is used to investigate the solidification phenomena of the said long-range alloy by varying the pouring temperature, casting speed and the metal-mold contact heat transfer coefficient from 654 to 702 °C, 60-180 mm/min, and 1.0-4.0 kW/(m2 K), respectively. The important predicted results are presented and thoroughly discussed.

  7. Fatigue behaviour of synthetic nodular cast irons

    Directory of Open Access Journals (Sweden)

    A. Vaško

    2015-01-01

    Full Text Available The paper shows the influence of charge composition on microstructure, fatigue properties and failure micromechanisms of nodular cast irons. The additive of metallurgical silicon carbide (SiC in analysed specimens increases the content of ferrite in the matrix, decreases the size of graphite and increases the average count of graphitic nodules per unit of area. Consequently, the mechanical and fatigue properties of nodular cast iron are improved. The best fatigue properties (fatigue strength were reached in the melt which was created by 60 % of steel scrap and 40 % of pig iron in the basic charge with SiC additive.

  8. Reshock and release response of aluminum single crystal

    International Nuclear Information System (INIS)

    Huang, H.; Asay, J. R.

    2007-01-01

    Reshock and release experiments were performed on single crystal aluminum along three orientations and on polycrystalline 1050 aluminum with 50 μm grain size at shock stresses of 13 and 21 GPa to investigate the mechanisms for previously observed quasielastic recompression behavior. Particle velocity profiles obtained during reshocking both single crystals and polycrystalline aluminum from initial shock stresses of 13-21 GPa show similar quasielastic recompression behavior. Quasielastic release response is also observed in all single crystals, but the magnitude of the effect is crystal orientation dependent, with [111] and [110] exhibiting more ideal elastic-plastic release for unloading from the shocked state than for the [100] orientation and polycrystalline aluminum. The quasielastic response of 1050 aluminum is intermediate to that of the [100] and [111] orientations. Comparison of the wave profiles obtained for both unloading and reloading of single crystals and polycrystalline 1050 aluminum from shocked states suggests that the observed quasielastic response of polycrystalline aluminum results from the averaging response of single crystals for shock propagation along different orientations, and that the response of 1050 aluminum with large grain boundaries is not significantly different from the results obtained on single crystal aluminum. The yield strength of the single crystals and 1050 aluminum is found to increase with shock stress, which is consistent with previous results [H. Huang and I. R. Asay, J. Appl. Phys. 98, 033524 (2005)

  9. Properties of experimental titanium cast investment mixing with water reducing agent solution.

    Science.gov (United States)

    Zhang, Zutai; Ding, Ning; Tamaki, Yukimichi; Hotta, Yasuhiro; Han-Cheol, Cho; Miyazaki, Takashi

    2012-01-01

    This study aimed to develop a dental investment for titanium casting. ZrO(2) and Al(2)O(3) were selected as refractory materials to prepare three investments (Codes: A-C) according to the quantity of Zr. Al(2)O(3) cement was used as a binder at a ratio of 15%, they were mixed with special mixing liquid. B1 was used as a control mixed with water. Fundamental examinations were statistically evaluated. A casting test was performed with investment B. Fluidities, setting times, and green strengths showed no remarkable differences; however, they were significantly different from those of B1. Expansion values for A, B, C, and B1 at 850°C were 1.03%±0.08%, 1.96%±0.17%, 4.35%±0.23%, and 1.50%±0.28%, respectively. Castings were covered by only small amounts of mold materials. The hardness test showed no significant differences between castings from B and the ones from commercial investments. The experimental special mixing liquid effectively reduced the water/powder ratio and improved the strength and thermal expansion.

  10. Rheologic behaviors of A356 aluminum alloy billet produced by semisolid continuous casting process

    Directory of Open Access Journals (Sweden)

    Shuming XING

    2004-08-01

    Full Text Available The experiments for rheologic behaviors of semisolid continous casting billets of A356 alloy in semisolid state has been carried out with a multifunctional rheometer. The results show that the deformation rate increases with loading time, the maximum strain reaches 120% (which is one time larger than that of traditional casting billet and the strain can be rapidly eliminated to 10% after unloading. Moreover, there is a critic stress for billet deformation even in semisolid state, which is named as critic shear stress. This stress increases with the decreasing of heating time. The rheologic behaviors can be expressed by five elements mechanical model and can be modified with the increasing of heating time.

  11. Formation and stability of aluminum-based metallic glasses in Al-Fe-Gd alloys

    International Nuclear Information System (INIS)

    He, Y.; Poon, S.J.; Shiflet, G.J.

    1988-01-01

    Metallic glasses, a class of amorphous alloys made by rapid solidification, have been studied quite extensively for almost thirty years. It has been recognized for a long time that metallic glasses are usually very strong and ductile, and exhibit high corrosion resistance relative to crystalline alloys with the same compositions. Recently, metallic glasses containing as much as 90 atomic percent aluminum have been discovered independently by two groups. This discovery has both scientific and technological implications. The formability of these new glasses have been found to be unusual. Studies of mechanical properties in these new metallic glasses show that many of them have tensile strengths over 800MPa, greatly exceeding the strongest commercial aluminum alloys. The high strengths of aluminum-rich metallic glasses can be of significant importance in obtaining high strength low density materials. Therefore, from both scientific and technological standpoints, it is important to understand the formation and thermal stability of these metallic glasses. Al-Fe-Gd alloys were chosen for a more detailed study since they exhibit high tensile strengths

  12. Mechanical properties of mill-annealed Ti6Al4V investment cast

    CSIR Research Space (South Africa)

    Mutombo, K

    2011-07-01

    Full Text Available Ti6Al4V alloy, produced by investment casting using yttria stabilized zirconia, was machined and then mill-annealed in vacuum furnace. The ultimate strength, yield strength and percentage elongation were largely improved compared to the same alloy...

  13. Impression creep properties of a semi-solid processed magnesium-aluminum alloy containing calcium and rare earth elements

    International Nuclear Information System (INIS)

    Nami, B.; Razavi, H.; Miresmaeili, S.M.; Mirdamadi, Sh.; Shabestari, S.G.

    2011-01-01

    The creep properties of a thixoformed magnesium-aluminum alloy containing calcium and rare earth elements were studied under shear modulus-normalized stresses ranging from 0.0225 to 0.035 at temperatures of 150-212 o C using the impression creep technique. Analysis of the creep mechanism based on a power-law equation indicated that pipe diffusion-controlled dislocation climb is the dominant mechanism during creep. The alloy has a better creep resistance than high-pressure die-cast magnesium-aluminum alloy.

  14. Automatic TV X-ray unit for testing aluminium castings

    International Nuclear Information System (INIS)

    Morgunov, V.I.; Firstov, V.G.; Kisin, V.I.; Savostenok, M.I.

    1989-01-01

    The automatic TV X-ray unit for testing of aluminum alloy castings in a flow is described. The unit includes RAP-150/300 X-ray apparatus and PI-60TK TV X-ray device. The biological protection chamber and the common control board are the main functional units. The tests of the unit have shown that as regards its characteristics it is not worse than its foreign-made analogues, for example, devices of the DP-35 and DP-38 type of the 'Seifert' company

  15. Determination of aluminum by four analytical methods

    International Nuclear Information System (INIS)

    Hanson, T.J.; Smetana, K.M.

    1975-11-01

    Four procedures have been developed for determining the aluminum concentration in basic matrices. Atomic Absorption Spectroscopy (AAS) was the routine method of analysis. Citrate was required to complex the aluminum and eliminate matrix effects. AAS was the least accurate of the four methods studied and was adversely affected by high aluminum concentrations. The Fluoride Electrode Method was the most accurate and precise of the four methods. A Gran's Plot determination was used to determine the end point and average standard recovery was 100% +- 2%. The Thermometric Titration Method was the fastest method for determining aluminum and could also determine hydroxide concentration at the same time. Standard recoveries were 100% +- 5%. The pH Electrode Method also measures aluminum and hydroxide content simultaneously, but is less accurate and more time consuming that the thermal titration. Samples were analyzed using all four methods and results were compared to determine the strengths and weaknesses of each. On the basis of these comparisons, conclusions were drawn concerning the application of each method to our laboratory needs

  16. Initial assessment of the processes and significance of thermal aging in cast stainless steels

    International Nuclear Information System (INIS)

    Chopra, O.K.; Chung, H.M.

    1988-10-01

    Charpy-impact and J-R curve data for thermally aged cast stainless steel are presented. The effects of material variables on the embrittlement of cast materials are evaluated. The chemical composition and ferrite morphology have a strong effect on the kinetics and extent of embrittlement. The procedure and correlations for predicting the impact strength and fracture toughness of cast component during reactor service are described. 19 refs., 17 figs., 4 tabs

  17. Cast Alloys for Advanced Ultra Supercritical Steam Turbines

    Energy Technology Data Exchange (ETDEWEB)

    G. R. Holcomb, P. Wang, P. D. Jablonski, and J. A. Hawk,

    2010-05-01

    The proposed steam inlet temperature in the Advanced Ultra Supercritical (A-USC) steam turbine is high enough (760 °C) that traditional turbine casing and valve body materials such as ferritic/martensitic steels will not suffice due to temperature limitations of this class of materials. Cast versions of several traditionally wrought Ni-based superalloys were evaluated for use as casing or valve components for the next generation of industrial steam turbines. The full size castings are substantial: 2-5,000 kg each half and on the order of 100 cm thick. Experimental castings were quite a bit smaller, but section size was retained and cooling rate controlled to produce equivalent microstructures. A multi-step homogenization heat treatment was developed to better deploy the alloy constituents. The most successful of these cast alloys in terms of creep strength (Haynes 263, Haynes 282, and Nimonic 105) were subsequently evaluated by characterizing their microstructure as well as their steam oxidation resistance (at 760 and 800 °C).

  18. The Properties of Arc-Sprayed Aluminum Coatings on Armor-Grade Steel

    Directory of Open Access Journals (Sweden)

    Marcin Adamiak

    2018-02-01

    Full Text Available This article presents the results of an examination of the properties of arc-sprayed aluminum on alloyed armor-grade steel. Thermal arc spraying was conducted with a EuTronic Arc Spray 4 wire arc sprayer. Aluminum wire 1.6 mm in diameter was used to produce dense, abrasion- and erosion-resistant coatings approx. 1.0 mm thick with and without nickel/5% aluminum-buffered subcoating. Aluminum coatings were characterized in accordance with ASTM G 65-00 abrasion resistance test, ASTM G 76-95 erosion resistance tests, ASTM C 633-01 adhesion strength, HV0.1 hardness tests and metallographic analyses. Results demonstrate properties of arc-sprayed aluminum and aluminum-nickel material coatings that are especially promising in industrial applications where erosion-, abrasion- and corrosion-resistant coating properties are required.

  19. Three-dimensional stress and strain around real shape Si particles in cast aluminum alloy under cyclic loading

    Energy Technology Data Exchange (ETDEWEB)

    Teranishi, Masaki [Department of Nuclear Power & Energy Safety Engineering, University of Fukui (Japan); Kuwazuru, Osamu, E-mail: kuwa@u-fukui.ac.jp [Department of Nuclear Power & Energy Safety Engineering, University of Fukui (Japan); Gennai, Shota [Department of Nuclear Power & Energy Safety Engineering, University of Fukui (Japan); Kobayashi, Masakazu [Department of Mechanical Engineering, Toyohashi University of Technology (Japan); Toda, Hiroyuki [Department of Mechanical Engineering, Kyushu University (Japan)

    2016-12-15

    The crack initiation mechanism of cast Al-Si-Mg alloy under low-cycle fatigue was addressed by using the synchrotron X-ray computed tomography (CT) and the image-based finite element analysis. The fatigue test and its in situ CT observation were conducted to visualize the crack initiation behavior. In the low-cycle fatigue, the cracking generally started with the voiding by the fracture of silicon particles, and the coalescence of these voids formed the crack. To elucidate the mechanism of silicon particle fracture, the finite element elastic-plastic analyses were performed with regard to twelve silicon particles including the fractured and intact particles detected by the chronological CT observation. By using the image-based modeling technique, the interested particle was embedded in the finite element model along with the surrounding particles as they were in the specimen. The material properties of silicon phase and aluminum matrix were identified by the nanoindentation tests. Ten cycles of loading by the uniform stress which was equivalent to the load in the fatigue test was applied to the finite element model, and the stress, strain and their cyclic response around the silicon particles were simulated. The morphology analysis was also carried out for the interested particles, and the geometrical parameters affecting the particle fracture were examined. By comparing the results of fractured and intact particles, we found that there were some geometrical conditions for the fracture of silicon particles, and a certain magnitude of hydrostatic stress was required to break the particles.

  20. Study of Shell Zone Formation in Lithographic and Anodizing Quality Aluminum Alloys: Experimental and Numerical Approach

    Science.gov (United States)

    Brochu, Christine; Larouche, André; Hark, Robert

    Shell thickness is an important quality factor for lithographic and anodizing quality aluminum alloys. Increasing pressure is placed on casting plants to produce a thinner shell zone for these alloys. This study, based on plant trials and mathematical modelling highlights the most significant parameters influencing shell zone formation. Results obtained show the importance of metal temperature and distribution and mould metal level on shell zone formation. As an answer to specific plant problems, this study led to the development of improved metal distribution systems for DC casting of litho and anodizing quality alloys.

  1. THE CORROSION BEHAVIOR AND WEAR RESISTANCE OF GRAY CAST IRON

    Directory of Open Access Journals (Sweden)

    Lina F. Kadhim

    2018-01-01

    Full Text Available Gray cast iron has many applications as pipes , pumps and valve bodies where it has influenced by heat and contact with other solutions . This research has studied the corrosion behavior and Vickers hardness of gray cast iron by immersion in four strong alkaline solutions (NaOH, KOH, Ca(OH2, LiOHwith three concentrations (1%,2%,3% of each solution. Dry sliding wear has carried out before and after the heat treatments (stress relief ,normalizing, hardening and tempering. In this work ,maximum wear strength has obtained at tempered gray cast iron and minimum corrosion rate has obtained in LiOH solution by forming protective white visible oxide layer.

  2. Technology for producing synthetic cast iron for nuclear power station parts

    International Nuclear Information System (INIS)

    Blozhko, N.K.; Kurochkin, V.S.; Narkevich, E.A.; Nikitin, L.A.; Petrov, L.A.

    1984-01-01

    A technology was developed and implemented for producing grades SCh-30 through SCh-40 synthetic cast iron in industrial-frequency induction melting furnaces. Alternative innoculations with ferrosilicon and silicocalcium and alloying with chrome and nickel were studied. The mechanical properties and structure of cast irons produced by various technological methods were studied. The research showed that the sector's plants, equipped with industrial-frequency induction furnaces, can produce high-quality synthetic cast irons containing flake graphite for nuclear-power-station casting, without the use of expensive innoculants. Careful observance of the melting and innoculating technologies makes it possible to produce SCh 40 cast iron, without cementite inclusions, by innoculating with FS 75 ferrosilicon in the amount of 0.7% of the total melt weight. Using an innoculant mixture of 0.2% FS 75 and 0.5% SK 30 and low alloying with nickel and chromium, the cast-iron strength can be increased to 440-450 MPa, although the danger of cementite inclusions increase

  3. Current and Future Uses of Aluminum in the Automotive Industry

    Science.gov (United States)

    Long, R. S.; Boettcher, E.; Crawford, D.

    2017-12-01

    Aluminum use is growing in automotive closures and body in white applications to improve vehicle performance and fuel economy. The auto industry is looking for higher-strength aluminum materials needed for strength-driven safety-critical parts. Through cooperation with industrial partners and support from the Department of Energy (DOE), multiple experimental 7xxx alloys were developed for automotive applications. The objective is to enable complex shapes to be formed at temperatures below 225°C. A demonstration part has been developed that is representative of the forming challenges within a current hot-stamped door ring component. This part tooling has been built and installed into a press line which includes blank heating and robotic transfer. Forming trials of these alloys are currently underway and the formability, strength and corrosion performance of these materials are being evaluated.

  4. FINITE-ELEMENT MODELING OF HOT FORMING OF BUSHES MADE FROM HIGH-STRENGTH CAST IRON WITH A GRADIENT DISTRIBUTION OF GRAPHITE INCLUSIONS OVER CROSS-SECTION

    Directory of Open Access Journals (Sweden)

    A. I. Pokrovsky

    2016-01-01

    Full Text Available Imitation modeling of direct hot extrusion of bushes made from high-strength cast iron is performed using finite-element method. The evolution of stress and strain fields during processing and the probability of crack formation are evaluated. The specific feature of the work is that during hot forming a special technique was used which permitted obtaining a gradient distribution of graphite inclusions over the cross-section of bushes. The results of modeling are used in certain technologies which are implemented in industrial practice.

  5. Aluminum alloy excellent in neutron absorbing performance

    International Nuclear Information System (INIS)

    Iida, Tetsuya; Tamamura, Tadao; Morimoto, Hiroyuki; Ouchi, Ken-ichiro.

    1987-01-01

    Purpose: To obtain structural materials made of aluminum alloys having favorable neutron absorbing performance and excellent in the performance as structural materials such as processability and strength. Constitution: Powder of Gd 2 O 3 as a gadolinium compound or metal gadolinium is uniformly mixed with the powder of aluminum or aluminum alloy. The amount of the gadolinium compound added is set to 0.1 - 30 % by weight. No sufficient neutron absorbing performance can be obtained if it is less than 0.1 % by weight, whereas the processability and mechanical property of the alloy are degraded if it exceeds 30 % by weight. Further, the grain size is set to less about 50 μm. Further, since the neutron absorbing performance varies greatly if the aluminum powder size exceeds 100 μm, the diameter is set to less than about 100 μm. These mixtures are molded in a hot press. This enables to obtain aimed structural materials. (Takahashi, M.)

  6. Evaluation of the mechanical properties of Niobium modified cast AISI H 13 hot work tool steel

    International Nuclear Information System (INIS)

    Noorian, A.; Kheirandish, Sh.; Saghafian, H.

    2010-01-01

    In this research, the effects of partially replacing of vanadium and molybdenum with niobium on the mechanical properties of AISIH 13 hot-work tool steel have been studied. Cast samples made of the modified new steel were homogenized and austenitized at different conditions, followed by tempering at the specified temperature ranges. Hardness, red hardness, three point bending test and Charpy impact test were carried out to evaluate the mechanical properties together with characterizing the microstructure of the modified steel using scanning electron microscope. The results show that niobium addition modifies the cast structure of Nb-alloyed steel, and increases its maximum hardness. It was found that bending strength; bending strain, impact strength, and red hardness of the modified cast steel are also higher than those of the cast H13 steel, and lower than those of the wrought H13 steel.

  7. A Comparative Study on Permanent Mold Cast and Powder Thixoforming 6061 Aluminum Alloy and Sicp/6061Al Composite: Microstructures and Mechanical Properties

    Directory of Open Access Journals (Sweden)

    Xuezheng Zhang

    2016-05-01

    Full Text Available Microstructural and mechanical characterization of 10 vol% SiC particles (SiCp reinforced 6061 Al-based composite fabricated by powder thixoforming (PTF was investigated in comparison with the PTF and permanent mold cast (PMC 6061 monolithic alloys. The results reveal that the microstructure of the PMC alloy consists of coarse and equiaxed α dendrites and interdendritic net-like eutectic phases. However, the microstructure of the PTF composite, similar to that of the PTF alloy, consists of near-spheroidal primary particles and intergranular secondarily solidified structures except SiCp, which are distributed in the secondarily solidified structures. The eutectics amount in the PTF materials is distinctly lower than that in the PMC alloy, and the microstructures of the former materials are quite compact while that of the latter alloy is porous. Therefore, the PTF alloy shows better tensile properties than the PMC alloy. Owing to the existence of the SiC reinforcing particles, the PTF composite attains an ultimate tensile strength and yield strength of 230 MPa and 128 MPa, representing an enhancement of 27.8% and 29.3% than those (180 MPa and 99 MPa of the PTF alloy. A modified model based on three strengthening mechanisms was proposed to calculate the yield strength of the PTF composite. The obtained theoretical results were quite consistent with the experimental data.

  8. A Comparative Study on Permanent Mold Cast and Powder Thixoforming 6061 Aluminum Alloy and Sicp/6061Al Composite: Microstructures and Mechanical Properties.

    Science.gov (United States)

    Zhang, Xuezheng; Chen, Tijun; Qin, He; Wang, Chong

    2016-05-24

    Microstructural and mechanical characterization of 10 vol% SiC particles (SiC p ) reinforced 6061 Al-based composite fabricated by powder thixoforming (PTF) was investigated in comparison with the PTF and permanent mold cast (PMC) 6061 monolithic alloys. The results reveal that the microstructure of the PMC alloy consists of coarse and equiaxed α dendrites and interdendritic net-like eutectic phases. However, the microstructure of the PTF composite, similar to that of the PTF alloy, consists of near-spheroidal primary particles and intergranular secondarily solidified structures except SiC p , which are distributed in the secondarily solidified structures. The eutectics amount in the PTF materials is distinctly lower than that in the PMC alloy, and the microstructures of the former materials are quite compact while that of the latter alloy is porous. Therefore, the PTF alloy shows better tensile properties than the PMC alloy. Owing to the existence of the SiC reinforcing particles, the PTF composite attains an ultimate tensile strength and yield strength of 230 MPa and 128 MPa, representing an enhancement of 27.8% and 29.3% than those (180 MPa and 99 MPa) of the PTF alloy. A modified model based on three strengthening mechanisms was proposed to calculate the yield strength of the PTF composite. The obtained theoretical results were quite consistent with the experimental data.

  9. Microstructure and mechanical properties of TiAl castings produced by zirconia ceramic mould

    Directory of Open Access Journals (Sweden)

    Tian Jing

    2011-11-01

    Full Text Available Owing to their low density and attractive high-temperature properties, gamma titanium aluminide alloys (TiAl alloys, hereafter have significant potential application in the aerospace and automobile industries, in which these materials may replace the heavier nickel-based superalloys at service temperatures of 600 – 900℃. Investment casting of TiAl alloys has become the most promising cost-effective technique for the manufacturing of TiAl components. Ceramic moulds are fundamental to fabricating the TiAl casting components. In the present work, ceramic mould with a zirconia primary coat was designed and fabricated successfully. Investment casting of TiAl blades and tensile test of specimens was carried out to verify the correctness and feasibility of the proposed method. The tensile test results indicate that, at room temperature, the tensile strength and the elongation are about 450 MPa and 0.8%, respectively. At 700℃, the tensile strength decreases to about 410 MPa and the elongation increases to 2.7%. Microstructure and mechanical properties of investment cast TiAl alloy are discussed.

  10. Microstructure of As-cast Co-Cr-Mo Alloy Prepared by Investment Casting

    Science.gov (United States)

    Park, Jong Bum; Jung, Kyung-Hwan; Kim, Kang Min; Son, Yong; Lee, Jung-Il; Ryu, Jeong Ho

    2018-04-01

    The microstructure of a cobalt-base alloy (Co-Cr-Mo) obtained by an investment casting process was studied. This alloy complies with the ASTM F75 standard and is widely used in the manufacturing of orthopedic implants owing to its high strength, good corrosion resistance, and excellent biocompatibility. This work focuses on the resulting microstructures arising from normal industrial environmental conditions. The characterization of the samples was carried out using optical microscopy, field emission scanning electron microscopy and energy-dispersive spectroscopy. In this study, the as-cast microstructure is an γ-Co (face-centered cubic) dendritic matrix with the presence of a secondary phase, such as M23C6 carbides precipitated at grain boundaries and interdendritic zones. These precipitates are the main strengthening mechanism in this type of alloy. Other minority phases, such as the σ phase, were also detected, and their presence could be linked to the manufacturing process and environment.

  11. Characterisation of solution cast cellulose nanofibre – reinforced poly(lactic acid

    Directory of Open Access Journals (Sweden)

    2010-01-01

    Full Text Available Cellulose nanofibres, 20 nm in diameter and 300 nm long, were prepared by acid hydrolysis of flax yarns. Composite films containing 2.5 and 5.0 wt% flax cellulose (FC fibres were prepared by solution casting of mixtures of poly(lactic acid (PLA solution and cellulose nanofibre suspension in chloroform. The resulting composite films and solution cast pure PLA film, with thickness of around 160 m, showed good transparency. For composites with 2.5 and 5.0 wt% FC, the tensile strength increased by 25 and 59% and tensile modulus by 42 and 47%, respectively, compared to pure PLA film. The composite film with 2.5 wt% FC combined high strength and ductility with tensile strength of 24.3 MPa and 70% elongation at break. Flax cellulose appeared to facilitate nucleation and subsequent crystallisation of PLA more effectively in the amorphous composites than in the crystalline composites.

  12. Effect of rare earth element on microstructure formation and mechanical properties of thin wall ductile iron castings

    International Nuclear Information System (INIS)

    Choi, J.O.; Kim, J.Y.; Choi, C.O.; Kim, J.K.; Rohatgi, P.K.

    2004-01-01

    Ductile iron castings with 2, 3, 4, 6, 8, and 25 mm thickness and various amount of rare earth elements (RE) (from 0 to 0.04%), were cast in sand molds to identify the effects of sample thickness and the content of RE% on microstructural formation and selected mechanical properties. The effects of RE content and sample thickness on microstructural formation, including on graphite nodule count, graphite nodule shape, spherodization, and ferrite amount, were observed. The yield strength of the samples with RE within the range investigated were lower than those of the specimens without RE. The elongation was improved with the addition of RE up to 0.03% in ductile iron castings. The additions of 0.02% RE caused a smaller graphite nodule size and a higher number of graphite nodules than those in the specimen without RE at all levels of RE addition; the nodule count decreased with increase in section size. The chill zones were observed in the 2 mm thick samples, but were absent in the samples from castings which were thicker than 2 mm, irrespective of the addition of RE. The nodularity of graphite nodules improved due to the addition of 0.02-0.04% RE. The specimens with RE content up to 0.03% had a lower tensile strength and hardness, higher elongation than that of the specimens without RE. The ferrite content in all castings increased with additions of 0.02% RE. The tensile strengths of the 2 and 3 mm thick samples were also estimated using the relationship between strength and hardness, obtained from the data on the tensile strength and hardness of the 25 mm thick samples

  13. Nodular cast iron and casting monitoring

    Directory of Open Access Journals (Sweden)

    S. Pietrowski

    2008-10-01

    Full Text Available In this paper quality monitoring of nodular cast iron and casting made of it is presented. A control system of initial liquid cast iron to spheroidization, after spheroidization and inoculation with using of TDA method was shown. An application of an ultrasonic method to assessment of the graphite form and the metal matrix microstructure of castings was investigated.

  14. Filtration Efficiency of Functionalized Ceramic Foam Filters for Aluminum Melt Filtration

    Science.gov (United States)

    Voigt, Claudia; Jäckel, Eva; Taina, Fabio; Zienert, Tilo; Salomon, Anton; Wolf, Gotthard; Aneziris, Christos G.; Le Brun, Pierre

    2017-02-01

    The influence of filter surface chemistry on the filtration efficiency of cast aluminum alloys was evaluated for four different filter coating compositions (Al2O3—alumina, MgAl2O4—spinel, 3Al2O3·2SiO2—mullite, and TiO2—rutile). The tests were conducted on a laboratory scale with a filtration pilot plant, which facilitates long-term filtration tests (40 to 76 minutes). This test set-up allows the simultaneous use of two LiMCAs (before and after the filter) for the determination of the efficiency of inclusion removal. The four tested filter surface chemistries exhibited good thermal stability and mechanical robustness after 750 kg of molten aluminum had been cast. All four filter types exhibited a mean filtration efficiency of at least 80 pct. However, differences were also observed. The highest filtration efficiencies were obtained with alumina- and spinel-coated filter surfaces (>90 pct), and the complete removal of the largest inclusions (>90 µm) was observed. The efficiency was slightly lower with mullite- and rutile-coated filter surfaces, in particular for large inclusions. These observations are discussed in relation to the properties of the filters, in particular in terms of, for example, the surface roughness.

  15. Effect of Zirconia Nanoparticles in Epoxy-Silica Hybrid Adhesives to Join Aluminum Substrates

    Directory of Open Access Journals (Sweden)

    José de Jesús Figueroa-Lara

    2017-09-01

    Full Text Available This research presents the interaction of the epoxy polymer diglicydil ether of bisphenol-A (DGEBA with silica (SiO2 nanoparticles plus zirconia (ZrO2 nanoparticles obtained via the sol-gel method in the synthesis of an epoxy-silica-zirconia hybrid adhesive cured with polyamide. ZrO2 nanoparticles were added to the epoxy-silica hybrid adhesive produced in situ to modify the apparent shear strength of two adhesively bonded aluminum specimens. The results showed that the addition of different amounts of ZrO2 nanoparticles increased the shear strength of the adhesively bonded aluminum joint, previously treated by sandblasting, immersion in hot water and silanized with a solution of hydrolyzed 3-glycidoxipropyltrimethoxysilane (GPTMS. The morphology and microstructure of the nanoparticles and aluminum surfaces were examined by scanning electron microscopy (SEM, and elemental analysis was performed with the Energy-dispersive X-ray spectroscopy (EDS detector; the chemical groups were investigated during the aluminum surface modification using Fourier transform infrared spectroscopy (FTIR.

  16. Strengthening mechanism in graphene nanoplatelets reinforced aluminum composite fabricated through spark plasma sintering

    Energy Technology Data Exchange (ETDEWEB)

    Bisht, Ankita [Biomaterials and Multiscale Mechanics Laboratory, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Uttarakhand 247667 (India); Srivastava, Mukul [Biomaterials and Multiscale Mechanics Laboratory, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Uttarakhand 247667 (India); Nanomaterials and Applications Laboratory, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Uttarakhand 247667 (India); Kumar, R. Manoj [Biomaterials and Multiscale Mechanics Laboratory, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Uttarakhand 247667 (India); Lahiri, Indranil [Nanomaterials and Applications Laboratory, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Uttarakhand 247667 (India); Lahiri, Debrupa, E-mail: dlahifmt@iitr.ac.in [Biomaterials and Multiscale Mechanics Laboratory, Department of Metallurgical and Materials Engineering, Indian Institute of Technology Roorkee, Uttarakhand 247667 (India)

    2017-05-17

    Graphene nanoplatelets (GNP) reinforced aluminum matrix composites, with ≤5 wt% GNP content, were synthesized by spark plasma sintering (SPS). GNPs were found to withstand severe conditions of high pressure and temperature during processing. Strength of composite was observed to be depending on the content and uniform dispersion of GNP in aluminum matrix, as verified by scanning electron micrographs. X-ray diffraction analysis confirmed that no reaction products exist at Al-GNP interface in significant amount. Instrumented indentation studies revealed improvement in hardness by 21.4% with 1 wt% GNP. This is due to the presence of stronger reinforcement, which provides high resistance to matrix against deformation. Improvement in yield strength and tensile strength was 84.5% and 54.8%, respectively, with 1 wt% GNP reinforcement. Properties deteriorated at higher concentration due to agglomeration of GNP. Reinforcing effect of GNPs, in terms of strengthening of composite, is found to be dominated by Orowan strengthening mechanism. Pinning of grains boundaries by GNPs led to uniform grain size distribution in the composites structure. Overall, graphene reinforcement has offered 86% improvement in specific strength of aluminum matrix.

  17. Influence of heat treatment on microstructure and properties of GX12CrMoVNbN9-1 cast steel

    Directory of Open Access Journals (Sweden)

    G. Golański

    2010-07-01

    Full Text Available The paper presents results of research on the influence of multistage heat treatment on microstructure and properties of high-chromiummartensitic GX12CrMoVNbN9 – 1 (GP91 steel. The material under investigation were samples taken out from a test coupon. Heattreatment of GP91 cast steel was performed at the parameters of temperature and time typical of treatment for multi-ton steel casts. The research has proved that in the as-received condition (as-cast state GP91 cast steel was characterized by a coarse grain, martensitic microstructure which provided the required standard mechanical properties. The heat treatment of GP91 cast steel contributed to obtainment of a fine grain microstructure of high tempered martensite with numerous precipitations of carbides of diverse size. The GP91 cast steel structure received through heat treatment made it possible to obtain high plastic properties, particularly impact strength, maintaining strength properties on the level of the required minimum.

  18. Thermomechanical treatment of welded joints of aluminum-lithium alloys modified by scandium

    Science.gov (United States)

    Malikov, A. G.

    2017-12-01

    At present, the aeronautical equipment manufacture involves up-to-date high-strength aluminum alloys of decreased density resulting from the lithium admixture. Various technologies of fusible welding of these alloys are being developed. The paper presents experimental investigations of the optimization of the laser welding of aluminum alloys with the scandium-modified welded joint after thermomechanical treatment. The effect of scandium on the micro- and macrostructure is studied along with strength characteristics of the welded joint. It is found that thermomechanical treatment allows us to obtain the strength of the welded joint 0.89 for the Al-Mg-Li system and 0.99 for the Al-Cu-Li system with the welded joint modified by scandium in comparison with the base alloy after treatment.

  19. Long-term embrittlement of cast duplex stainless steels in LWR systems

    International Nuclear Information System (INIS)

    Chopra, O.K.; Chung, H.M.

    1990-08-01

    This progress report summarizes work performed by Argonne National Laboratory on long-term embrittlement of cast duplex stainless steels in LWR systems during the six months from April to September 1988. Characteristics of the primary mechanism of aging embrittlement (i.e., spinodal decomposition of ferrite) and synergistic effects of alloying and impurity elements that influence the kinetics of the primary mechanism are discussed. Several secondary metallurgical processes of embrittlement, strongly dependent on the C, N, Ni, Mo, and Si content of various heats, are identified. Information on kinetics and data on impact properties are analyzed and correlated with microstructural characteristics to provide a unified method of extrapolating accelerated-aging data to reactor operating conditions. Fracture toughness data are presented for several heats of cast stainless steel aged at temperatures between 320 and 450 degrees C for times up to 10,000 h. Mechanical property data are analyzed to develop the procedure and correlations or predicting the kinetics and extent of embrittlement of reactor components from known material parameters. The method and examples of estimating the impact strength and fracture toughness of cast components during reactor service are described. The lower-bound values of impact strength and fracture toughness for cast stainless steels at LWR operating temperatures are defined. 42 refs., 14 figs., 6 tabs

  20. Graphene-reinforced aluminum matrix composites prepared by spark plasma sintering

    Institute of Scientific and Technical Information of China (English)

    Wen-ming Tian; Song-mei Li; Bo Wang; Xin Chen; Jian-hua Liu; Mei Yu

    2016-01-01

    Graphene-reinforced 7055 aluminum alloy composites with different contents of graphene were prepared by spark plasma sinter-ing (SPS). The structure and mechanical properties of the composites were investigated. Testing results show that the hardness, compressive strength, and yield strength of the composites are improved with the addition of 1wt% graphene. A clean, strong interface is formed between the metal matrix and graphene via metallurgical bonding on atomic scale. Harmful aluminum carbide (Al4C3) is not formed during SPS processing. Further addition of graphene (above 1wt%) results in the deterioration in mechanical properties of the composites. The agglomeration of graphene plates is exacerbated with increasing graphene content, which is the main reason for this deterioration.

  1. Graphite nodules in fatigue-tested cast iron characterized in 2D and 3D

    DEFF Research Database (Denmark)

    Mukherjee, Krishnendu; Fæster, Søren; Hansen, Niels

    2017-01-01

    Thick-walled ductile iron casts have been studied by applying (i) cooling rate calculations by FVM, (ii) microstructural characterization by 2D SEM and 3D X-ray tomography techniques and (iii) fatigue testing of samples drawn from components cast in sand molds and metal molds. An analysis has shown...... correlations between cooling rate, structure and fatigue strengths demonstrating the benefit of 3D structural characterization to identify possible causes of premature fatigue failure of ductile cast iron....

  2. Experimental studies of thermal and chemical interactions between molten aluminum and water

    Energy Technology Data Exchange (ETDEWEB)

    Farahani, A.A.; Corradini, M.L. [Univ. of Wisconsin, Madison, WI (United States)

    1995-09-01

    The possibility of rapid physical and chemical aluminum/water interactions during a core melt accident in a noncommercial reactor (e.g., HFIR, ATR) has resulted in extensive research to determine the mechanism by which these interactions occur and propagate on an explosive time scale. These events have been reported in nuclear testing facilities, i.e., during SPERT 1D experiment, and also in aluminum casting industries. Although rapid chemical reactions between molten aluminum and water have been subject of many studies, very few reliable measurements of the extent of the chemical reactions have thus far been made. We have modified an existing 1-D shock tube facility to perform experiments in order to determine the extent of the explosive thermal/chemical interactions between molton aluminum and water by measuring important physical quantities such as the maximum dynamic pressure and the amount of the generated hydrogen. Experimental results show that transient pressures greater than 69 MPa with a rise time of less than 125 {mu}sec can occur as the result of the chemical reaction of 4.2 grams of molton aluminum (approximately 15% of the total mass of the fuel of 28 grams) at 980 C with room temperature water.

  3. The evaluation of dynamic cracking resistance of chosen casting alloys in the aspect of the impact bending test

    Directory of Open Access Journals (Sweden)

    J.Sadowski

    2008-10-01

    Full Text Available The increase of quality and durability of produced casting alloys can be evaluated on the base of material tests performed on a high level. One of such modern test methods are tests of the dynamic damage process of materials and the evaluation on the base of obtained courses F(f, F(t of parameters of dynamic cracking resistance KId, JId, performed with the usage of instrumented Charpy pendulums. In the paper there was presented the evaluation of dynamic cracking resistance parameters of casting alloys such as: AK12 aluminum alloy, L20G cast steel and spheroid cast iron. The methodology of the evaluation of that parameters was described and their change as well, for the AK12 alloy with the cold work different level, L20G cast steel cooled from different temperatures in the range +20oC -60oC, and for the spheroid cast iron in different stages of treatment i.e. raw state, after normalization, spheroid annealing and graphitizing annealing.Obtained parameters of dynamic cracking resistance KId, JId of tested casting alloys enabled to define the critical value of the ad defect that can be tolerated by tested castings in different work conditions with impact loadings.

  4. In vitro shear bond strength of cementing agents to fixed prosthodontic restorative materials.

    Science.gov (United States)

    Piwowarczyk, Andree; Lauer, Hans-Christoph; Sorensen, John A

    2004-09-01

    Durable bonding to fixed prosthodontic restorations is desirable; however, little information is available on the strength of the bond between different cements and fixed prosthodontic restorative materials. This study determined the shear-bond strength of cementing agents to high-gold-content alloy castings and different dental ceramics: high-strength aluminum oxide (Procera AllCeram), leucite-reinforced (IPS Empress), and lithium disilicate glass-ceramic (IPS Empress 2). Prepolymerized resin composite cylinders (5.5 mm internal diameter, n=20) were bonded to the pretreated surfaces of prosthodontic materials. High-gold-content alloy and high-strength aluminum oxide surfaces were airborne-particle-abraded, and pressable ceramics were hydrofluoric acid-etched and silanized prior to cementing. The cementing agents tested were a zinc-phosphate cement (Fleck's zinc cement), glass ionomer cements (Fuji I, Ketac-Cem), resin-modified glass ionomer cements (Fuji Plus, Fuji Cem, RelyX Luting), resin cements (RelyX ARC, Panavia F, Variolink II, Compolute), and a self-adhesive universal resin cement (RelyX Unicem). Half the specimens (n=10) were tested after 30 minutes; the other half (n=10) were stored in distilled water at 37 degrees C for 14 days and then thermal cycled 1000 times between 5 degrees C and 55 degrees C prior to testing. Shear-bond strength tests were performed using a universal testing machine at a constant crosshead speed of 0.5 mm/min. Statistical analysis was performed by multifactorial analysis of variance taking interactions between effects into account. For multiple paired comparisons, the Tukey method was used (alpha=.05). In a 3-way ANOVA model, the main factors substrate, cement, time, and all corresponding interactions were statistically significant (all P <.0001). In subsequent separate 1-way or 2-way ANOVA models for each substrate type, significant differences between cement types and polymerizing modes were found (all P <.001). None of the

  5. Inertia and friction welding of aluminum alloy 1100 to type 316 stainless steel

    International Nuclear Information System (INIS)

    Perkins, M.A.

    1979-01-01

    The inertia and friction-welding processes were evaluated for joining aluminum alloy 1100-H14 and Type 316 vacuum-induction melted, vacuum-arc remelted (VIM VAR) stainless steel. While both processes consistently produced joints in which the strength exceeded the strength of the aluminum base metal, 100 percent bonding was not reliably achieved with inertia welding. The deficiency points out the need for development of nondestructive testing techniques for this type of joint. Additionally, solid-state volume diffusion did not appear to be a satisfactory explanation for the inertia and friction-welding bonding mechanism

  6. Mechanical joining of materials with limited ductility: Analysis of process-induced defects

    Science.gov (United States)

    Jäckel, M.; Coppieters, S.; Hofmann, M.; Vandermeiren, N.; Landgrebe, D.; Debruyne, D.; Wallmersberger, T.; Faes, K.

    2017-10-01

    The paper shows experimental and numerical analyses of the clinching process of 6xxx series aluminum sheets in T6 condition and the self-pierce riveting process of an aluminum die casting. In the experimental investigations the damage behavior of the materials when using different tool parameters is analyzed. The focus of the numerical investigations is the damage prediction by a comparison of different damage criteria. Moreover, strength-and fatigue tests were carried out to investigate the influence of the joining process-induced damages on the strength properties of the joints.

  7. Study on Type C Coal Fly ash as an Additive to Molding Sand for Steel Casting

    Science.gov (United States)

    Palaniappan, Jayanthi

    2017-04-01

    Study of physio-chemical properties studies such as granulometric analysis, moisture, X ray fluorescence etc. were performed with Type C coal—combustion fly ash to investigate their potential as a distinct option for molding sand in foundry, thereby reducing the dependency on latter. Technological properties study such as compressive strength, tensile strength, permeability and compaction of various compositions of fly ash molding sand (10, 20 and 30 % fly ash substitute to chemically bonded sand) were performed and compared with silica molding sand. Steel casting production using this fly ash molding sand was done and the casting surface finish and typical casting parameters were assessed. It was noted that a good quality steel casting could be produced using type C fly ash molding sand, which effectively replaced 20 % of traditional molding sand and binders thereby providing greater financial profits to the foundry and an effective way of fly ash utilization (waste management).

  8. Factors affecting the grain-refinement of aluminum using titanium and boron additives

    International Nuclear Information System (INIS)

    Jones, G.P.; Pearson, J.

    1976-01-01

    The development of grain-refining techniques for the casting of aluminum, and the results achieved using additions of ternary Al--Ti--B master-alloys, are briefly described. A test procedure is given for assessing the relative effectiveness of these master-alloys, and the results are related to the various kinds of alloy treated, including those with constituents which poison the grain-refining agent. The equilibrium conditions which affect the behavior of the constituents of the grain-refined alloys are examined quantitatively from a thermodynamic viewpoint. One theory about the mechanism of nucleation of aluminum on titanium diboride is examined and found inapplicable. New data on the solubility of TiB 2 , ZrB 2 , TiC, ZrC, Cr 3 C 2 , and CrB 2 in liquid aluminum are presented graphically. Practical aspects of alloy behavior in grain-refining practice are analyzed and discussed on the basis of the quantitative data

  9. Effects of low-frequency magnetic field on grain boundary segregation in horizontal direct chill casting of 2024 aluminum alloy

    Institute of Scientific and Technical Information of China (English)

    2005-01-01

    Effects of low frequency electromagnetic field on grain boundary segregation in horizontal direct chill (HDC)casting process was investigated experimentally. The grain boundary segregation and microstructures of the ingots,which manufactured by conventional HDC casting and low frequency electromagnetic HDC casting were compared.Results show that low frequency electromagnetic field significantly refines the microstructures and reduces grain boundary segregation. Decreasing electromagnetic frequency or increasing electromagnetic intensity has great effects in reducing grain boundary segregation. Meanwhile, the governing mechanisms were discussed.

  10. The Effects of Grain Refinement and Rare Earth Intermetallics on Mechanical Properties of As-Cast and Wrought Magnesium Alloys

    Science.gov (United States)

    Pourbahari, Bita; Mirzadeh, Hamed; Emamy, Massoud

    2018-03-01

    The effects of rare earth intermetallics and grain refinement by alloying and hot extrusion on the mechanical properties of Mg-Gd-Al-Zn alloys have been studied to elucidate some useful ways to enhance the mechanical properties of magnesium alloys. It was revealed that aluminum as an alloying element is a much better grain refining agent compared with gadolinium, but the simultaneous presence of Al and Gd can refine the as-cast grain size more efficiently. The presence of fine and widely dispersed rare earth intermetallics was found to be favorable to achieve finer recrystallized grains during hot deformation by extrusion. The presence of coarse dendritic structure in the GZ61 alloy, grain boundary eutectic containing Mg17Al12 phase in the AZ61 alloy, and rare earth intermetallics with unfavorable morphology in the Mg-4Gd-2Al-1Zn alloy was found to be detrimental to mechanical properties of the alloy in the as-cast condition. As a result, the microstructural refinement induced by hot extrusion process resulted in a significant enhancement in strength and ductility of the alloys. The presence of intermetallic compounds in the extruded Mg-4Gd-2Al-1Zn and Mg-2Gd-4Al-1Zn alloys deteriorated tensile properties, which was related to the fact that such intermetallic compounds act as stress risers and microvoid initiation sites.

  11. Microstructure and tensile properties of bulk nanostructured aluminum/graphene composites prepared via cryomilling

    Energy Technology Data Exchange (ETDEWEB)

    Li, J.L., E-mail: ljlhpu123@163.com; Xiong, Y.C.; Wang, X.D.; Yan, S.J.; Yang, C.; He, W.W.; Chen, J.Z.; Wang, S.Q.; Zhang, X.Y.; Dai, S.L.

    2015-02-25

    In order to develop high strength metal–matrix composites with acceptable ductility, bulk nanostructured aluminum–matrix composites reinforced with graphene nanoflakes were fabricated by cryomilling and hot extrusion processes. Microstructure and mechanical properties were characterized and determined using transmission electron microscopy, electron dispersion spectroscopy, as well as static tensile tests. The results show that, with an addition of only 0.5 wt% graphene nanoflakes, the bulk nanostructured aluminum/graphene composite exhibited increased strength and unsubdued ductility over pure aluminum. Besides, the mechanical properties of the composites with higher content of graphene nanoflakes were also measured and investigated. Above 1.0 wt% of graphene nanoflakes, however, this strengthening effect sharply dropped due to the clustering of graphene nanoflakes. Furthermore, the optimal addition of graphene nanoflakes into the nanocrystalline aluminum matrix was calculated and discussed.

  12. Ultimate stress increase in unbonded tendons in post-tensioned indeterminate I-beams cast with high strength normal and self compacting concrete

    Directory of Open Access Journals (Sweden)

    Yousef Askari Dolatabad

    2018-06-01

    Full Text Available The use of un-bonded tendons is prevalent in post-tensioned concrete structures. Equations for prediction of stress in un-bonded tendons of post-tensioned normal (vibrating concrete flexural members have been given in various codes. They are based on experience and don’t account all of important parameters such as concrete strength (normal and high strength and its type (vibrating and non-vibrating concrete. Since self-compacting concrete (SCC is nearly a new innovation therefore, understanding the implementation of this type of non-vibrating concrete on the ultimate unbonded tendon stress is critical. For this aim, in this paper there are presented experimental results of six continuous un-bonded post-tensioned I-beams in two groups were casted and monitored by different electrical strain gauges. In the first tested group, the beams (UPN1-12, UPN1-18, UPN1-22 were consisting of high strength normal concrete (HSNC where as in the second group (UPS1-12, UPS1-18, UPS1-22 high strength self-compacting concrete (HSSCC were tested. The variables included the type of concrete and percentage of bounded non-prestressed steel. Experimental monitored results of ultimate stress increase in unbonded tendons are compared with predicted equations of different researchers and standards. It was found that, the proposed equation is in better agreement with the test results. The results of standard error of estimate Sy/x, indicates that for two types of HSCs, the ACI 318-2011 provides better estimates than AASHTO-2010 model whereas this model provides better estimates than BS 8110-97. Keywords: Post-tensioned, Unbonded tendons, Stress increase, High strength normal and self-compacting concrete, Continuous beams

  13. Casting Technology.

    Science.gov (United States)

    Wright, Michael D.; And Others

    1992-01-01

    Three articles discuss (1) casting technology as it relates to industry, with comparisons of shell casting, shell molding, and die casting; (2) evaporative pattern casting for metals; and (3) high technological casting with silicone rubber. (JOW)

  14. The Effect of Heat Treatment on Microstructure and Mechanical Properties of Cast Bainitic Steel Used for Frogs in Railway Crossovers

    Directory of Open Access Journals (Sweden)

    Parzych S.

    2017-12-01

    Full Text Available This work deals with the effect of heat treatment on a microstructure and mechanical properties of a selected cast steel assigned as a material used for frogs in railway crossovers. Materials used nowadays in the railway industry for frogs e.g. Hadfield cast steel (GX120Mn13 or wrougth pearlitic steel (eg. R260 do not fulfil all exploitation requirements indicated in the UIC (International Union of Railways Decision No. 1692/96 in terms of train speed that should be reached on railways. One of the possible solution is using a cast steel with bainitic or bainitic-martensitic microstructure that allows to gain high strength properties the ultimate tensile strength (UTS of 1400 MPa, the tensile yield strength (TYS of 900 MPa and the hardness of up to 400 BHN. The tested material is considered as an alternative to Hadfield cast steel that is currently used for railway frogs.

  15. X-ray Radiographic Study of Simulated Voids-like Defects in Al-Castings and Welded in Steel

    International Nuclear Information System (INIS)

    Mahrok, M.; Juma, Th.; Saeed, F.

    2013-01-01

    the detection and evaluation of imperfections in internal structures of casting and welded joints by x - ray radiography were studied.Optimum radiography conditions that improved the radiographic detection were attempted.Mathematical equations for radiography were used to calculate the size and depth of defects in casting were tested for validity to a wide range of parameters commonly used in radiography and for variable density and shape of the defects with respect to surrounding.Two kinds of samples are prepared.The first is aluminum casting through which two different sizes of a regular steel spheres are included and then radio graphed from two opposite sides to estimate their dimensional information from the radiographs.The second sample is steel plates which are welded and then radio graphed by x - rays.Imperfections such as incomplete root penetration, undercut and porosity were detected in the radiographs.

  16. TiN coated aluminum electrodes for DC high voltage electron guns

    International Nuclear Information System (INIS)

    Mamun, Md Abdullah A.; Elmustafa, Abdelmageed A.; Taus, Rhys; Forman, Eric; Poelker, Matthew

    2015-01-01

    Preparing electrodes made of metals like stainless steel, for use inside DC high voltage electron guns, is a labor-intensive and time-consuming process. In this paper, the authors report the exceptional high voltage performance of aluminum electrodes coated with hard titanium nitride (TiN). The aluminum electrodes were comparatively easy to manufacture and required only hours of mechanical polishing using silicon carbide paper, prior to coating with TiN by a commercial vendor. The high voltage performance of three TiN-coated aluminum electrodes, before and after gas conditioning with helium, was compared to that of bare aluminum electrodes, and electrodes manufactured from titanium alloy (Ti-6Al-4V). Following gas conditioning, each TiN-coated aluminum electrode reached −225 kV bias voltage while generating less than 100 pA of field emission (<10 pA) using a 40 mm cathode/anode gap, corresponding to field strength of 13.7 MV/m. Smaller gaps were studied to evaluate electrode performance at higher field strength with the best performing TiN-coated aluminum electrode reaching ∼22.5 MV/m with field emission less than 100 pA. These results were comparable to those obtained from our best-performing electrodes manufactured from stainless steel, titanium alloy and niobium, as reported in references cited below. The TiN coating provided a very smooth surface and with mechanical properties of the coating (hardness and modulus) superior to those of stainless steel, titanium-alloy, and niobium electrodes. These features likely contributed to the improved high voltage performance of the TiN-coated aluminum electrodes

  17. Study on Friction and Wear Characteristics of Aluminum Alloy Hydraulic Valve Body and Its Antiwear Mechanism

    Directory of Open Access Journals (Sweden)

    Rong Li

    2017-03-01

    Full Text Available In order for the working status of the aluminum alloyed hydraulic valve body to be controlled in actual conditions, a new friction and wear design device was designed for the cast iron and aluminum alloyed valve bodies comparison under the same conditions. The results displayed that: (1 The oil leakage of the aluminum alloyed hydraulic valve body was higher than the corresponding oil leakage of the iron body during the initial running stage. Besides during a later running stage, the oil leakage of the aluminum alloyed body was lower than corresponding oil leakage of the iron body; (2 The actual oil leakage of different materials consisted of two parts: the foundation leakage that was the leakage of the valve without wear and wear leakage that was caused by the worn valve body; (3 The aluminum alloyed valve could rely on the dust filling furrow and melting mechanism that led the body surface to retain dynamic balance, resulting in the valve leakage preservation at a low level. The aluminum alloy modified valve body can meet the requirements of hydraulic leakage under pressure, possibly constituting this alloy suitable for hydraulic valve body manufacturing.

  18. Data Package for Secondary Waste Form Down-Selection-Cast Stone

    International Nuclear Information System (INIS)

    Serne, R. Jeffrey; Westsik, Joseph H.

    2011-01-01

    Available literature on Cast Stone and Saltstone was reviewed with an emphasis on determining how Cast Stone and related grout waste forms performed in relationship to various criteria that will be used to decide whether a specific type of waste form meets acceptance criteria for disposal in the Integrated Disposal Facility (IDF) at Hanford. After the critical review of the Cast Stone/Saltstone literature, we conclude that Cast Stone is a good candidate waste form for further consideration. Cast stone meets the target IDF acceptance criteria for compressive strength, no free liquids, TCLP leachate are below the UTS permissible concentrations and leach rates for Na and Tc-99 are suiteably low. The cost of starting ingredients and equipment necessary to generate Cast Stone waste forms with secondary waste streams are low and the Cast Stone dry blend formulation can be tailored to accommodate variations in liquid waste stream compositions. The database for Cast Stone short-term performance is quite extensive compared to the other three candidate waste solidification processes. The solidification of liquid wastes in Cast Stone is a mature process in comparison to the other three candidates. Successful production of Cast Stone or Saltstone has been demonstrated from lab-scale monoliths with volumes of cm3 through m3 sized blocks to 210-liter sized drums all the way to the large pours into vaults at Savannah River. To date over 9 million gallons of low activity liquid waste has been solidified and disposed in concrete vaults at Savannah River.

  19. Data Package for Secondary Waste Form Down-Selection—Cast Stone

    Energy Technology Data Exchange (ETDEWEB)

    Serne, R. Jeffrey; Westsik, Joseph H.

    2011-09-05

    Available literature on Cast Stone and Saltstone was reviewed with an emphasis on determining how Cast Stone and related grout waste forms performed in relationship to various criteria that will be used to decide whether a specific type of waste form meets acceptance criteria for disposal in the Integrated Disposal Facility (IDF) at Hanford. After the critical review of the Cast Stone/Saltstone literature, we conclude that Cast Stone is a good candidate waste form for further consideration. Cast stone meets the target IDF acceptance criteria for compressive strength, no free liquids, TCLP leachate are below the UTS permissible concentrations and leach rates for Na and Tc-99 are suiteably low. The cost of starting ingredients and equipment necessary to generate Cast Stone waste forms with secondary waste streams are low and the Cast Stone dry blend formulation can be tailored to accommodate variations in liquid waste stream compositions. The database for Cast Stone short-term performance is quite extensive compared to the other three candidate waste solidification processes. The solidification of liquid wastes in Cast Stone is a mature process in comparison to the other three candidates. Successful production of Cast Stone or Saltstone has been demonstrated from lab-scale monoliths with volumes of cm3 through m3 sized blocks to 210-liter sized drums all the way to the large pours into vaults at Savannah River. To date over 9 million gallons of low activity liquid waste has been solidified and disposed in concrete vaults at Savannah River.

  20. ON MODELLING OF MICROSTRUCTURE FORMATION, LOCAL MECHANICAL PROPERTIES AND STRESS – STRAIN DEVELOPMENT IN ALUMINIUM CASTINGS

    DEFF Research Database (Denmark)

    Svensson, Ingvar; Seifeddine, Salem; Kotas, Petr

    2009-01-01

    , related to mechanical properties as elastic modulus, yield stress, ultimate strength and elongation. In the present work, a test case of a complex casting in an aluminium alloy is considered including simulation of the entire casting process with focus on of microstructure formation, related to mechanical...