Showing papers on "Aluminium alloy published in 2003"

Microstructure and mechanical properties of Mg–Al based alloy with calcium and rare earth additions

Abstract: Effects of calcium and rare earth additions to alloy AZ91 on the microstructure and mechanical properties were investigated. The results indicated that small amounts of calcium addition to AZ91 did not cause the formation of any new phases in the microstructure, but refined the as-cast microstructure and increased the thermal stability of the β phase so that the yield strength and creep resistance of the alloy were significantly improved. Additions of lanthanum-rich misch metal (MM) resulted in the formation of needle-shaped particles, which showed very high thermal stability and did not dissolve into the matrix after the solution treatment at 420 °C for 20 h. The strength as well as creep resistance of the alloy at elevated temperatures was remarkably increased when MM was added combined with calcium. The highest creep resistance was obtained from the alloy with 3% of MM and 0.3% of calcium addition and its steady state creep rate reached as low as 2.69×10 −8 s −1 , one order of magnitude lower than that of alloy AZ91 without MM and calcium additions.

Characterisation of aluminium alloy 6061 for the ultrasonic consolidation process

Abstract: Ultrasonic consolidation (UC) is a freeform fabrication technique developed for the layered fabrication of metal parts. The process uses a high intensity ultrasonic energy source to induce combined static and oscillating shear forces within layers of metal foil to produce solid-state bonds. This paper will consider control parameter optimisation and surface preparation issues, for the production of aluminium alloy 6061 specimens. It will assess weld quality through both mechanical testing and optical observation. Aluminium 6061 specimens were successfully welded by the UC machine using both unprepared and surface prepared foils. In the unprepared specimens, thick oxide films exist along the whole specimen length of the weld interface. Results showed that the dynamic interfacial stresses, generated under UC conditions, compact the oxide layer to form brittle, ceramic bonds at the weld interface. A simple cleaning procedure increased metallurgical bonds, within the weld interface, by up to 45%. A general process window was produced for 6061 alloy based on a combination of the peel test data and microstructural analysis.

Production and properties of SiCp-reinforced aluminium alloy composites

Abstract: A vacuum infiltration process was developed to produce aluminium alloy composites containing various volume fractions of ceramic particles. The matrix composites of aluminium with 9.42 wt%Si and 0.36 wt%Mg containing up to 55 vol% SiCp were successfully infiltrated and the effect of infiltration temperature and volume fraction of particle on infiltration behaviour was investigated. In addition to aluminium powder, magnesium was used to improve the wetting of SiC particles by the molten aluminium alloy. The infiltration rate increased with increasing infiltration time, temperature and volume fraction of particle, but full infiltration appeared at the optimum process parameters for the various volumes of fraction composite compacts. In addition, the microstructure, hardness, density, porosity and wear resistance of the composites were also examined. It is observed that the distribution of SiC particles was uniform. The hardness and density of the composite increased with increasing reinforcement volume fraction and porosity decreased with increasing particle content. Moreover, the wear rate of the composite increased with increasing load and decreased with increasing particle content.

Experimental and numerical analysis of aluminium alloy 7075-T7351 friction stir welds

Abstract: This paper describes a systematic series of friction stir welding experiments using aluminium alloy 7075, designed to provide validation data for a numerical model of the process. The numerical mod...

Effect of Quaternary Additions on the Oxidation Behavior of Hf-Doped NiAl

Abstract: Cast model alloys, based on β-NiAl+0.05at.%Hf, were used to study the effects on oxidation behavior of elements that are commonly present in low-activity aluminide bond coatings on single-crystal, Ni-base superalloys. Single additions of Re, Ti, Ta, and Cr were examined in cyclic and isothermal exposures at 1100 to 1200°C in order to determine their effect on the oxide growth rate and resistance to scale spallation. With 1 at.% additions, all of these elements were found to be detrimental to the oxidation performance of the base NiAl+Hf alloy. Additions of Re and Cr were found to form second-phase precipitates in the alloy, which appeared to lead to scale spallation, while additions of Ti and Ta were internally oxidized and incorporated into the scale as grain-boundary segregants. These results suggest that it is necessary to minimize the levels of these types of elements that enter Hf-modified aluminide coatings by using process modifications or a diffusion barrier.

Empty and foam-filled circular aluminium tubes subjected to axial and oblique quasi- static loading

Abstract: Tests on tubular columns made of the aluminium alloy 6060-T4 under axial and oblique, quasi-static loading have been performed. The columns were fixed at one extremity, while a concentrated force was applied at the other through a rigid collar. Empty and foam-filled columns were tested for load angles equal to 0, 5, 15 and 30 degrees with respect to the longitudinal direction of the column. The column's outer diameter was 80 mm and the thickness was 1.5 mm, while the distance from the point of load application to the fixed support was 245 mm. The aluminium foam density was about 0.3 g/cm 3 . The response parameters were the peak force, the absorbed energy and the mean crush force, in addition to visual observations of the deformation mode and fracture. Furthermore, LS-DYNA simulations of the experiments were performed. The columns were modelled with shell elements, while brick elements were used to model the aluminium foam core. The aluminium alloy was modelled using an isotropic elastoplastic model with isotropic strain hardening. Fracture in the aluminium column was not considered in the simulations. The aluminium foam was modelled using the Deshpande-Fleck model. In selected simulations, fracture was assumed to occur at a critical value of the plastic volumetric strain. The agreement between the experimental and predicted results was in general good.

Neutron and synchrotron measurements of residual strain in TIG welded aluminium alloy 2024

Abstract: Tungsten inert gas (TIG) welding is one method of joining aluminium alloys with potential application in the aerospace industry. However, for it to be seriously considered as an alternative to mechanical fasteners the interrelated problems of residual stress and distortion need to be addressed. In this paper neutron, laboratory and synchrotron X-ray diffraction methods are used to provide non-destructive information about the residual stress field in TIG-welded 2024 Al alloy. The results compare well despite the differing penetration and sampling volumes associated with each technique. It is found that the magnitudes of the tensile longitudinal stresses decrease along the plate due to progressive heating up of the plate ahead of the arc during welding, so that steady-state conditions are not achieved. Comparison of the data with a finite element model indicates that softening of the heat-affected region must be included to simulate the resulting stress field. The FE model is found to be in good agreement with the data especially in the vicinity of the weld slope-out.

Examination of the effect of Sc on 2000 and 7000 series aluminium alloy castings: for improvements in fusion welding

Abstract: It has been reported that small additions of scandium (Sc) can improve the weldability and mechanical properties of some aluminium aerospace alloys that are normally considered to be ‘unweldable’. In order to determine the mechanisms by which these improvements occur, and more rapidly arrive at optimum Sc addition levels, small wedge-shaped castings have been used to simulate the cooling rates found in MIG/TIG welds. Using this technique, a range of Sc addition levels have been made to two typical Al-aerospace alloys, 2024 and 7475. It has been found that when the Sc level exceeds a critical concentration, small Al 3 Sc primary particles form in the melt and act as very efficient grain nucleants, resulting in simulated fusion zone grain sizes as fine as 15 μm. This exceptional level of grain refinement produced an unusual grain structure that exhibited no dendritic, or cellular, substructure and a large increase in strength and ductility of the castings. Sc also produced changes in the alloy's freezing paths, which cannot yet be fully explained, but led to the appearance of the W phase in the 2024 alloy and, in both alloys, an overall reduction in the amount of eutectic formed during solidification. When coupled with the high level of grain refinement, this behaviour could be used to explain the increased strength and ductility of the castings. In 2000 and 7000 series aluminium alloys, it is therefore, anticipated that optimised Sc bearing filler wires will significantly improve the mechanical properties of the weld metal, as well as reducing the tendency for solidification cracking.

Friction stir welding of magnesium alloy AZ31B to aluminium alloy 5083

Abstract: A preliminary investigation has been carried out into the application of friction stir welding for joining a magnesium alloy to an aluminium alloy. The work has shown that liquation during the welding process can lead to the formation of a brittle intermetallic at the joint interface. This intermetallic has a microstructure composed of a divorced lamellar eutectic containing Al12Mg17 and magnesium. The formation of this microstructure and its influence on mechanical properties are discussed in terms of solidification theory.

Some water vapor effects during the oxidation of alloys that are α-Al2O3 formers

Abstract: Oxidation studies were performed at 1100 °C in dry air and air containing fixed partial pressures of water vapor on a number of alloys and coatings that form α-Al2O3 scales under oxidizing conditions. The alloys investigated included RENE N5, PWA 1484, diffusion aluminide coatings (with and without Pt modification) on RENE N5, and a Ni-8 wt pct Cr-6 wt pct Al model alloy. The water vapor affected the oxidation of the alloys in three important ways: (1) The scales spalled more profusely during cyclic oxidation in wet air than in dry air, particularly for those alloys with alumina scales, which are only moderately adherent under dry conditions. The results were consistent with the mechanism previously proposed (Reference 1), whereby the water molecules decrease the fracture toughness of the alumina/alloy interface. (2) Thicker oxides are formed during oxidation in wet air than dry air. This effect comes primarily from accelerated transient oxidation during exposure in wet air. (3) Spinel was found to form on top of the alumina scales during long-term exposure. This phenomenon occurred in all atmospheres but was much more pronounced for exposures in wet atmospheres. Mechanisms for the preceding observations are proposed.

Mechanical properties of friction stir welded joints of 1050 – H24 aluminium alloy

Abstract: The friction stir welding (FSW) of 1050 - H24 aluminium alloy was performed to investigate the mechanical properties of the joints and determine the optimum FSW parameters. The mechanical properties of the joints were evaluated via tensile tests. The experimental results showed that a distinct softened region located at the weld and heat affected zones occurred in the joints. The degree of softening and tensile properties of the joints are significantly affected by the welding process parameters, such as welding speed and rotation speed. The optimum FSW parameters can be determined from the relations between the tensile properties and the welding parameters, and the maximum tensile strength of the joints is equivalent to 80% of that of the base material. When the welding parameters deviate from the optimum values, a crack like defect or significant softening is produced in the joints, thus the tensile properties of the joints deteriorate and the fracture locations of the joints change. All these ...

Oxidation-resistant aluminide coatings on γ-TiAl

Abstract: The long-term application of TiAl alloys based on the γ-phase at temperatures above 750–800°C requires suitable surface coatings to provide the needed oxidation resistance. Without a coating, these alloys, containing large amounts of titanium, suffer from rapid oxidation attack at elevated temperatures. The pack-cementation coating process was used to aluminize the surface region of a Ti–50 at.% Al alloy to TiAl3, the most promising, oxidation-resistant phase in the Ti–Al system. The isothermal oxidation behavior of the coated alloy was studied in the temperature range 800–1000°C in air for up to 300 hr. The aluminide coating greatly improves the oxidation resistance of γ-TiAl, forming a protective alumina scale. The rapid aluminum interdiffusion between the TiAl3 coating and the γ-TiAl substrate determined the effective life of the coating. In addition, the oxidation behavior of the TiAl2 phase formed by interdiffusion of the coating system was studied by oxidation of cross sections.