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Sample records for processed 6061-t6 aluminum

  1. Laser shock processing to improve residual stresses with and without paint layer on 6061-T6 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Gomez-Rosas, G.; Rubio-Gonzalez, C.; Ocaña, J. L.; Molpeceres, C.; Porro, J. A.; Morales, M.; Casillas, F. J.; Mora-Gonzalez, M.; Chi-Moreno, W.

    2007-03-01

    Laser shock processing (LSP) or laser shock peening has been proposed as a competitive alternative technology to classical treatments for improving fatigue and wear resistance of metals. This process induces a compressive residual stress field which increases fatigue crack initiation life and reduce fatigue crack growth rate. We present a configuration and results in the LSP concept for metal surface treatments in underwater laser irradiation at 1064 nm with and without a thin surface paint layer. A convergent lens is used to deliver 1, 2 J/cm2 with a 8 ns laser FWHM pulse produced by a 10 Hz, Q-switched Nd:YAG laser with a spot diameter of a 1,5 mm moving forward along the workpiece. A LSP configuration with experimental results using a pulse density of 5000 pulses/cm2 in 6061-T6 aluminum samples are presented.

  2. Effects of Applied Load on 6061-T6 Aluminum Joined Employing a Novel Friction Bonding Process

    SciTech Connect

    Douglas E. Burkes; Neil P. Hallinan; Karen L. Shropshire; Peter B. Wells

    2008-12-01

    Friction bonding is under consideration for use in mass production of plate-type nuclear fuels for research reactors. This article discusses the effects of applied load (the most important process parameter for fabrication of these fuels) on temperature distribution, microstructure, and mechanical properties. Friction bonding experiments showed that tool geometry caused temperature gradients across the tool surface. Temperatures at the joint interface suggested the advancing side of the tool produced a majority of the frictional heat, while the retreating side of the tool mainly forged the plasticized material while bonding increased with applied load. The microstructure across the tool surface was also altered and, as a function of applied load, affected the mechanical properties. The 6061 aluminum alloy had mechanical properties close to a T4 temper after processing. Results documented in this article will aid in continual enhancement of friction bonding for nuclear fuel plate fabrication, and will hopefully contribute to continued advancement of friction stir welding (FSW) state of the art.

  3. Mechanical shielding reduces weld surface cracking in 6061 T6 aluminum

    NASA Technical Reports Server (NTRS)

    Hill, J. E.

    1968-01-01

    Mechanical shield of high melting point material protects 6061-T6 aluminum welded with high frequency ac tungsten arc equipment. It is held in place around the weld bead area and eliminates heat check cracks.

  4. Experiments and simulation for 6061-T6 aluminum alloy resistance spot welded lap joints

    NASA Astrophysics Data System (ADS)

    Florea, Radu Stefanel

    This comprehensive study is the first to quantify the fatigue performance, failure loads, and microstructure of resistance spot welding (RSW) in 6061-T6 aluminum (Al) alloy according to welding parameters and process sensitivity. The extensive experimental, theoretical and simulated analyses will provide a framework to optimize the welding of lightweight structures for more fuel-efficient automotive and military applications. The research was executed in four primary components. The first section involved using electron back scatter diffraction (EBSD) scanning, tensile testing, laser beam profilometry (LBP) measurements, and optical microscopy(OM) images to experimentally investigate failure loads and deformation of the Al-alloy resistance spot welded joints. Three welding conditions, as well as nugget and microstructure characteristics, were quantified according to predefined process parameters. Quasi-static tensile tests were used to characterize the failure loads in specimens based upon these same process parameters. Profilometer results showed that increasing the applied welding current deepened the weld imprints. The EBSD scans revealed the strong dependency between the grain sizes and orientation function on the process parameters. For the second section, the fatigue behavior of the RSW'ed joints was experimentally investigated. The process optimization included consideration of the forces, currents, and times for both the main weld and post-heating. Load control cyclic tests were conducted on single weld lap-shear joint coupons to characterize the fatigue behavior in spot welded specimens. Results demonstrate that welding parameters do indeed significantly affect the microstructure and fatigue performance for these welds. The third section comprised residual strains of resistance spot welded joints measured in three different directions, denoted as in-plane longitudinal, in-plane transversal, and normal, and captured on the fusion zone, heat affected zone

  5. CO2 laser beam welding of 6061-T6 aluminum alloy thin plate

    NASA Astrophysics Data System (ADS)

    Hirose, Akio; Kobayashi, Kojiro F.; Todaka, Hirotaka

    1997-12-01

    Laser beam welding is an attractive welding process for age-hardened aluminum alloys, because its low heat input minimizes the width of weld fusion and heat-affected zones (HAZs). In the present work, 1-mm-thick age-hardened Al-Mg-Si alloy, 6061-T6, plates were welded with full penetration using a 2.5-kW CO2 laser. Fractions of porosity in the fusion zones were less than 0.05 pct in bead-on-plate welding and less than 0.2 pct in butt welding with polishing the groove surface before welding. The width of a softened region in the-laser beam welds was less than 1/4 times that of a tungsten inert gas (TIG) weld. The softened region is caused by reversion of strengthening β″ (Mg2Si) precipitates due to weld heat input. The hardness values of the softened region in the laser beam welds were almost fully recovered to that of the base metal after an artificial aging treatment at 448 K for 28.8 ks without solution annealing, whereas those in the TIG weld were not recovered in a partly reverted region. Both the bead-on-plate weld and the butt weld after the postweld artificial aging treatment had almost equivalent tensile strengths to that of the base plate.

  6. High strength and high ductility behavior of 6061-T6 alloy after laser shock processing

    NASA Astrophysics Data System (ADS)

    Gencalp Irizalp, Simge; Saklakoglu, Nursen

    2016-02-01

    The plastic deformation behavior of 6061-T6 alloy which was subjected to severe plastic deformation (SPD) at high strain rates during laser shock processing (LSP) was researched. In LSP-treated materials, the near surface microstructural change was examined by TEM and fracture surfaces after tensile testing were examined by SEM. An increase in strength of metallic materials brings about the decrease in ductility. In this study, the results showed that LSP-treated 6061-T6 alloy exhibited both high strength and high ductility. TEM observation showed that stacking fault (SF) ribbon enlarged, deformation twins formed and twin boundary increased in LSP-treated 6061-T6 alloy. This observation was an indication of stacking fault energy (SFE) decrease. Work hardening capability was recovered after LSP impacts.

  7. The corrosion protection of 6061-T6 aluminum by a polyurethane-sealed anodized coat

    NASA Technical Reports Server (NTRS)

    Danford, M. D.

    1990-01-01

    The corrosion protection of 6061-T6 anodized aluminum afforded by a newly patented polyurethane seal was studied using the ac impedance technique. Values of the average corrosion rates over a 27-day exposure period in 3.5 percent NaCl solutions at pH 5.2 and pH 9.5 compared very favorably for Lockheed-prepared polyurethane-sealed and dichromate-sealed coats of the same thickness. Average corrosion rates for both specimens over the first 7 days of exposure compared well with those for a hard anodized, dichromate-sealed coat, but rose well above those for the hard anodized coat over the entire 27-day period. This is attributed both to the greater thickness of the hard anodized coat, and possibly to its inherently better corrosion protective capability.

  8. Cavitation pitting and erosion of aluminum 6061-T6 in mineral oil water

    NASA Technical Reports Server (NTRS)

    Rao, B. C. S.; Buckley, D. H.

    1983-01-01

    Cavitation erosion studies of aluminum 6061-T6 in mineral oil and in ordinary tap water are presented. The maximum erosion rate (MDPR, or mean depth of penetration rate) in mineral oil was about four times that in water. The MDPR in mineral oil decreased continuously with time, but the MDPR in water remained approximately constant. The cavitation pits in mineral oil were of smaller diameter and depth than the pits in water. Treating the pits as spherical segments, we computed the radius r of the sphere. The logarithm of h/a, where h is the pit depth and 2a is the top width of the pit, was linear when plotted against the logarithm of 2r/h - 1.

  9. Characteristics of laser beam welds of age-hardenable 6061-T6 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Hirose, Akio; Kobayashi, Kojiro F.

    2003-03-01

    Laser beam welding is attractive for joining age-hardenable aluminum alloys, because its low over-all heat input results in a narrow weld heat affected zone (HAZ), where softening caused by dissolution of age precipitates occurs. In the present work, 1mm-thick 6061-T6 aluminum alloy plates were welded using a 2.5 kW CO2 laser and it was experimentally proved that the width of the softened region in the laser beam weld was less than 1/7 that of a TIG weld. Moreover the hardness in the softened region of the laser beam weld was found to be almost fully recovered to the base metal hardness by applying a post-weld aging treatment at 443 K for 28.8 ks without solution annealing unlike the TIG weld. These results characterize the advantage of laser beam welding in joining of the age-hardenable aluminum alloy as compared with the conventional arc welding. The hardness distributions in the HAZ were theoretically evaluated based on kinetic equations describing the dissolution of hardening β' (Mg2Si) precipitates and the precipitation of non-hardening β' (Mg2Si) precipitates during the weld thermal cycles to quantitatively prove above mentioned advantageous characteristics of laser beam welding.

  10. Effect of laser peening with different energies on fatigue fracture evolution of 6061-T6 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Sheng, J.; Huang, S.; Zhou, J. Z.; Lu, J. Z.; Xu, S. Q.; Zhang, H. F.

    2016-03-01

    To deeply understand the effect of laser peening (LP) with different laser pulse energies on 6061-T6 aluminum alloy, the fatigue fracture morphologies evolution process at various fatigue crack growth (FCG) stages and the corresponding strengthen mechanism were investigated. At the initial stage of FCG, more fatigue micro-cliffs were found after LP, while the fatigue striation spacing simultaneously reduced. A "stop-continue" phenomenon of crack propagation was discovered for laser peened samples. The fatigue striation spacing at the middle stage of FCG increased significantly while compared with that at the initial stage, in addition, the fatigue striation spacing decreased with an increase in laser pulse energy. Fracture morphologies in transition region of laser peened samples exhibit a mixing fracture characteristic of striations and dimples. The laser peened sample with laser pulse energy of 7 J presents more circuitous growing paths. Due to the complex stress state induced by LP, dimples with different sizes appeared in the final fracture region.

  11. Erosion of aluminum 6061-T6 under cavitation attack in mineral oil and water

    NASA Technical Reports Server (NTRS)

    Rao, B. C. S.; Buckley, D. H.

    1985-01-01

    Studies of the erosion of aluminum 6061-T6 under cavitation attack in distilled water, ordinary tap water and a viscous mineral oil are presented. The mean depth of penetration for the mineral oil was about 40 percent of that for water at the end of a 40 min test. The mean depth of penetration and its rate did not differ significantly for distilled and tap water. The mean depth of penetration rate for both distilled and tap water increased to a maximum and then decreased with test duration, while that for mineral oil had a maximum during the initial period. The ratio h/2a of the pit depth h to the pit diameter 2a varied from 0.04 to 0.13 in water and from 0.06 to 0.20 in mineral oil. Scanning electron microscopy indicates that the pits are initially formed over the grain boundaries and precipitates while the surface grains are deformed under cavitation attack.

  12. Low-temperature densification of ultrafine grained aluminum 6061-T6 by polymer bonding

    NASA Astrophysics Data System (ADS)

    Kim, Boumseock

    Ultrafine grained and nanocrytalline materials have many beneficial properties such as higher hardness, strength and wear resistance. A machining process has been developed as a new method to make nanostructured metals or alloys. Through the process, severe plastic deformation can be applied to metals or alloys and they become ultrafine grain and nanocrystalline in their structures. Because ultrafine grained alloys made by machining are made up to small chips, not bulk, to make bulk material, the alloy chips must be densified through processes such as sintering. Unfortunately, during the conventional sintering, the ultrafine grained alloys show grain growth at high rate and lose their hardness and strength. Therefore, low-temperature densification of ultrafine grained alloys has been pursued. In this thesis, ultrafine-grained (UFG) Al 6061-T6 particulate produced from machining chips have been consolidated and bonded using liquid epoxies that cure at 100?, below the coarsening temperature of the UFG structure. Two routes were explored---die-pressing premixed alloy particulate and epoxy and pressure infiltration of pre-pressed alloy particulate preforms. The effects of pressing pressure and epoxy viscosity were investigated. In order to reduce porosity and contamination, three treatments---application of pressure during curing of epoxy, the cleaning of the alloy powder with NaOH solution and degassing epoxy before pressing---were tried. In order to overcome limitation of diepressing, infiltration method was compared with die-pressing and the resulting properties of the composite discussed. Bond thickness between the alloy particles increases with the viscosity of the epoxies. In the hardness results by micro-indentor, the value of composite with more than 80% volume fraction of Al alloy chip (Va) was more than 120 kg/mm2. In those measurements, the hardness of the composite depends mainly on the volume fraction of Al alloy and was clearly influenced by the boundary

  13. Laser peening without coating on aluminum alloy Al-6061-T6 using low energy Nd:YAG laser

    NASA Astrophysics Data System (ADS)

    Sathyajith, S.; Kalainathan, S.; Swaroop, S.

    2013-02-01

    The present study investigates the effect of laser peening without coating on aluminum alloy Al-6061-T6 with a 300 mJ infrared laser. The surface topography, microstructure, surface topography, surface residual stress and micro-hardness of peened and unpeened surfaces were studied. The study shows that laser peening without coating can significantly improve surface compressive stress and micro-hardness with trivial increase in surface roughness. Microstructure evaluation confirmed there was no near surface solidification after LPwC.

  14. Recovery of Mechanical Properties of a 6061-T6 Aluminum Weld by Heat Treatment After Welding

    NASA Astrophysics Data System (ADS)

    Pérez, Javier Serrano; Ambriz, Ricardo Rafael; López, Francisco Fernando Curiel; Vigueras, David Jaramillo

    2016-07-01

    The dilution effects in welds of a 6061-T6 (Al-Si-Mg) alloy obtained by the modified indirect electric arc (MIEA), using an ER4043 filler metal (Al-Si), and postweld heat treatment (PWHT) were analyzed. The soft zone (55 to 70 HV0.1) formed by the microstructural transformation in the heat-affected zone (HAZ) was eliminated. The hardness measurements were presented on a traditional microhardness profile and mapping representation. A hardening effect of the fusion zone was observed; the hardness values were above 120 HV0.1 and tended to be uniform. This behavior could be attributed to the chemical composition of the filler metal, the Mg migration from the base to the weld metal, and the reversible process of the PWHT, which promotes precipitation hardening. Improvement for yield (260 MPa) and tensile strength (310 MPa) of the MIEA joints was observed; these values were similar to those obtained for the base metal. However, the presence of porosity in the fusion zone limits the ductility of the joints (4.3 pct). Even though the yield and tensile strengths of the base metal and welded joints were similar, the stress concentration due to porosity in the weld metal generated data dispersion in fatigue life. As a consequence, the high-cycle fatigue life decreases with respect to the base metal. In contrast, when the crack propagates under elastic conditions, the crack-tip singularity is affected by the porosity in the weld metal (stress liberator). This aspect, in conjunction with the hardening effect in joints subjected to PWHT, improves the fatigue crack growth rate when compared to the as-welded condition.

  15. Recovery of Mechanical Properties of a 6061-T6 Aluminum Weld by Heat Treatment After Welding

    NASA Astrophysics Data System (ADS)

    Pérez, Javier Serrano; Ambriz, Ricardo Rafael; López, Francisco Fernando Curiel; Vigueras, David Jaramillo

    2016-05-01

    The dilution effects in welds of a 6061-T6 (Al-Si-Mg) alloy obtained by the modified indirect electric arc (MIEA), using an ER4043 filler metal (Al-Si), and postweld heat treatment (PWHT) were analyzed. The soft zone (55 to 70 HV0.1) formed by the microstructural transformation in the heat-affected zone (HAZ) was eliminated. The hardness measurements were presented on a traditional microhardness profile and mapping representation. A hardening effect of the fusion zone was observed; the hardness values were above 120 HV0.1 and tended to be uniform. This behavior could be attributed to the chemical composition of the filler metal, the Mg migration from the base to the weld metal, and the reversible process of the PWHT, which promotes precipitation hardening. Improvement for yield (260 MPa) and tensile strength (310 MPa) of the MIEA joints was observed; these values were similar to those obtained for the base metal. However, the presence of porosity in the fusion zone limits the ductility of the joints (4.3 pct). Even though the yield and tensile strengths of the base metal and welded joints were similar, the stress concentration due to porosity in the weld metal generated data dispersion in fatigue life. As a consequence, the high-cycle fatigue life decreases with respect to the base metal. In contrast, when the crack propagates under elastic conditions, the crack-tip singularity is affected by the porosity in the weld metal (stress liberator). This aspect, in conjunction with the hardening effect in joints subjected to PWHT, improves the fatigue crack growth rate when compared to the as-welded condition.

  16. On Residual Stresses in Resistance Spot-Welded Aluminum Alloy 6061-T6: Experimental and Numerical Analysis

    NASA Astrophysics Data System (ADS)

    Afshari, D.; Sedighi, M.; Karimi, M. R.; Barsoum, Z.

    2013-12-01

    In this study, an electro-thermal-structural-coupled finite element (FE) model and x-ray diffraction residual stress measurements have been utilized to analyze distribution of residual stresses in an aluminum alloy 6061-T6 resistance spot-welded joint with 2-mm-thickness sheet. Increasing the aluminum sheet thickness to more than 1 mm leads to creating difficulty in spot-welding process and increases the complexity of the FE model. The electrical and thermal contact conductances, as mandatory factors are applied in contact areas of electrode-workpiece and workpiece-workpiece to resolve the complexity of the FE model. The physical and mechanical properties of the material are defined as thermal dependent to improve the accuracy of the model. Furthermore, the electrodes are removed after the holding cycle using the birth-and-death elements method. The results have a good agreement with experimental data obtained from x-ray diffraction residual stress measurements. However, the highest internal tensile residual stress occurs in the center of the nugget zone and decreases toward nugget edge; surface residual stress increases toward the edge of the welding zone and afterward, the area decreases slightly.

  17. Ballistic limit of 6061 T6 aluminum and threat to surface coatings for use with orbiting space station space suit materials

    NASA Technical Reports Server (NTRS)

    Fish, D.

    1986-01-01

    In recent years orbiting satellites, spent components, collisions and explosions have populated the near earth orbit with debris potentially more hazardous than the average meteoroid debris. This new debris has an average density of aluminum (2.78 g/cc) and an average encounter velocity of 10 km/sec. The space station will require many hours of work in this environment and there is concern over hazard to the assembly personnel. A proposed hard suit design utilizes 6061-T6 Aluminum for most of its exposed area. The aluminum surface will be treated for thermal and radiation control. The basic thickness of this suit will be on the order of 1.78 mm (0.070 inches). The selection of 6061-T6 Aluminum for space suits for use on the space station would appear to be worthwhile. The relatively ductile behavior of 6061-T6 aluminum is better than a choice of a more brittle material.

  18. Barrier anodic coatings formed on 6061-T6 aluminum alloy in electrolytes containing different ethanol to water ratios

    SciTech Connect

    Panitz, J.K.G.; Sharp, D.J.; Martinez, F.E.; Merrill, R.M.; Ward, K.J.

    1988-12-01

    We have studied barrier anodic film formation on 6061-T6 aluminum alloy substrates as a function of electrolyte composition for five mixtures of ammonium tartrate dissolved in water and diluted with different amounts of ethanol. The effects of electrolyte temperatures within the range of 18/degree/C to 38/degree/C were explored. The results of this study indicate that the best dielectric coatings and the shortest processing times occur for the 100% water-ammonium tartrate electrolyte. The second best coatings and processing times occur in conjunction with the use of 98% ethanol, 2% water plus ammonium tartrate electrolyte. In general, visibly flawed coatings, scintillation events at cell voltages in excess of approximately 750-800 volts and/or abnormally long processing times occur in conjunction with the use of electrolyte mixtures containing 20%, 60%, and 90% water. We analysed samples of electrolyte as a function of usage, and evaluated the composition of the coatings using Fourier Transform Infrared Analysis to better understand the mechanisms which contribute to anodic coating growth that result in the observed variations in the dielectric properties. All of the coatings exhibited similar compositions except with regard to the amount of CO2 that was physisorbed in the coatings. The dielectrically inferior coatings that were typically produced by the electrolytes containing ethanol contain substantially more CO2 than the coatings grown in the 100% water-based electrolyte. These results strongly suggest that the ethanol in the electrolyte oxidizes and forms CO2 which is incorporated in the coatings and results in inferior dielectric properties. 8 refs., 7 figs.

  19. Effect of Welding Speeds on Mechanical Properties of Level Compensation Friction Stir Welded 6061-T6 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Wen, Quan; Yue, Yumei; Ji, Shude; Li, Zhengwei; Gao, Shuangsheng

    2016-04-01

    In order to eliminate the flash, arc corrugation and concave in weld zone, level compensation friction stir welding (LCFSW) was put forward and successfully applied to weld 6061-T6 aluminum alloy with varied welding speed at a constant tool rotational speed of 1,800 rpm in the present study. The glossy joint with equal thickness of base material can be attained, and the shoulder affected zone (SAZ) was obviously reduced. The results of transverse tensile test indicate that the tensile strength and elongation reach the maximum values of 248 MPa and 7.1% when the welding speed is 600 mm/min. The microhardness of weld nugget (WN) is lower than that of base material. The tensile fracture position locates at the heat affected zone (HAZ) of the advancing side (AS), where the microhardness is the minimum. The fracture surface morphology represents the typical ductile fracture.

  20. Full Field Measurement of The Dynamic Response of AA6061-T6 Aluminum Alloy under High Strain Rate Compression and Torsion Loads

    NASA Astrophysics Data System (ADS)

    Odoh, Daniel Oghenekewhe Oluwatobi

    The dynamic response of AA6061-T6 aluminum alloy under high strain rate loading in compression and torsion loading conditions was studied using the split Hopkinson pressure bar, the Kolsky torsion bar, and the high speed digital image correlation system. AA6061-T6 alloy, the most widely used in the AA6000 series, is a multi-purpose Al-Mg-Si-Cu alloy containing about 0.4 % wt. of Cu and other alloying additives. The properties of AA6061-T6 aluminum alloy including medium to high strength, good fracture toughness, and high corrosion resistance make it to find application in high performance structures such as the automotive parts, panels, and armored carriers. In this work, the effect of strain rate during dynamic test on formation of adiabatic shear bands in AA6061-T6 alloy was investigated. A post deformation analysis of the tested specimen was performed in order to determine the damage evolution and strain localization along the narrow adiabatic shear bands within the specimen. The formation of an adiabatic shear band in the aluminum alloy tested was found to depend on the strain rate at which the test was conducted. Stress, strain, and strain rate data obtained from the elastic waves in the compression and torsion bar tests were also compared with those obtained using the high speed digital cameras. Results show good agreement between both measurement techniques with the 3D digital image correlation technique giving a slightly lower result. Scanning and electron microscopy results show that both deformed and transformed bands can be formed in AA6061-T6 alloy during dynamic loading. The type of adiabatic shear band formed depends on the strain rate at which test was performed.

  1. Quench sensitivity of hot extruded 6061-T6 and 6069-T6 aluminum alloys

    SciTech Connect

    Bergsma, S C; Kassner, M E; Li, X; Rosen, R S

    2000-08-08

    The purpose of this study is to investigate the quench sensitivity of mechanical properties of hot extruded 6061 and 6069 aluminum alloys. The relationship between mechanical properties and quench delzty time at various temperatures between 200-500 C was determined. It was concluded that the 6069-T6 was somewhat more quench sensitive than 6061, which may be consistent with the composition difference.

  2. A Micro-Electrochemical Study of Friction Stir Welded Aluminum 6061-T6

    NASA Technical Reports Server (NTRS)

    Hintze, Paul E.; Calle, Luz M.

    2005-01-01

    The corrosion behavior of friction stir welded Aluminum alloy 606 1-T6 was studied using a micro-electrochemical cell. The micro-electrochemical cell has a measurement area of about 0.25 square mm which allows for measurement of corrosion properties at a very small scale. The corrosion and breakdown potentials were measured at many points inside and outside the weld along lines perpendicular to the weld. The breakdown potential is approximately equal inside and outside the weld; however, it is lower in the narrow border between the weld and base material. The results of electrochemical measurements were correlated to micro-structural analysis. The corrosion behavior of the friction stir welded samples was compared to tungsten inert gas (TIG) welded samples of the same material.

  3. Modeling of Residual Stresses and Property Distributions in Friction Stir Welds of Aluminum Alloy 6061-T6

    SciTech Connect

    Feng, Zhili; David, Stan A; Wang, Xun-Li; Sklad, Philip S

    2007-01-01

    An integrated thermal-metallurgical-mechanical model is used to analyze and provide insights into the formation of the residual stress and the changes in microstructure and property of Al6061-T6 friction stir welds. The simulations were conducted by means of a three-dimensional finite element model that accounts for the phenomena of frictional heating, weld microstructure and strength changes due to dissolution and reprecipitation of the hardening precipitate particles, and the mechanical workpiece/tool contact during the friction stir welding (FSW) process. The model predictions were confirmed by experimental measurement data from previous studies. For the friction stir welds investigated, it was found that the residual stress distribution is strongly dependent on the welding process parameters and the degree of material softening caused by welding. The recovery of material strength from natural aging does not increase the residual stress in the weld. The failure of friction stir weld under tensile load is controlled by the combination of the reduction in strength and the residual stresses in the heat affected zone (HAZ).

  4. Galvanic coupling between D6AC steel, 6061-T6 aluminum, Inconel 718 and graphite-epoxy composite material: Corrosion occurrence and prevention

    NASA Technical Reports Server (NTRS)

    Danford, M. D.; Higgins, R. H.

    1983-01-01

    The effects of galvanic coupling between D6AC steel, 6061-T6 aluminum, Inconel 718, and graphite-epoxy composite material (G/E) in 3.5% NaCl were studied. Measurements of corrosion potentials, galvanic currents and corrosion rates of the bare metals using weight-loss methods served to establish the need for corrosion protection in cases where D6AC steel and 6061-T6 aluminum are galvanically coupled to G/E in salt water while Inconel 718 was shown to be compatible with G/E. Six tests were made to study corrosion protective methods for eliminating galvanic corrosion in the cases of D6AC steel and 6061-T6 aluminum coupled to G/E. These results indicate that, when the G/E is completely coated with paint or a paint/polyurethane resin combination, satisfactory protection of the D6AC steel is achieved with either a coat of zinc-rich primer or a primer/topcoat combination. Likewise, satisfactory corrosion protection of the aluminum is achieved by coating it with an epoxy coating system.

  5. In-situ neutron diffraction measurements of temperature and stresses during friction stir welding of 6061-T6 aluminum alloy

    SciTech Connect

    Feng, Zhili; Wang, Xun-Li; David, Stan A; Choo, Hahn; Hubbard, Camden R; Woo, Wan Chuck; Brown, D. W.; Clausen, B; An, Ke

    2007-01-01

    The evolution of temperature and thermal stresses during friction stir welding of Al6061-T6 was investigated by means of in situ, time resolved neutron diffraction technique. A method was developed to deconvolute the temperature and stress from the lattice spacing changes measured by neutron diffraction. The deep penetration capability of neutrons made it possible for the first time to obtain the temperature and thermal stresses inside a friction stir weld.

  6. In-situ neutron diffraction measurements of temperature and stresses during friction stir welding of 6061-T6 aluminum alloy

    SciTech Connect

    Woo, Wan Chuck; Feng, Zhili; Wang, Xun-Li; Brown, D. W.; Clausen, B; An, Ke; Choo, Hahn; Hubbard, Camden R; David, Stan A

    2007-01-01

    The evolution of temperature and thermal stresses during friction stir welding of Al6061-T6 was investigated by means of in-situ, time-resolved neutron diffraction technique. A method is developed to deconvolute the temperature and stress from the lattice spacing changes measured by neutron diffraction. The deep penetration capability of neutrons made it possible for the first time to obtain the temperature and thermal stresses inside a friction stir weld.

  7. Prediction of hardness minimum locations during natural aging in an aluminum alloy 6061-T6 friction stir weld

    SciTech Connect

    Woo, Wan Chuck; Choo, Hahn; Feng, Zhili; Withers, Prof Philip

    2009-01-01

    This study describes a simple model that can predict the evolution of hardness distribution as a function of natural aging time in a heat-treatable 6061-T6 Al alloy plate subjected to friction stir welding (FSW). First, two dimensional thermal distributions were simulated as a function of time in the FSW plate by finite element modeling. Second, the hardness changes during natural aging were measured as a function of aging time for a number of Al specimens that had been previously isothermally heat-treated to different hold temperatures in order to determine the natural aging kinetics. Finally, the simulated temperature profiles and the natural aging kinetics were correlated to predict the hardness profiles in the FSW plate. The predicted hardness variations are consistent with measured hardness profiles in that the location of minimum hardness moves away from the centerline as the aging time and/or heat input increases. The hardness variation was also related to the location of failure in cross-weld tensile samples.

  8. Microstructure and mechanical properties of twin-wire arc sprayed Ni-Al composite coatings on 6061-T6 aluminum alloy sheet

    NASA Astrophysics Data System (ADS)

    Wang, Ji-xiao; Liu, Jing-shun; Zhang, Lun-yong; Sun, Jian-fei; Wang, Zhi-ping

    2014-05-01

    We have systematically studied the microstructure and mechanical properties of Ni-5wt%Al and Ni-20wt%Al composite coatings fabricated on 6061-T6 aluminum alloy sheet by twin-wire arc spraying under different experimental conditions. The abrasive wear behavior and interface diffusion behavior of the composite coatings were evaluated by dry/wet rubber wheel abrasive wear tests and heat treatment, respectively. Experimental results indicate that the composite coatings exhibit features of adhesive wear. Besides, the Vickers microhardness of NiAl and Ni3Al intermetallic compounds is relatively larger than that of the substrate, which is beneficial for enhancing the wear resistance. With the increase of annealing temperature and time, the interface diffusion area between the Ni-Al coating and the substrate gradually expands with the formation of NiAl3 and Ni2Al3 phases, and is controlled by diffusion of aluminum atoms. The grain growth exponent n of diffusion kinetics of the Ni-Al coating, calculated via a high-temperature diffusion model at 400, 480, and 550°C, is between 0.28 and 0.38. This satisfies the cubic law, which is consistent with the general theoretical relationship of high-temperature diffusion.

  9. The Young's modulus of 1018 steel and 6061-T6 aluminum measured from quasi-static to elastic precursor strain-rates

    NASA Astrophysics Data System (ADS)

    Rae, Philip; Trujillo, Carl; Gray, Rusty

    2009-06-01

    It is commonly assumed in engineering and physics that the elastic moduli of metals is independent of strain-rate, but is a weak function of temperature. An extensive literature search however has failed to find any citable reference in which the Young's modulus of any pedigreed metal was measured over a wide variety of strain-rates. To rectify this, samples of pedigreed 1018 steel and 6061-T6 aluminum have been tested at strain-rates from 10-4 s-1 to 10^6 s-1. Low strain-rate data (10-4-10-2 s-1)was obtained from commercial bonded strain gauges. Intermediate rate data ( 10-4 s-1) was obtained from time of flight ultrasonic measurements. Shock rate data was obtained by examining the elastic precursor using shock pins and PDV (photonic Doppler velocimetry). Correction for the adiabatic versus thermal nature of the disparate strain-rate regimes have been made. Additionally, the implications of the uniaxial strain nature of the shock elastic precursor are examined with respect to comparison with uniaxial stress lower rate data.

  10. Parametric studies on tensile strength in joining AA6061- T6 and AA7075-T6 by gas metal arc welding process

    NASA Astrophysics Data System (ADS)

    Ishak, M.; Noordin, N. F. M.; Shah, L. H.

    2015-12-01

    Proper selection of the welding parameters can result in better joining. In this study, the effects of various welding parameters on tensile strength in joining dissimilar aluminum alloys AA6061-T6 and AA7075-T6 were investigated. 2 mm thick samples of both base metals were welded by semi-automatic gas metal arc welding (GMAW) using filler wire ER5356. The welding current, arc voltage and welding speed were chosen as variables parameters. The strength of each specimen after the welding operations were tested and the effects of these parameters on tensile strength were identified by using Taguchi method. The range of parameter for welding current were chosen from 100 to 115 A, arc voltage from 17 to 20 V and welding speed from 2 to 5 mm/s. L16 orthogonal array was used to obtained 16 runs of experiments. It was found that the highest tensile strength (194.34 MPa) was obtained with the combination of a welding current of 115 A, welding voltage of 18 V and welding speed of 4 mm/s. Through analysis of variance (ANOVA), the welding voltage was the most effected parameter on tensile strength with percentage of contribution at 41.30%.

  11. Microscopic Observation of the Side Surface of Dynamically-Tensile-Fractured 6061-T6 and 2219-T87 Aluminum Alloys with Pre-Fatigue

    NASA Astrophysics Data System (ADS)

    Itabashi, Masaaki; Nakajima, Shigeru; Fukuda, Hiroshi

    After unexpected failure of metallic structure, microscopic investigation will be performed. Generally, such an investigation is limited to search striation pattern with a SEM (scanning electron microscope). But, when the cause of the failure was not severe repeated stress, this investigation is ineffective. In this paper, new microscopic observation technique is proposed to detect low cycle fatigue-impact tensile loading history. Al alloys, 6061-T6 and 2219-T87, were fractured in dynamic tension, after severe pre-fatigue. The side surface of the fractured specimens was observed with a SEM. Neighboring fractured surface, many opened cracks on the side surface have been generated. For each specimen, the number of the cracks was counted together with information of individual sizes and geometric features. For 6061-T6 alloy specimen with the pre-fatigue, the number of the cracks is greater than that for the specimen without the pre-fatigue. For 2219-T87 alloy, the same tendency can be found after a certain screening of the crack counting. Therefore, the crack counting technique may be useful to detect the existence of the pre-fatigue from the dynamically fractured specimen surface.

  12. In-situ Time-Resolved Neutron Diffraction Measurements of Microstructure Variations during Friction Stir Welding in a 6061-T6 Aluminum Alloy

    SciTech Connect

    Woo, Wan Chuck; Wang, Xun-Li; Ungar, Prof Tomas; Feng, Zhili; David, Stan A; Clausen, B; Hubbard, Camden R

    2008-01-01

    The microstructure change is one of the most important research areas in the friction stir welding (FSW). However, direct observation of microstructure changes during FSW has been extremely challenging because many measurement techniques are inapplicable. Recently developed in-situ time-resolved neutron diffraction methodology, which drastically improves the temporal resolution of neutron diffraction, enables to observe the transient microstructure changes during FSW. We installed a portable FSW system in the Spectrometer for MAterials Research at Temperature and Stress (SMARTS) at Los Alamos Neutron Science Center and the FSW was made on 6.35mm-thickness 6061-T6 Al alloy plate. At the same time, the neutron beam was centered on the mid-plane of the Al plate at 8 mm from the tool center (underneath the tool shoulder) and the diffraction peak was continuously measured during welding. The peak broadening analysis has been performed using the Williamson-Hall Method. The result shows that the dislocation density of about 3.2 x 10^15 m-2 duing FSW, which is the significant increse compared to the before (4.5 x 10^14 m-2) and after (4.0 x 10^14 m-2) the FSW. The quantitatively analysis of the grain structure can provide an insight to understand the transient variation of the microstructure during FSW.

  13. Evaluation of Dissimilar Welds of 5083-H12 and 6061-T6 Produced by Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Ghaffarpour, Morteza; Kolahgar, Sina; Dariani, Bijan Mollaei; Dehghani, Kamran

    2013-08-01

    In the present study, the dissimilar aluminum alloys of 5083-H12 and 6061-T6 were joined by friction stir welding (FSW). Then, the design of experiments (DOE), the Box-Benken method, and the response surface methodology (RSM) were used to optimize the effective parameters of the FSW process. The optimized parameters that led to the maximum tensile strength in dissimilar friction stir welded sheets were determined. The predicted results were then compared with those measured experimentally. The results show that there is good agreement between the predicted and measured amounts. By applying the limit dome height (LDH) test, the formability of friction stir welded sheets was studied. During the LDH test, the minimum formability occurred in the heat-affected zone (HAZ) of the 6061-T6 side. The results of microhardness and tensile tests confirm the results of the LDH tests.

  14. Quasi-steady state principle and in-situ real-time investigation of transient strains in 6061-T6 Al alloy using neutron diffraction

    SciTech Connect

    Woo, Wan Chuck; Brown, D. W.; Choo, Hahn; Clausen, B; David, Stan A; Feng, Zhili; Hubbard, Camden R; Wang, Xun-Li

    2007-01-01

    Neutron diffraction research has been limited to the "static" behavior of materials since the number of collected neutrons is insufficient to reach the adequate neutron counts in rapid changes of material state. In order to achieve the desired precision for the study of the transient material behavior, we propose an in-situ neutron-diffraction measurement method based on the quasi-steady state (QSS) phenomenon. The QSS principle was applied for the measurement of transient lattice spacing changes in a 6061-T6 aluminum alloy plate during thermo-mechanical processing.

  15. Effects of select parameters on electron beam welding of AL6061-T6 alloy

    NASA Astrophysics Data System (ADS)

    Yost, Thomas E.

    Electron beam welding was used for joining Al6061-T6, precision machined, cylindrical sections. The welded assembly exhibited a minimum amount of distortion, but a better understanding of the effects of several key welding parameters on the structural integrity of the weld was required. The contents of this document describe the relative importance and interaction between welding speed, volume of filler, and beam pattern on the microstructural and mechanical properties of the welded joint. Understanding of the relationship between welding parameters and weld properties was accomplished by macrophotography and microstructural examination, microhardness testing, energy dispersive spectroscopy (EDX), and mechanical tensile testing of weld coupons. The results of this study will help quantify the robustness of the EBW process for this common aerospace material and joint geometry and will help determine the impacts of process deviations on weld fidelity in the production environment.

  16. Effect of Fatigue Crack on Static Strength: 2014-T6, 2024-T4, 6061-T6, 7075-T6 Open-Hole Monobloc Specimens

    NASA Technical Reports Server (NTRS)

    Nordmark, Glenn E.; Eaton, Ian D.

    1957-01-01

    Static tensile test results are presented for specimens of 2014-T6, 2024-T4, 6061-T6, and 7075-T6 aluminum alloy containing fatigue cracks. The results are found to be in good agreement with the results reported for similar tests from other sources. The results indicate that the presence of a fatigue crack reduced the static strength, in all cases, by an amount larger than the corresponding reduction in net area; the 6061-T6 alloy specimens were least susceptible to the crack and the 7075-T6 alloy specimens were most susceptible. It is indicated that a 7075-T6 specimen may develop as little as one-third of the expected static tensile strength when the fatigue crack was consumed only one-fourth of the original area. It was found that the static strength was substantially higher for specimens which had stop holes drilled at the end of the fatigue crack.

  17. Cavitation pitting and erosion of Al 6061-T6 in mineral oil and water

    NASA Technical Reports Server (NTRS)

    Rao, B. C. S.; Buckley, D. H.

    1983-01-01

    The authors are currently carrying out a study of the cavitation erosion of different bearing metals and alloys in mineral oils were studied. The variations of weight loss, the pit diameter and depth due to cavitation erosion on Al 6061-T6 in mineral oil and water are presented.

  18. Effects of Intermittent Versus Continuous Heating upon the Tensile Properties of 2024-T4, 6061-T6 and 7075-T6 Alloys

    NASA Technical Reports Server (NTRS)

    Stickley, G. W.; Anerson, H. L.

    1956-01-01

    In some applications, aluminum alloys are subjected to intermittent heating at elevated temperature. It is generally considered that the effects of such intermittent heating are cumulative, and therefore are the same as if the heating had been continuous for the same total length of time. The object of these tests was to determine the effects of intermittent and continuous heating at 300 and 400 F, for total periods of 100 and 200 hr, upon the tensile properties of 2024-T4 and 6061-T6 alloy rolled-and-drawn rod and 7075-T6 alloy extrusions, at room temperature and at the temperature of heating.

  19. Near surface modification of aluminum alloy induced by laser shock processing

    NASA Astrophysics Data System (ADS)

    Saklakoglu, Nursen; Gencalp Irizalp, Simge; Akman, Erhan; Demir, Arif

    2014-12-01

    This paper investigates the influences of near surface modification induced in 6061-T6 aluminum alloy by laser shock processing (LSP). The present study evaluates LSP with a Q-switched Nd:YAG low power laser using water confinement medium and absorbent overlay on the workpiece. The near surface microstructural change of 6061-T6 alloy after LSP was studied. The residual stress variation throughout the depth of the workpiece was determined. The results showed an improvement of the material resistance to pit formation. This improvement may be attributed to compressive residual stress and work-hardening. The size and number of pits revealed by immersion in an NaOH-HCl solution decreased in comparison with the untreated material.

  20. Effect of Laser Shock Peening on surface properties and residual stress of Al6061-T6

    NASA Astrophysics Data System (ADS)

    Salimianrizi, A.; Foroozmehr, E.; Badrossamay, M.; Farrokhpour, H.

    2016-02-01

    The purpose of this study is to investigate the effects of Laser Shock Peening (LSP) on Al 6061-T6. The confined LSP regime using Nd: YAG laser with 1200 mJ of energy per pulse and 8 ns of pulse width were applied. The treated specimens were evaluated by means of surface integrity with optical microscopy, scanning electron microscope, microhardness, surface roughness and induced residual stress using an X-ray diffraction method. Results showed that by the use of LSP, compressive residual stress could effectively be induced on the surface of treated material. It was also revealed that the hardened depth of the material, up to a maximum depth of 1875 μm, could be achieved due to work hardening and grain refinement. In addition, surface roughness measurements showed that the LSP could deteriorate surface quality depending on the LSP parameters. The influences of beam overlap rates, number of laser shots and scanning pattern on microhardness as well as surface roughness are discussed.

  1. Structure/property relations of aluminum under varying rates and stress states

    SciTech Connect

    Tucker, Matthew T; Horstemeyer, Mark F; Whittington, Wilburn R; Solanki, Kiran N

    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. Structural-phase changes in Al6061-T6 alloy during high-dose N-2(+) implantation

    NASA Astrophysics Data System (ADS)

    Soukieh, M.

    2004-02-01

    N 2 + nitrogen ions with an energy of 50 keV were implanted into Al6061-T6 alloy with high dose (10(16) - 2 x 10(17) ions/cm(2)) at room temperature in order to form thin aluminium nitride (AlN) layers. The structural-phase changes in implanted Al 6061-T6 alloy were investigated using Rutherford back-scattering and transmission electron microscopic techniques. The results indicate that nitrogen implantation led to the formation of nitride phases (AlN, Al7N C-3(3)) which improved the surface hardness by 80% and increased the electrical resistance up to 1800% at maximum dose (2 x 10(17) ions/cm(2)).

  3. Effects of aging treatment and heat input on the microstructures and mechanical properties of TIG-welded 6061-T6 alloy joints

    NASA Astrophysics Data System (ADS)

    Peng, Dong; Shen, Jun; Tang, Qin; Wu, Cui-ping; Zhou, Yan-bing

    2013-03-01

    Aging treatment and various heat input conditions were adopted to investigate the microstructural evolution and mechanical properties of TIG welded 6061-T6 alloy joints by microstructural observations, microhardness tests, and tensile tests. With an increase in heat input, the width of the heat-affected zone (HAZ) increases and grains in the fusion zone (FZ) coarsen. Moreover, the hardness of the HAZ decreases, whereas that of the FZ decreases initially and then increases with an increase in heat input. Low heat input results in the low ultimate tensile strength of the welded joints due to the presence of partial penetrations and pores in the welded joints. After a simple artificial aging treatment at 175°C for 8 h, the microstructure of the welded joints changes slightly. The mechanical properties of the welded joints enhance significantly after the aging process as few precipitates distribute in the welded seam.

  4. A study on ultra-precision machining technique for Al6061-T6 to fabricate space infrared optics

    NASA Astrophysics Data System (ADS)

    Ryu, Geun-man; Lee, Gil-jae; Hyun, Sang-won; Sung, Ha-yeong; Chung, Euisik; Kim, Geon-hee

    2014-08-01

    In this paper, analysis of variance on designed experiments with full factorial design was applied to determine the optimized machining parameters for ultra-precision fabrication of the secondary aspheric mirror, which is one of the key elements of the space cryogenic infrared optics. A single point diamond turning machine (SPDTM, Nanotech 4μpL Moore) was adopted to fabricate the material, AL6061-T6, and the three machining parameters of cutting speed, feed rate and depth of cut were selected. With several randomly assigned experimental conditions, surface roughness of each condition was measured by a non-contact optical profiler (NT2000; Vecco). As a result of analysis using Minitab, the optimum cutting condition was determined as following; cutting speed: 122 m/min, feed rate: 3 mm/min and depth of cut: 1 μm. Finally, a 120 mm diameter aspheric secondary mirror was attached to a particularly designed jig by using mixture of paraffin and wax and successfully fabricated under the optimum machining parameters. The profile of machined surface was measured by a high-accuracy 3-D profilometer(UA3P; Panasonic) and we obtained the geometrical errors of 30.6 nm(RMS) and 262.4 nm(PV), which satisfy the requirements of the space cryogenic infrared optics.

  5. Mechanical Properties of Aluminum-Based Dissimilar Alloy Joints by Power Beams, Arc and FSW Processes

    NASA Astrophysics Data System (ADS)

    Okubo, Michinori; Kon, Tomokuni; Abe, Nobuyuki

    Dissimilar smart joints are useful. In this research, welded quality of dissimilar aluminum alloys of 3 mm thickness by various welding processes and process parameters have been investigated by hardness and tensile tests, and observation of imperfection and microstructure. Base metals used in this study are A1050-H24, A2017-T3, A5083-O, A6061-T6 and A7075-T651. Welding processes used are YAG laser beam, electron beam, metal inert gas arc, tungsten inert gas arc and friction stir welding. The properties of weld zones are affected by welding processes, welding parameters and combination of base metals. Properties of high strength aluminum alloy joints are improved by friction stir welding.

  6. The effects of maintaining temperature in annealing heat treatment for an FSWed 6061-T6 Al alloy.

    PubMed

    Lee, Seung-Jun; Han, Min-Su; Kim, Seong-Jong

    2013-08-01

    The technological development of all kinds of lightweight transportation devices including vehicles, aircraft, ships, etc. has progressed markedly with the demand for energy saving and environmental protection. Aluminum alloy is in the spotlight as it is a suitable environmentally friendly material. However, deformation is a major problem during the welding process because aluminum alloy has a large thermal expansion coefficient. In addition, it is known that its corrosion resistance is excellent; nevertheless, in practice, considerable corrosion is generated and this is a major problem. To solve this problem, the friction stir welding (FSW) technology is applied extensively at various industrial fields as a new welding technique. This method involves a process in which materials are joined by frictional heat and physical force. Therefore, we evaluated improvements in mechanical properties and corrosion resistance through annealing heat treatment after FSW. The electrochemical experiment did not show a significant difference. However, the microstructure observation showed defectless, fine crystal particles, indicating excellent properties at 200-225°C. PMID:23920178

  7. Aluminum alloy welding and stress-corrosion testing. Final report

    SciTech Connect

    Gates, W.G.; Jimenez, E.

    1981-04-01

    The weldability, strength, and corrosion resistance of four 5XXX aluminum alloys electron beam welded to 6061-T6 aluminum alloy without a filler metal were evaluated. Adding filler metal raises weld energy requirements and makes the process more difficult to control. In this study, instead of using a filler metal, a high-magnesium 5XXX alloy was welded to the 6061 alloy. The four 5XXX alloys used (5456-H321, 5052-H34, 5086-H323, and 5083-H32) were selected for their high magnesium content which reduces weld crack sensitivity.

  8. Effect of an absorbent overlay on the residual stress field induced by laser shock processing on aluminum samples

    NASA Astrophysics Data System (ADS)

    Rubio-González, C.; Gomez-Rosas, G.; Ocaña, J. L.; Molpeceres, C.; Banderas, A.; Porro, J.; Morales, M.

    2006-07-01

    Laser shock processing (LSP) or laser shock peening is a new technique for strengthening metals. This process induces a compressive residual stress field, which increases fatigue crack initiation life and reduces fatigue crack growth rate. Specimens of 6061-T6 aluminum alloy are used in this investigation. A convergent lens is used to deliver 2.5 J, 8 ns laser pulses by a Q-switch Nd:YAG laser, operating at 10 Hz. The pulses are focused to a diameter of 1.5 mm onto aluminum samples. Density of 2500 pulses/cm 2 with infrared (1064 nm) radiation was used. The effect of an absorbent overlay on the residual stress field using this LSP setup and this energy level is evaluated. Residual stress distribution as a function of depth is assessed by the hole drilling method. It is observed that the overlay makes the compressive residual stress profile move to the surface. This effect is explained on the basis of the vaporization of the coat layer suppressing thermal effects on the metallic substrate. The effect of coating the specimen surface before LSP treatment may have advantages on improving wear and contact fatigue properties of this aluminum alloy.

  9. Alkaline oxide conversion coatings for aluminum alloys

    SciTech Connect

    Buchheit, R.G.

    1996-02-01

    Three related conversion coating methods are described that are based on film formation which occurs when aluminum alloys are exposed to alkaline Li salt solutions. Representative examples of the processing methods, resulting coating structure, composition and morphology are presented. The corrosion resistance of these coatings to aerated 0.5 M NaCl solution has been evaluated as a function of total processing time using electrochemical impedance spectroscopy (EIS). This evaluation shows that excellent corrosion resistance can be uniformly achieved using no more than 20 minutes of process time for 6061-T6. Using current methods a minimum of 80 minutes of process time is required to get marginally acceptable corrosion resistance for 2024-T3. Longer processing times are required to achieve uniformly good corrosion resistance.

  10. An ultra-low surface finish process for 6061-Al mirrors

    NASA Astrophysics Data System (ADS)

    Wamboldt, Leonard; Roy, Brian; Crifasi, Joseph; Stephens, Shane; Hanninen, Derek; Woodard, Kenneth; Felock, Robert; Cunha-Vasconcelos, Sofia; Polczwartek, Stephen; Parenteau, Jeffrey

    2015-05-01

    An ultra-low surface finishing process for 6061 T6 type aluminum has been developed by Corning Incorporated, Specialty Materials Division, and has been successfully applied to mirrors up to 13 inches in diameter. This paper presents finish and figure data achieved from the mirror finishing process. Mirror stability is demonstrated through Pre and post thermal cycle surface figure measurements; temperature range of cycle -55°C to +70°C. As an added benefit, the process enables the use of deterministic finishing and enhances the reflective optics resistance to corrosion. Survivability of the reflective optic is evaluated through extended humidity testing.

  11. Aluminum powder metallurgy processing

    NASA Astrophysics Data System (ADS)

    Flumerfelt, Joel Fredrick

    In recent years, the aluminum powder industry has expanded into non-aerospace applications. However, the alumina and aluminum hydroxide in the surface oxide film on aluminum powder require high cost powder processing routes. A driving force for this research is to broaden the knowledge base about aluminum powder metallurgy to provide ideas for fabricating low cost aluminum powder components. The objective of this dissertation is to explore the hypothesis that there is a strong linkage between gas atomization processing conditions, as-atomized aluminum powder characteristics, and the consolidation methodology required to make components from aluminum powder. The hypothesis was tested with pure aluminum powders produced by commercial air atomization commercial inert gas atomization and gas atomization reaction synthesis (GARS). The commercial atomization methods are bench marks of current aluminum powder technology. The GARS process is a laboratory scale inert gas atomization facility. A benefit of using pure aluminum powders is an unambiguous interpretation of the results without considering the effects of alloy elements. A comparison of the GARS aluminum powders with the commercial aluminum powders showed the former to exhibit superior powder characteristics. The powders were compared in terms of size and shape, bulk chemistry, surface oxide chemistry and structure, and oxide film thickness. Minimum explosive concentration measurements assessed the dependence of explosibility hazard on surface area, oxide film thickness, and gas atomization processing conditions. The GARS aluminum powders were exposed to different relative humidity levels, demonstrating the effect of atmospheric conditions on post-atomization oxidation of aluminum powder. An Al-Ti-Y GARS alloy exposed in ambient air at different temperatures revealed the effect of reactive alloy elements on post-atomization powder oxidation. The pure aluminum powders were consolidated by two different routes, a

  12. Aluminum powder metallurgy processing

    SciTech Connect

    Flumerfelt, J.F.

    1999-02-12

    The objective of this dissertation is to explore the hypothesis that there is a strong linkage between gas atomization processing conditions, as-atomized aluminum powder characteristics, and the consolidation methodology required to make components from aluminum powder. The hypothesis was tested with pure aluminum powders produced by commercial air atomization, commercial inert gas atomization, and gas atomization reaction synthesis (GARS). A comparison of the GARS aluminum powders with the commercial aluminum powders showed the former to exhibit superior powder characteristics. The powders were compared in terms of size and shape, bulk chemistry, surface oxide chemistry and structure, and oxide film thickness. Minimum explosive concentration measurements assessed the dependence of explosibility hazard on surface area, oxide film thickness, and gas atomization processing conditions. The GARS aluminum powders were exposed to different relative humidity levels, demonstrating the effect of atmospheric conditions on post-atomization processing conditions. The GARS aluminum powders were exposed to different relative humidity levels, demonstrating the effect of atmospheric conditions on post-atomization oxidation of aluminum powder. An Al-Ti-Y GARS alloy exposed in ambient air at different temperatures revealed the effect of reactive alloy elements on post-atomization powder oxidation. The pure aluminum powders were consolidated by two different routes, a conventional consolidation process for fabricating aerospace components with aluminum powder and a proposed alternative. The consolidation procedures were compared by evaluating the consolidated microstructures and the corresponding mechanical properties. A low temperature solid state sintering experiment demonstrated that tap densified GARS aluminum powders can form sintering necks between contacting powder particles, unlike the total resistance to sintering of commercial air atomization aluminum powder.

  13. The aluminum smelting process.

    PubMed

    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. PMID:24806722

  14. The Aluminum Smelting Process

    PubMed Central

    2014-01-01

    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. PMID:24806722

  15. Tests Of Polyurethane And Dichromate Coats On Aluminum

    NASA Technical Reports Server (NTRS)

    Danford, M. D.

    1992-01-01

    Report describes experiments to determine relative effectiveness of new polyurethane and more-conventional dichromate coat in helping to retard corrosion of anodized 6061-T6 aluminum. Concludes by suggesting greater protection against corrosion achieved by combining polyurethane-sealing method with hard-anodizing method and by increasing thickness of coat.

  16. Tribological Properties of Aluminum Alloy treated by Fine Particle Peening/DLC Hybrid Surface Modification

    NASA Astrophysics Data System (ADS)

    Amano, Y.; Nanbu, H.; Kameyama, Y.; Komotori, J.

    2010-06-01

    In order to improve the adhesiveness of the DLC coating, Fine Particle Peening (FPP) treatment was employed as pre-treatment of the DLC coating process. FPP treatment was performed using SiC shot particles, and then AA6061-T6 aluminum alloy was DLC-coated. A SiC-rich layer was formed around the surface of the aluminum alloy by the FPP treatment because small chips of shot particles were embedded into the substrate surface. Reciprocating sliding tests were conducted to measure the friction coefficients. While the DLC coated specimen without FPP treatment showed a sudden increase in friction coefficient at the early stage of the wear cycles, the FPP/DLC hybrid treated specimen maintained a low friction coefficient value during the test period. Further investigation revealed that the tribological properties of the substrate after the DLC coating were improved with an increase in the amount of Si at the surface.

  17. The corrosion protection of several aluminum alloys by chromic acid and sulfuric acid anodizing

    NASA Technical Reports Server (NTRS)

    Danford, M. D.

    1994-01-01

    The corrosion protection afforded 7075-T6, 7075-T3, 6061-T6, and 2024-T3 aluminum alloys by chromic acid and sulfuric acid anodizing was examined using electrochemical techniques. From these studies, it is concluded that sulfuric acid anodizing provides superior corrosion protection compared to chromic acid anodizing.

  18. PROCESS FOR REMOVING ALUMINUM COATINGS

    DOEpatents

    Flox, J.

    1959-07-01

    A process is presented for removing aluminum jackets or cans from uranium slugs. This is accomplished by immersing the aluminum coated uranium slugs in an aqueous solution of 9 to 20% sodium hydroxide and 35 to 12% sodium nitrate to selectively dissolve the aluminum coating, the amount of solution being such as to obtain a molar ratio of sodium hydroxide to aluminum of at least

  19. Initial Subdivision of Genesis Early Science Polished Aluminum Collector

    NASA Technical Reports Server (NTRS)

    Allton, J. H.; Stansbery, E. K.; McNamara, K. M.; Meshik, A.; See, T. H.; Bastien, R.

    2005-01-01

    A large surface, about 245 square centimeters, of highly polished aluminum 6061 T6 alloy was attached to the science canister thermal panel for the purpose of collecting solar wind noble gases. The analysis of this collector will be part of the Genesis Early Science results. The pre-launch configuration of the collector is shown. The collector sustained some damage during the recovery impact in Utah, September 8, 2004.

  20. Evaluation of Johnson-Cook model constants for aluminum based particulate metal matrix composites

    NASA Astrophysics Data System (ADS)

    Hilfi, H.; Brar, N. S.

    1996-05-01

    High strain rate and high temperature response of three types of aluminum based particulate metal matrix ceramic composites is investigated by performing split Hopkinson pressure bar (SHPB) experiments. The composites are: NGP-2014 (15% SiC), NGT-6061 (15% SiC), and NGU-6061 (15% Al2O3), in which all the reinforcement materials are percentage by volume. Johnson-Cook constitutive model constants are evaluated from the high strain rate/high temperature data and implemented in a two dimensional finite element computer code (EPIC-2D) to simulate the penetration of an ogive nose tungsten projectile (23 grams) at a velocity 1.17 km/sec into the base 6061-T6 aluminum alloy and the composite NGU-6061. The simulated penetrations in the composite and in 6061-T6 aluminum agree with in 2%, in both materials, with the measured values.

  1. Joining of Cast ZE41A Mg to Wrought 6061 Al by the Cold Spray Process and Friction Stir Welding

    NASA Astrophysics Data System (ADS)

    Champagne, Victor Kenneth; West, Michael K.; Reza Rokni, M.; Curtis, Todd; Champagne, Victor; McNally, Baillie

    2016-01-01

    This paper presents a novel method for joining cast ZE41A-T5 Mg to wrought 6061-T6 Al, without forming deleterious, coarse intermetallic compounds, which is not currently possible with conventional technologies. The novel aspect of the process includes the development of a joint design using cold spray (CS) as the enabling technology, to produce a transitional layer onto which a conventional welding technique can be employed to join the two dissimilar materials. The emphasis in this study will be on the CS transitional layer (T-layer) which enables the joining of cast ZE41A-T5 magnesium (Mg) and wrought 6061-T6 aluminum (Al) by friction-stir welding and the subsequent materials characterization to show the structural integrity of the entire joint. In order to join Mg and Al plates by this method, a transitional layer of CS Al is first deposited along the edge of cast ZE41A Mg plate. The CS Al T-layer enables the Mg to be friction stir welded to a plate of wrought 6061 Al, thereby completing the Mg plate to Al plate joint. Friction stir welding was chosen in this study to join the CS Al T-layer to the wrought Al plate; however, other conventional welding techniques could also be employed for joining Mg to Al in this manner. The CS Al T-layer is compatible to the wrought 6061 Al plate and serves as an insulating layer that prevents heat generated during the friction stir welding process from extending into the magnesium, thus preventing the formation of intermetallics. In this study, two sets of samples were produced joining cast ZE41A-T5 magnesium (Mg) and wrought 6061-T6 aluminum: one set using CS 6061 Al as the transition material between the ZE41A Mg plate and 6061 Al plate and the other set using CS 5056 Al as the transition material. Microstructural analysis by scanning and transmission electron microscopy and optical microscopy, along with mechanical test results including triple lug shear, tension, and micro hardness will be presented. Comparisons will be

  2. Galvanic corrosion of aluminum-matrix composites. Technical report No. 2, 1 Mar-31 Dec 90

    SciTech Connect

    Hihara, L.H.; Latanision, R.M.

    1991-02-01

    Galvanic-corrosion rates of Al-matrix composites were high in aerated chloride-containing solutions. Oxygen reduction was found to be the primary cathodic reaction. Aluminum corroded by pitting. The type of noble constituent (i.e., graphite, SiC, or TiB{sub 2}) also affected galvanic-corrosion rates. For example, results indicated that the galvanic-corrosion rate of Al should be about 30 times greater when coupled to graphite than when coupled to SiC or TiB{sub 2}. In dearated solutions, galvanic corrosion was negligible even if chlorides were present. The galvanic-corrosion rates were determined using the zero-resistance ammeter technique and from potentiodynamic polarization diagrams of ultrapure Al, 6061-T6 Al, graphite fiber, SiC, TiB2, and a commercial graphite fiber/6061-T6 Al metal-matrix composite.

  3. Manufacturing of an aluminum alloy mold for micro-hot embossing of polymeric micro-devices

    NASA Astrophysics Data System (ADS)

    Tran, N. K.; Lam, Y. C.; Yue, C. Y.; Tan, M. J.

    2010-05-01

    In micro-hot embossing of polymeric micro-devices, e.g. microfluidic devices, the quality of the mold plays an important role in determining not only the product quality but also the overall production cost. Often the mold is made of silicon, which is brittle and fails after producing a limited number of parts. Metallic molds produced by micro-machining have a much longer life; however, the surface finish of the mold is not ideal for producing polymeric devices that require good surface finish. The metallic glass mold produced by micro-hot embossing with a silicon master is a recent development, which could produce high quality and high strength molds with long life span. However, metallic glasses are rather costly. In an attempt to reduce the production cost of the mold with acceptable quality, strength and life span, we explore here the manufacture of an aluminum alloy (AA6061-T6) mold by hot embossing using a silicon master. Using a set of channels to be produced on the aluminum alloy as the benchmark, we examine the orientation effect of the channels on the AA6061-T6 mold produced by hot embossing. Finally, to examine the effectiveness of the AA6061-T6 mold, it is employed for the hot embossing of polymeric (TOPAS 8007) substrates.

  4. Characterization of an Effective Cleaning Procedure for Aluminum Alloys: Surface Enhanced Raman Spectroscopy and Zeta Potential Analysis

    SciTech Connect

    Cherepy, N J; Shen, T H; Esposito, A P; Tillotson, T M

    2004-06-02

    We have developed a cleaning procedure for aluminum alloys for effective minimization of surface-adsorbed sub-micron particles and non-volatile residue. The procedure consists of a phosphoric acid etch followed by an alkaline detergent wash. To better understand the mechanism whereby this procedure reduces surface contaminants, we characterized the aluminum surface as a function of cleaning step using Surface Enhanced Raman Spectroscopy (SERS). SERS indicates that phosphoric acid etching re-establishes a surface oxide of different characteristics, including deposition of phosphate and increased hydration, while the subsequent alkaline detergent wash appears to remove the phosphate and modify the new surface oxide, possibly leading to a more compact surface oxide. We also studied the zeta potential of <5 micron pure aluminum and aluminum alloy 6061-T6 particles to determine how surface electrostatics may be affected during the cleaning process. The particles show a decrease in the magnitude of their zeta potential in the presence of detergent, and this effect is most pronounced for particles that have been etched with phosphoric acid. This reduction in magnitude of the surface attractive potential is in agreement with our observation that the phosphoric acid etch followed by detergent wash results in a decrease in surface-adsorbed sub-micron particulates.

  5. Process for anodizing aluminum foil

    SciTech Connect

    Ball, J.A.; Scott, J.W.

    1984-11-06

    In an integrated process for the anodization of aluminum foil for electrolytic capacitors including the formation of a hydrous oxide layer on the foil prior to anodization and stabilization of the foil in alkaline borax baths during anodization, the foil is electrochemically anodized in an aqueous solution of boric acid and 2 to 50 ppm phosphate having a pH of 4.0 to 6.0. The anodization is interrupted for stabilization by passing the foil through a bath containing the borax solution having a pH of 8.5 to 9.5 and a temperature above 80/sup 0/ C. and then reanodizing the foil. The process is useful in anodizing foil to a voltage of up to 760 V.

  6. PROCESS OF ELECTROPLATING METALS WITH ALUMINUM

    DOEpatents

    Schickner, W.C.

    1960-04-26

    A process of electroplating aluminum on metals from a nonaqueous bath and a novel method of pretreating or conditioning the metal prior to electrodeposition of the aluminum are given. The process of this invention, as applied by way of example to the plating of uranium, comprises the steps of plating the uranium with the barrier inetal, immersing the barrier-coated uranium in fatty acid, and electrolyzing a water-free diethyl ether solution of aluminum chloride and lithium hydride while making the uranium the cathode until an aluminum deposit of the desired thickness has been formed. According to another preferred embodiment the barrier-coated uranium is immersed in an isopropyl alcohol solution of sterato chromic chloride prior to the fatty acid treatment of this invention.

  7. Impact Welding of Aluminum to Copper and Stainless Steel by Vaporizing Foil Actuator: Effect of Heat Treatment Cycles on Mechanical Properties and Microstructure

    NASA Astrophysics Data System (ADS)

    Vivek, Anupam; Hansen, Steven; Benzing, Jake; He, Mei; Daehn, Glenn

    2015-10-01

    This work studies the mechanical property effect of microstructure on impact welds of aluminum alloy AA6061 with both copper alloy Cu 110 and stainless steel AISI 304. AA6061-T6 and T4 temper aluminum sheets of 1 mm thickness were launched toward copper and stainless steel targets using the vaporizing foil actuator technique. Flyer plate velocities, measured via photonic Doppler velocimetry, were observed to be approximately 800 m/s. The welded aluminum-copper samples were subjected to instrumented peel testing, microhardness testing, energy-dispersive X-ray spectroscopy, and scanning electron microscopy. The welded joints exhibited cracks through their continuous intermetallic layers. The cracks were impeded upon encountering a ductile metallic wave. The welds created with T6 temper flyer sheets were found to have smaller intermetallic-free and wavy interface regions as compared to those created with T4 temper flyer sheets. Peel strength tests of the two weld combinations resulted in failure along the interface in the case of the T6 flyer welds, while the failure generally occurred in the parent aluminum for the T4 temper flyer welds. Half of the T4 flyer welds were subjected to aging for 18 h at 433 K (160 °C) to convert the aluminum sheet to the T6 condition. Although the aged flyer material did not attain the hardness of the as-received T6 material, it was found to be significantly stronger than the T4 material. These welds retained their strength after the aging process, and diffusion across the interface was minimal. The welded aluminum-stainless steel samples were analyzed on a more basic level than aluminum-copper samples, but were found to exhibit similar results.

  8. NEUTRON DIFFRACTION MEASUREMENT OF RESIDUAL STRESSES IN FRICTION STIR PROCESSED NANOCOMPOSITE SURFACE LAYER

    SciTech Connect

    Xu, Hanbing; Hubbard, Camden R; An, Ke; Wang, Xun-Li; Feng, Zhili; Qu, Jun

    2009-01-01

    Friction stir processing (FSP) was successfully used to stir and mix nano-sized Al2O3 particles into a Al6061-T6 aluminum plate to form a nanocomposite layer up to 3 mm thick. This nanocomposite surface has demonstrated significantly improved surface hardness, yield strength, and wear-resistance without sacrificing the substrate ductility and conductivity. Neutron diffraction analysis was conducted to determine the residual stress distribution in the nanocomposite surface layer. For comparison, the residual stress of the aluminum surface that was processed similarly but had no particle involved was also measured. Results showed that the macro-level residual stresses in the FSP zone without particles are low due to the annealing effect induced by the long heating time and large heat input. The macro-level residual stresses in the FSP-processed Al-Al2O3 nanocomposite zone are tensile up to 100 MPa in all three directions. The details of the results will be further discussed in the paper.

  9. Process simulation of aluminum reduction cells

    SciTech Connect

    Tabsh, I.; Dupuis, M.; Gomes, A.

    1996-10-01

    A program was developed to model the dynamic behavior of an aluminum reduction cell. The program simulates the physical process by solving the heat and mass balance equations that characterize the behavior of eleven chemical species in the system. It also models operational events (such as metal tapping, anode change, etc.) and the process control logic including various alumina feeding policies and anode effect quenching. The program is a PC based Windows{reg_sign} application that takes full advantage of the Windows user interface. This paper describes the implementation of the process model and the control logic. Various results using the simulation are compared to measured data.

  10. Anodization process produces opaque, reflective coatings on aluminum

    NASA Technical Reports Server (NTRS)

    1965-01-01

    Opaque, reflective coatings are produced on aluminum articles by an anodizing process wherein the anodizing bath contains an aqueous dispersion of finely divided insoluble inorganic compounds. These particles appear as uniformly distributed occlusions in the anodic deposit on the aluminum.

  11. Processing of boron carbide-aluminum composites

    SciTech Connect

    Halverson, D.C. ); Pyzik, A.J.; Aksay, I.A. . Dept. of Materials Science and Engineering); Snowden, W.E. )

    1989-05-01

    The processing problems associated with boron carbide and the limitations of its mechanical properties can be significantly reduced when a metal phase (e.g., aluminum) is added. Lower densification temperatures and higher fracture toughness will result. Based on fundamental capillarity thermodynamics, reaction thermodynamics, and densification kinetics, we have established reliable criteria for fabricating B{sub 4}C-Al particulate composites. Because chemical reactions cannot be eliminated, it is necessary to process B{sub 4}C-Al by rapidly heating to near 1200{degrees} C (to ensure wetting) and subsequently heat-treating below 1200{degrees} C (for microstructural development).

  12. Microstructural Characterization of Friction Stir Welded Aluminum-Steel Joints

    NASA Astrophysics Data System (ADS)

    Patterson, Erin E.; Hovanski, Yuri; Field, David P.

    2016-06-01

    This work focuses on the microstructural characterization of aluminum to steel friction stir welded joints. Lap weld configuration coupled with scribe technology used for the weld tool have produced joints of adequate quality, despite the significant differences in hardness and melting temperatures of the alloys. Common to friction stir processes, especially those of dissimilar alloys, are microstructural gradients including grain size, crystallographic texture, and precipitation of intermetallic compounds. Because of the significant influence that intermetallic compound formation has on mechanical and ballistic behavior, the characterization of the specific intermetallic phases and the degree to which they are formed in the weld microstructure is critical to predicting weld performance. This study used electron backscatter diffraction, energy dispersive spectroscopy, scanning electron microscopy, and Vickers micro-hardness indentation to explore and characterize the microstructures of lap friction stir welds between an applique 6061-T6 aluminum armor plate alloy and a RHA homogeneous armor plate steel alloy. Macroscopic defects such as micro-cracks were observed in the cross-sectional samples, and binary intermetallic compound layers were found to exist at the aluminum-steel interfaces of the steel particles stirred into the aluminum weld matrix and across the interfaces of the weld joints. Energy dispersive spectroscopy chemical analysis identified the intermetallic layer as monoclinic Al3Fe. Dramatic decreases in grain size in the thermo-mechanically affected zones and weld zones that evidenced grain refinement through plastic deformation and recrystallization. Crystallographic grain orientation and texture were examined using electron backscatter diffraction. Striated regions in the orientations of the aluminum alloy were determined to be the result of the severe deformation induced by the complex weld tool geometry. Many of the textures observed in the weld

  13. Microstructural Characterization of Friction Stir Welded Aluminum-Steel Joints

    NASA Astrophysics Data System (ADS)

    Patterson, Erin E.; Hovanski, Yuri; Field, David P.

    2016-03-01

    This work focuses on the microstructural characterization of aluminum to steel friction stir welded joints. Lap weld configuration coupled with scribe technology used for the weld tool have produced joints of adequate quality, despite the significant differences in hardness and melting temperatures of the alloys. Common to friction stir processes, especially those of dissimilar alloys, are microstructural gradients including grain size, crystallographic texture, and precipitation of intermetallic compounds. Because of the significant influence that intermetallic compound formation has on mechanical and ballistic behavior, the characterization of the specific intermetallic phases and the degree to which they are formed in the weld microstructure is critical to predicting weld performance. This study used electron backscatter diffraction, energy dispersive spectroscopy, scanning electron microscopy, and Vickers micro-hardness indentation to explore and characterize the microstructures of lap friction stir welds between an applique 6061-T6 aluminum armor plate alloy and a RHA homogeneous armor plate steel alloy. Macroscopic defects such as micro-cracks were observed in the cross-sectional samples, and binary intermetallic compound layers were found to exist at the aluminum-steel interfaces of the steel particles stirred into the aluminum weld matrix and across the interfaces of the weld joints. Energy dispersive spectroscopy chemical analysis identified the intermetallic layer as monoclinic Al3Fe. Dramatic decreases in grain size in the thermo-mechanically affected zones and weld zones that evidenced grain refinement through plastic deformation and recrystallization. Crystallographic grain orientation and texture were examined using electron backscatter diffraction. Striated regions in the orientations of the aluminum alloy were determined to be the result of the severe deformation induced by the complex weld tool geometry. Many of the textures observed in the weld

  14. Internal Heterogeneous Processes in Aluminum Combustion

    NASA Technical Reports Server (NTRS)

    Dreizin, E. L.

    1999-01-01

    This paper discusses the aluminum particle combustion mechanism which has been expanded by inclusion of gas dissolution processes and ensuing internal phase transformations. This mechanism is proposed based on recent normal and microgravity experiments with particles formed and ignited in a pulsed micro-arc. Recent experimental findings on the three stages observed in Al particle combustion in air and shows the burning particle radiation, trajectory (streak), smoke cloud shapes, and quenched particle interiors are summarized. During stage I, the radiation trace is smooth and the particle flame is spherically symmetric. The temperature measured using a three-color pyrometer is close to 3000 K. Because it exceeds the aluminum boiling point (2730 K), this temperature most likely characterizes the vapor phase flame zone rather than the aluminum surface. The dissolved oxygen content within particles quenched during stage I was below the detection sensitivity (about 1 atomic %) for Wavelength Dispersive Spectroscopy (WDS). After an increase in the radiation intensity (and simultaneous decrease in the measured color temperature from about 3000 to 2800 K) indicative of the transition to stage II combustion, the internal compositions of the quenched particles change. Both oxygen-rich (approx. 10 atomic %) and oxygen-lean (< 1 %) regions are identified within the particles using back-scattered electron imaging and WDS. During stage II, oscillations are observed in particle radiation and the flame and smoke cloud are distorted from their original spherically-symmetric shape. In stage III, particle radiation continues to exhibit oscillations, but its radiation intensity drops and remains at a nearly constant level. The measured temperature decreases to about 2300 K. Also, larger changes in particle velocities are observed, and oxide caps are found on quenched particle surfaces. While these results showed the correlation between the aluminum particle combustion behavior and the

  15. Tool design in friction stir processing: dynamic forces and material flow

    SciTech Connect

    D. E. Clark; K. S. Miller; C. R. Tolle

    2006-08-01

    Friction stir processing involves severe plastic flow within the material; the nature of this flow determines the final morphology of the weld, the resulting microstructures, and the presence or absence of defects such as internal cavities or "wormholes." The forces causing this plastic flow are a function of process parameters, including spindle speed, travel speed, and tool design and angle. Some of these forces are directly applied or a result of the mechanical constraints and compliance of the apparatus, while others are resolved forces resulting from an interaction of these applied forces and tool forces governed by processing parameters, and can be diminished or even reversed in sign with appropriate choices of process parameters. The present investigation is concerned mostly with the friction stir processing of 6061-T6 aluminum plates in a low-cost apparatus built from a commercial milling machine. A rotating dynamometer allows in-process measurement of actual spindle speed, torque, and forces in the x-, y-, and z-directions, as well as force control on these axes. Two main types of tool, both unthreaded, were used. The first had a pin about 4 mm in diameter and 4 mm in length, with a shoulder about 10 mm in diameter, and produced wormhole defects; the second, with a tapered pin about 5 mm long, a base diameter of about 6 mm, a tip diameter of about 4 mm, and a shoulder diameter (flat or dished) of about 19 mm, produced sound welds over a wide range of parameters.

  16. Decarbonization process for carbothermically produced aluminum

    DOEpatents

    Bruno, Marshall J.; Carkin, Gerald E.; DeYoung, David H.; Dunlap, Sr., Ronald M.

    2015-06-30

    A method of recovering aluminum is provided. An alloy melt having Al.sub.4C.sub.3 and aluminum is provided. This mixture is cooled and then a sufficient amount of a finely dispersed gas is added to the alloy melt at a temperature of about 700.degree. C. to about 900.degree. C. The aluminum recovered is a decarbonized carbothermically produced aluminum where the step of adding a sufficient amount of the finely dispersed gas effects separation of the aluminum from the Al.sub.4C.sub.3 precipitates by flotation, resulting in two phases with the Al.sub.4C.sub.3 precipitates being the upper layer and the decarbonized aluminum being the lower layer. The aluminum is then recovered from the Al.sub.4C.sub.3 precipitates through decanting.

  17. Application of Laser Shock Processing System by Underwater Irradiation (1064 nm) in Metal Surface

    NASA Astrophysics Data System (ADS)

    Gomez-Rosas, G.; Rubio-González, C.; Ocaña, J. L.; Molpeceres, C.; Porro, J. A.; Morales, M.; Casillas, F. J.; Mora-Gonzalez, M.; Peña-Lecona, F. G.

    2008-04-01

    Laser shock processing (LSP) is a technique for strengthening metals. This process induces a compressive residual stress field which increases fatigue crack initiation life, reduces fatigue crack growth rate and increases wear resistance of metals. We present a configuration and results in the LSP concept for metal surfaces treatments in underwater layer with constant thickness using laser irradiation at 1064 nm. A convergent lens is used to deliver 2, 5 J/cm2 in a 8 ns laser FWHM pulse produced by a Q-switch Nd:YAG Laser. Experimental results using a pulse density of 5 000 pulses/cm2 and spots of 0, 8 mm to 1, 5 mm in diameter on AISI 1040 steel surfaces, Ti6A14V surfaces, 304 Stainless Steel surface and 6061-T6 Aluminum surfaces are presented. A compressive residual stress distribution as a function of depth is assessed by the hole drilling method. High level compressive residual stresses are produced using a 1064 nm wavelength. This method can be applied for surface treatment of final metal products.

  18. Ductile fracture processes in 7075 aluminum

    SciTech Connect

    You, C.P. ); Thompson, A.W. ); Bernstein, I.M. )

    1995-02-01

    The ductile fracture of 7075 aluminum was examined as a function of aging condition, from underaged to overaged. Notched specimens allowed the triaxiality of stress to be varied. Increasing triaxiality, which was due to increasing notch acuity, decreased ductility and increased nucleation of voids, in accord with expectations from ductile fracture models. Overaged material, which is generally resistant to environmental damage, was not susceptible to hydrogen embrittlement even with high triaxiality, but void sizes were increased by hydrogen. That increase suggested that void growth rates may be assisted by hydrogen in overaged 7075 aluminum.

  19. Extreme ultraviolet reflection efficiencies of diamond-turned aluminum, polished nickel, and evaporated gold surfaces. [for telescope mirrors

    NASA Technical Reports Server (NTRS)

    Malina, R. F.; Cash, W.

    1978-01-01

    Measured reflection efficiencies are presented for flat samples of diamond-turned aluminum, nickel, and evaporated gold surfaces fabricated by techniques suited for EUV telescopes. The aluminum samples were 6.2-cm-diameter disks of 6061-T6, the electroless nickel samples were formed by plating beryllium disks with 7.5-microns of Kanigen. Gold samples were produced by coating the aluminum and nickel samples with 5 strips of evaporated gold. Reflection efficiencies are given for grazing angles in the 5-75 degree range. The results indicate that for wavelengths over about 100 A, the gold-coated nickel samples yield highest efficiencies. For shorter wavelengths, the nickel samples yield better efficiencies. 500 A is found to be the optimal gold thickness.

  20. Aluminum foam, ALPORAS: The production process, properties and applications

    SciTech Connect

    Miyoshi, T.; Itoh, M.; Akiyama, S.; Kitahara, A.

    1998-12-31

    The production of foamed aluminum has long been considered difficult to realize because of such problems as the low foamability of molten metal, the varying size of cellular structures, solidification shrinkage and so on. Recently these problems have been solved by a number of researchers and some manufacturers produce foamed aluminum by their own methods. The authors have been employing a batch casting process and manufacturing foamed aluminum under the tradename ALPORAS{reg_sign} since 1986. This paper presents the manufacturing process, physical properties and some typical applications of ALPORAS.

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

    SciTech Connect

    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.

  2. Microstructural and Hardness Study of Pulsed Nd:YAG Laser Surface Alloyed Aluminum with Iron

    NASA Astrophysics Data System (ADS)

    Ansari, Mohammad; Soltani, Reza; Heydarzadeh Sohi, Mahmoud; Valefi, Zia

    2016-04-01

    In the present study, the feasibility of the formation of surface layers containing hard iron aluminides on AA6061-T6 aluminum via pre-plasma spraying with iron and subsequently double surface melting by pulsed Nd:YAG laser is studied. The effects of single and double laser surface melting on microstructure, phase formation, and hardness of the treated layers are examined. Single-step laser treatment resulted in the presence of undissolved iron particles surrounded by lump-like Al5Fe2 and needle-like Al3Fe intermetallic compounds. Double laser surface melting dissolved the retained undissolved irons and resulted in the formation of Al-Al3Fe eutectic structure. Microhardness profiles along cross section and top surface of the treated layers indicated that laser surface alloying with iron enhanced the hardness of the aluminum to more than twice of that of the base material.

  3. Process for strengthening aluminum based ceramics and material

    DOEpatents

    Moorhead, Arthur J.; Kim, Hyoun-Ee

    2000-01-01

    A process for strengthening aluminum based ceramics is provided. A gaseous atmosphere consisting essentially of silicon monoxide gas is formed by exposing a source of silicon to an atmosphere consisting essentially of hydrogen and a sufficient amount of water vapor. The aluminum based ceramic is exposed to the gaseous silicon monoxide atmosphere for a period of time and at a temperature sufficient to produce a continuous, stable silicon-containing film on the surface of the aluminum based ceramic that increases the strength of the ceramic.

  4. Study on the Inter-electrode Process of Aluminum Electrolysis

    NASA Astrophysics Data System (ADS)

    Yang, Youjian; Gao, Bingliang; Wang, Zhaowen; Shi, Zhongning; Hu, Xianwei

    2016-02-01

    The voltage distribution between carbon anode and aluminum cathode in cryolite electrolyte saturated with alumina was determined using a scanning reference electrode to investigate the inter-electrode process during aluminum electrolysis. The results showed that the anode-cathode-distance (ACD) is consisted of three parts: a relatively stable cathode boundary layer, bubble-free electrolyte layer, and gas-liquid layer near the anode. The aluminum diffusion layer with high electronic conductivity as well as the crystallization of cryolite was observed at the cathode boundary layer. The thickness of the aluminum diffusion layer varied with current density, which further determined the critical ACD. The thickness, coverage, and releasing frequency of the bubbles on both laboratory and industrial prebaked cells were derived, and it is found that the average bubble coverage decreases with current density, and the average coverage at 0.8 A cm-2 is approximately 50 pct.

  5. Friction stir welding process to repair voids in aluminum alloys

    NASA Technical Reports Server (NTRS)

    Rosen, Charles D. (Inventor); Litwinski, Edward (Inventor); Valdez, Juan M. (Inventor)

    1999-01-01

    The present invention provides an in-process method to repair voids in an aluminum alloy, particularly a friction stir weld in an aluminum alloy. For repairing a circular void or an in-process exit hole in a weld, the method includes the steps of fabricating filler material of the same composition or compatible with the parent material into a plug form to be fitted into the void, positioning the plug in the void, and friction stir welding over and through the plug. For repairing a longitudinal void (30), the method includes machining the void area to provide a trough (34) that subsumes the void, fabricating filler metal into a strip form (36) to be fitted into the trough, positioning the strip in the trough, and rewelding the void area by traversing a friction stir welding tool longitudinally through the strip. The method is also applicable for repairing welds made by a fusing welding process or voids in aluminum alloy workpieces themselves.

  6. The Aluminum Smelting Process and Innovative Alternative Technologies

    PubMed Central

    Drabløs, Per Arne

    2014-01-01

    Objective: The industrial aluminum production process is addressed. The purpose is to give a short but comprehensive description of the electrolysis cell technology, the raw materials used, and the health and safety relevance of the process. Methods: This article is based on a study of the extensive chemical and medical literature on primary aluminum production. Results: At present, there are two main technological challenges for the process—to reduce energy consumption and to mitigate greenhouse gas emissions. A future step may be carbon dioxide gas capture and sequestration related to the electric power generation from fossil sources. Conclusions: Workers' health and safety have now become an integrated part of the aluminum business. Work-related injuries and illnesses are preventable, and the ultimate goal to eliminate accidents with lost-time injuries may hopefully be approached in the future. PMID:24806723

  7. Cavitation Erosion of Copper, Brass, Aluminum and Titanium Alloys in Mineral Oil

    NASA Technical Reports Server (NTRS)

    Rao, B. C. S.; Buckley, D. H.

    1983-01-01

    The variations of the mean depth of penetration, the mean depth rate of penetration, MDRP, the pit diameter 2a and depth h due to cavitation attack on Al 6061-T6, Cu, brass of composition Cu-35Zn-3Pb and Ti-5A1-2.5Sn are presented. The experiments are conducted in a mineral oil of viscosity 110 CS using a magnetostrictive oscillator of 20 kHz frequency. Based on MDRP on the materials, it is found that Ti-5Al-2.5Sn exhibits cavitation erosion resistance which is two orders of magnitude higher than the other three materials. The values of h/a are the largest for copper and decreased with brass, titanium, and aluminum. Scanning electron microscope studies show that extensive slip and cross slip occurred on the surface prior to pitting and erosion. Twinning is also observed on copper and brass.

  8. The development of an aluminum toroidal shell-type impact limiter

    SciTech Connect

    Mello, R.M.; Wilson, W.K.; Nair, B.R.

    1989-01-01

    The impact limiters on a Type B transportation cask are designed to absorb the impact energy for the 9-meter (30 foot) drop accident conditions without bottoming out in order to limit deceleration loadings on the cask. Toroidal shell-type impact limiters made from stainless steel have been investigated in the past for transportation cask service in Japan (Y. Sugita and S. Mochizuki) and by the General Electric Company (R.J. Pomares, et al.). These designs were relatively heavy and quite rigid causing high deceleration loads on the cask. This paper presents the results of an investigation to determine the feasibility of an aluminum Alloy 6061-T6 toroidal shell impact limiter for a Legal Weight Truck (LWT) cask being developed by the Westinghouse Corporation for the United States Department of Energy. The incentives for the study were the potential advantages such as a compact configuration, lightweight, durability, and essentially maintenance-free operation. 4 refs., 10 figs.

  9. Material failure and inertial instabilities in a shocked imploded cylindrical aluminum sample

    SciTech Connect

    Chandler, E.A.; Egan, P.; Stokes, J.

    1998-12-31

    The authors have used the LANL Pegasus Z-pinch facility to drive a thin cylindrically-convergent Al liner to {approximately}3 km/s to launch {approximately}30 GPa shocks in a 3-mm thick 10-mm-i.d. aluminum cylinder whose interior is filled with 1 atm Xe gas. The subsequent material motion of the metal and gas is diagnosed with both radial and axial flash x-rays and with optical framing cameras. Instabilities are seeded by implanting wires of assorted higher density metal parallel to the cylinder axis. The authors have done two shots, varying the target from Al 1100-O to Al 6061-T6 to explore the effect of changing material strength. The images show the spallation failure of the metal-gas interface on shock release and the effect of the seeded instabilities.

  10. Electrochemistry of the Hall-Heroult Process for Aluminum Smelting.

    ERIC Educational Resources Information Center

    Haupin, W. E.

    1983-01-01

    Nearly all aluminum is produced by the electrolysis of alumina dissolved in a molten cryolite-based electrolyte, the Hall-Heroult Process. Various aspects of the procedure are discussed, focusing on electrolyte chemistry, dissolution of alumina, electrode reactions, current efficiency, and cell voltage. Suggestions for graduate study related to…

  11. Secondary Aluminum Processing Waste: Salt Cake Characterization and Reactivity

    EPA Science Inventory

    Thirty-nine salt cake samples were collected from 10 SAP facilities across the U.S. The facilities were identified by the Aluminum Association to cover a wide range of processes. Results suggest that while the percent metal leached from the salt cake was relatively low, the leac...

  12. In-situ processing of aluminum nitride particle reinforced aluminum alloy composites

    NASA Astrophysics Data System (ADS)

    Zheng, Qingjun

    Discontinuously reinforced aluminum alloy composites (DRACs) have potential applications in automotive, electronic packaging, and recreation industries. Conventional processing of DRACs is by incorporation of ceramic particles/whiskers/fibers into matrix alloys. Because of the high cost of ceramic particles, DRACs are expensive. The goal of this work was to develop a low-cost route of AlN-Al DRACs processing through bubbling and reacting nitrogen and ammonia gases with aluminum alloy melt in the temperature range of 1373--1523 K. Thermodynamic analysis of AlN-Al alloy system was performed based on Gibbs energy minimization theory. AlN is stable in aluminum, Al-Mg, Al-Si, Al-Zn, and Al-Li alloys over the whole temperature range for application and processing of DRACs. Experiments were carried out to form AlN by bubbling nitrogen and ammonia gases through aluminum, Al-Mg, and Al-Si alloy melts. Products were characterized with XRD, SEM, and EDX. The results showed that in-situ processing of AlN reinforced DRACs is technically feasible. Significant AlN was synthesized by bubbling deoxidized nitrogen and ammonia gases. When nitrogen gas was used as the nitrogen precursor, the AlN particles formed in-situ are small in size, (<10 mum). The formation of AlN is strongly affected by the trace oxygen impurities in the nitrogen gas. The deleterious effect of oxygen impurities is due to their inhibition to the chemisorption of nitrogen gas at the interface. In comparison with nitrogen gas, bubbling ammonia led to formation of AlN particles in smaller size (about 2 mum or less) at a significantly higher rate. Ammonia is not stable and dissociated into nitrogen and hydrogen at reaction temperatures. The hydrogen functions as oxygen-getter at the interface and benefits chemisorption of nitrogen, thereby promoting the formation of AlN. The overall process of AlN formation was modeled using two-film model. For nitrogen bubbling gas, the whole process is controlled by chemisorption

  13. Production of anhydrous aluminum chloride composition and process for electrolysis thereof

    DOEpatents

    Vandegrift, George F.; Krumpelt, Michael; Horwitz, E. Philip

    1983-01-01

    A process for producing an anhydrous aluminum chloride composition from a water-based aluminous material such as a slurry of aluminum hydroxide in a multistage extraction process in which the aluminum ion is first extracted into an organic liquid containing an acidic extractant and then extracted from the organic phase into an alkali metal chloride or chlorides to form a melt containing a mixture of chlorides of alkali metal and aluminum. In the process, the organic liquid may be recycled. In addition, the process advantageously includes an electrolysis cell for producing metallic aluminum and the alkali metal chloride or chlorides may be recycled for extraction of the aluminum from the organic phase.

  14. One step process for producing dense aluminum nitride and composites thereof

    DOEpatents

    Holt, J. Birch; Kingman, Donald D.; Bianchini, Gregory M.

    1989-01-01

    A one step combustion process for the synthesis of dense aluminum nitride compositions is disclosed. The process comprises igniting pure aluminum powder in a nitrogen atmosphere at a pressure of about 1000 atmospheres or higher. The process enables the production of aluminum nitride bodies to be formed directly in a mold of any desired shape.

  15. One step process for producing dense aluminum nitride and composites thereof

    DOEpatents

    Holt, J.B.; Kingman, D.D.; Bianchini, G.M.

    1989-10-31

    A one step combustion process for the synthesis of dense aluminum nitride compositions is disclosed. The process comprises igniting pure aluminum powder in a nitrogen atmosphere at a pressure of about 1,000 atmospheres or higher. The process enables the production of aluminum nitride bodies to be formed directly in a mold of any desired shape.

  16. Effect of processing on structural features of anodic aluminum oxides

    NASA Astrophysics Data System (ADS)

    Erdogan, Pembe; Birol, Yucel

    2012-09-01

    Morphological features of the anodic aluminum oxide (AAO) templates fabricated by electrochemical oxidation under different processing conditions were investigated. The selection of the polishing parameters does not appear to be critical as long as the aluminum substrate is polished adequately prior to the anodization process. AAO layers with a highly ordered pore distribution are obtained after anodizing in 0.6 M oxalic acid at 20 °C under 40 V for 5 minutes suggesting that the desired pore features are attained once an oxide layer develops on the surface. While the pore features are not affected much, the thickness of the AAO template increases with increasing anodization treatment time. Pore features are better and the AAO growth rate is higher at 20 °C than at 5 °C; higher under 45 V than under 40 V; higher with 0.6 M than with 0.3 M oxalic acid.

  17. Grain structure and dislocation density measurements in a friction stir welded aluminum alloy using x-ray peak profile analysis

    SciTech Connect

    Woo, Wan Chuck; Balogh, Levente; Ungar, Prof Tomas; Choo, Hahn; Feng, Zhili

    2008-01-01

    The dislocation density and grain structure of a friction stir welded 6061-T6 aluminum alloy was determined as a function of distance from the weld centerline using high-resolution micro-beam x-ray diffraction. The results of the x-ray peak profile analysis show that the dislocation density is about 1.2 x 10^14 m-2 inside and 4.8 x 10^14 m-2 outside of the weld region. The average subgrain size is about 180 nm in both regions. Compared to the base material, the dislocation density was significantly decreased in the dynamic recrystallized zone of the friction stir welds, which is a good correlation with the TEM observations. The influence of the dislocation density on the strain hardening behavior during tensile deformation is also discussed.

  18. Boron-doped back-surface fields using an aluminum-alloy process

    SciTech Connect

    Gee, J.M.; Bode, M.D.; Silva, B.L.

    1997-10-01

    Boron-doped back-surface fields (BSF`s) have potentially superior performance compared to aluminum-doped BSF`s due to the higher solid solubility of boron compared to aluminum. However, conventional boron diffusions require a long, high temperature step that is both costly and incompatible with many photovoltaic-grade crystalline-silicon materials. We examined a process that uses a relatively low-temperature aluminum-alloy process to obtain a boron-doped BSF by doping the aluminum with boron. In agreement with theoretical expectations, we found that thicker aluminum layers and higher boron doping levels improved the performance of aluminum-alloyed BSF`s.

  19. Shock-wave compression and release of aluminum/ceramic composites

    SciTech Connect

    Johnson, J.N.; Hixson, R.S.; Gray, G.T. III )

    1994-11-15

    Several composite materials consisting of ceramic particles embedded in a 6061-T6 aluminum matrix have been studied under conditions of shock-wave compression and release, including spallation. The 6061-T6 matrix represents a material for which high-rate shock-wave response has been extremely well characterized for thermoelastic-plastic deformation. The ceramic particles (alumina and mullite) are also well characterized, particularly in the elastic regime. Experimental tests consist of quasistatic, uniaxial-stress compression of both virgin and shock-recovered samples as well as time-resolved velocity interferometer measurements under conditions of flat-plate impact. The latter tests were performed with lithium fluoride windows for transmitted wave studies and free surfaces for spallation measurement. Theoretical analysis of the data is carried out with a pseudodissipation model originated by Barker [J. Composite Mat. [bold 5], 140 (1971)] for application to elastic deformation of layered composites and generalized here to include thermoelastic-plastic properties of the constituents. For a pseudodissipative model to apply to composite material response, significant geometrical randomization must be present in the composite structure; this is something that all commercially produced composites naturally possess. Randomization produces mechanical energy traps, which convert some fraction of regular, directed motion into random elastic vibrations behind the shock front. Within a few microseconds (depending on the pinned dislocation segment density) this macroscale, continuum vibrational energy is converted to heat by means of the anelastic properties of the metal matrix. The use of pseudodissipation as a means of representing dispersive composite material behavior is thus placed on a more secure physical foundation.

  20. EVALUATION OF PROCESS SYSTEMS FOR EFFECTIVE MANAGEMENT OF ALUMINUM FINISHING WASTEWATERS AND SLUDGES

    EPA Science Inventory

    Innovative processes for use in treatment of wastewaters and sludges produced in anodizing, etching and painting extruded aluminum were investigated. Results of the research can be immediately implemented at many aluminum-finishing plants where sludge disposal restrictions and co...

  1. Effects of fabrication and joining processes on compressive strength of boron/aluminum and borsic/aluminum structural panels

    NASA Technical Reports Server (NTRS)

    Royster, D. M.; Wiant, H. R.; Mcwithey, R. R.

    1978-01-01

    Processes for forming and joining boron/aluminum and borsic/aluminum to themselves and to titanium alloys were studied. Composite skin and titanium skin panels were joined to composite stringers by high strength bolts, by spotwelding, by diffusion bonding, by adhesive bonding, or by brazing. The effects of the fabrication and joining processes on panel compressive strengths were discussed. Predicted buckling loads were compared with experimental data.

  2. Microstructural and superplastic characteristics of friction stir processed aluminum alloys

    NASA Astrophysics Data System (ADS)

    Charit, Indrajit

    Friction stir processing (FSP) is an adapted version of friction stir welding (FSW), which was invented at The Welding Institute (TWI), 1991. It is a promising solid state processing tool for microstructural modification at localized scale. Dynamic recrystallization occurs during FSP resulting in fine grained microstructure. The main goal of this research was to establish microstructure/superplasticity relationships in FSP aluminum alloys. Different aluminum alloys (5083 Al, 2024 Al, and Al-8.9Zn-2.6Mg-0.09Sc) were friction stir processed for investigating the effect of alloy chemistry on resulting superplasticity. Tool rotation rate and traverse speeds were controlled as the prime FSP parameters to produce different microstructures. In another study, lap joints of 7475 Al plates were also studied to explore the possibility of developing FSW/superplastic forming route. Microstructures were evaluated using optical, scanning and transmission electron microscopy, orientation imaging microscopy and differential scanning calorimetry. Mechanical properties were evaluated using tensile testing. FSP 2024 Al (3.9 mum grain size) exhibited an optimum ductility of 525% at a strain rate of 10-2 s-1 and 430°C. Grain boundary sliding mechanism was found to be the dominant mode of deformation in this alloy. In 5083 Al alloy, it was found that changing the process parameters, grain sizes in the range of 3.5--8.5 mum grain size could be obtained. Material processed with colder processing parameters showed a decrease in ductility due to microstructural instability, and followed solute drag dislocation glide mechanism. On the other hand, materials processed with hotter parameter combinations showed mode of deformation related to grain boundary sliding mechanism. FSP of as-cast Al-Zn-Mg-Sc alloy resulted in ultrafine grains (0.68 mum) with attractive combination of high strain rate and low temperature superplasticity. This also demonstrated that superplastic microstructures could be

  3. Influence of sorption processes on aluminum determinations in acidic waters

    SciTech Connect

    Goenaga, X.; Bryant, R.; Williams, D.J.A.

    1987-11-15

    Progressive removal of particles from freshwater samples by filtration using various pore diameter polycarbonate capillary membranes (0.4, 0.1, 0.05, and 0.015 ..mu..m) caused a reduction in the levels of labile aluminum (0-23%), as detected with pyrocatechol violet (PCV), in the filtrates. Removal of aluminum adsorbed onto suspended solids and aluminum losses through adsorption onto the membranes are thought to be responsible for these observations. Losses of aluminum during filtration of freshwater samples were evaluated by filtration of particle-free synthetic solutions and found to be <10%. Experiments with a sample of Na-illite showed that aluminum adsorbed thereon is partially labile and detectable with PCV in synthetic and natural solutions. It appears that for freshwater samples with high solid surface to aluminum ratios, a significant fraction of the experimentally determined monomeric or inorganic monomeric aluminum may actually be adsorbed aluminum.

  4. The Effect of Impurities on the Processing of Aluminum Alloys

    SciTech Connect

    Zi-Kui Liu; Shengjun Zhang; Qingyou Han; Vinod Sikka

    2007-04-23

    For this Aluminum Industry of the Future (IOF) project, the effect of impurities on the processing of aluminum alloys was systematically investigated. The work was carried out as a collaborative effort between the Pennsylvania State University and Oak Ridge National Laboratory. Industrial support was provided by ALCOA and ThermoCalc, Inc. The achievements described below were made. A method that combines first-principles calculation and calculation of phase diagrams (CALPHAD) was used to develop the multicomponent database Al-Ca-K-Li-Mg-Na. This method was extensively used in this project for the development of a thermodynamic database. The first-principles approach provided some thermodynamic property data that are not available in the open literature. These calculated results were used in the thermodynamic modeling as experimental data. Some of the thermodynamic property data are difficult, if not impossible, to measure. The method developed and used in this project allows the estimation of these data for thermodynamic database development. The multicomponent database Al-Ca-K-Li-Mg-Na was developed. Elements such as Ca, Li, Na, and K are impurities that strongly affect the formability and corrosion behavior of aluminum alloys. However, these impurity elements are not included in the commercial aluminum alloy database. The process of thermodynamic modeling began from Al-Na, Ca-Li, Li-Na, K-Na, and Li-K sub-binary systems. Then ternary and higher systems were extrapolated because of the lack of experimental information. Databases for five binary alloy systems and two ternary systems were developed. Along with other existing binary and ternary databases, the full database of the multicomponent Al-Ca-K-Li-Mg-Na system was completed in this project. The methodology in integrating with commercial or other aluminum alloy databases can be developed. The mechanism of sodium-induced high-temperature embrittlement (HTE) of Al-Mg is now understood. Using the thermodynamic

  5. Aluminum base alloy powder metallurgy process and product

    NASA Technical Reports Server (NTRS)

    Paris, Henry G. (Inventor)

    1986-01-01

    A metallurgical method including cooling molten aluminum particles and consolidating resulting solidified particles into a multiparticle body, wherein the improvement comprises the provision of greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn. Aluminum containing greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn.

  6. Process of electrolysis and fractional crystallization for aluminum purification

    DOEpatents

    Dawless, Robert K.; Bowman, Kenneth A.; Mazgaj, Robert M.; Cochran, C. Norman

    1983-10-25

    A method for purifying aluminum that contains impurities, the method including the step of introducing such aluminum containing impurities to a charging and melting chamber located in an electrolytic cell of the type having a porous diaphragm permeable by the electrolyte of the cell and impermeable to molten aluminum. The method includes further the steps of supplying impure aluminum from the chamber to the anode area of the cell and electrolytically transferring aluminum from the anode area to the cathode through the diaphragm while leaving impurities in the anode area, thereby purifying the aluminum introduced into the chamber. The method includes the further steps of collecting the purified aluminum at the cathode, and lowering the level of impurities concentrated in the anode area by subjecting molten aluminum and impurities in said chamber to a fractional crystallization treatment wherein eutectic-type impurities crystallize and precipitate out of the aluminum. The eutectic impurities that have crystallized are physically removed from the chamber. The aluminum in the chamber is now suited for further purification as provided in the above step of electrolytically transferring aluminum through the diaphragm.

  7. Process of electrolysis and fractional crystallization for aluminum purification

    DOEpatents

    Dawless, R.K.; Bowman, K.A.; Mazgaj, R.M.; Cochran, C.N.

    1983-10-25

    A method is described for purifying aluminum that contains impurities, the method including the step of introducing such aluminum containing impurities to a charging and melting chamber located in an electrolytic cell of the type having a porous diaphragm permeable by the electrolyte of the cell and impermeable to molten aluminum. The method includes further the steps of supplying impure aluminum from the chamber to the anode area of the cell and electrolytically transferring aluminum from the anode area to the cathode through the diaphragm while leaving impurities in the anode area, thereby purifying the aluminum introduced into the chamber. The method includes the further steps of collecting the purified aluminum at the cathode, and lowering the level of impurities concentrated in the anode area by subjecting molten aluminum and impurities in said chamber to a fractional crystallization treatment wherein eutectic-type impurities crystallize and precipitate out of the aluminum. The eutectic impurities that have crystallized are physically removed from the chamber. The aluminum in the chamber is now suited for further purification as provided in the above step of electrolytically transferring aluminum through the diaphragm. 2 figs.

  8. Impact Delamination and Fracture in Aluminum/Acrylic Sandwich Plates

    NASA Technical Reports Server (NTRS)

    Liaw, Benjamin; Zeichner, Glenn; Liu, Yanxiong; Bowles, Kenneth J. (Technical Monitor)

    2000-01-01

    Impact-induced delamination and fracture in 6061-T6 aluminum/cast acrylic sandwich plates adhered by epoxy were generated in an instrumented drop-weight impact machine. Although only a small dent was produced on the aluminum side when a hemispherical penetrator tup was dropped onto it from a couple of inches, a large ring of delamination at the interface was observed. The delamination damage was often accompanied by severe shattering in the acrylic substratum. Damage patterns in the acrylic layer include radial and ring cracks and, together with delamination at the interface, may cause peeling-off of acrylic material from the sandwich plate. Theory of stress-wave propagation can be used to explain these damage patterns. The impact tests were conducted at various temperatures. The results also show clearly that temperature effect is very important in impact damage. For pure cast acrylic nil-ductile transition (NDT) occurs between 185-195 F. Excessive impact energy was dissipated into fracture energy when tested at temperature below this range or through plastic deformation when tested at temperature above the NDT temperature. Results from this study will be used as baseline data for studying fiber-metal laminates, such as GLARE and ARALL for advanced aeronautical and astronautical applications.

  9. Al/sub 2/S/sub 3/ preparation and use in electrolysis process for aluminum production

    DOEpatents

    Hsu, C.C.; Loutfy, R.O.; Yao, N.P.

    A continuous process for producing aluminum sulfide and for electrolyzing the aluminum sulfide to form metallic aluminum in which the aluminum sulfide is produced from aluminum oxide and COS or CS/sub 2/ in the presence of a chloride melt which also serves as the electrolysis bath. Circulation between the reactor and electrolysis cell is carried out to maintain the desired concentration of aluminum sulfide in the bath.

  10. Degradation Modeling of 2024 Aluminum Alloy During Corrosion Process

    NASA Astrophysics Data System (ADS)

    Pidaparti, Ramana M.; Aghazadeh, Babak Seyed

    2011-04-01

    Corrosion is one of the most damaging mechanisms in aluminum alloys used in aerospace engineering structures. In this article, the degradation behavior of AA 2024-T3 as a function of time under corrosive conditions is studied through experiments and modeling. Corrosion experiments were conducted on AA 2024-T3 specimens under controlled electrochemical conditions. The chemical element alloy map was investigated through EDS technique for evaluation purposes. Based on the experimental data, an analytical model is developed relating the material loss to the degradation during the corrosion process. The analytical model uses genetic algorithms (GAs) to map the relationship through optimization. The results obtained from GAs were compared with a standard non-linear regression model. The results obtained indicate that a quadratic relationship exists in time between the material loss due to corrosion and the degradation behavior of the alloy. Based on the good results obtained, the present approach of degradation modeling can be extended to other metals.

  11. Researches regarding the hydroforming process of aluminum components

    NASA Astrophysics Data System (ADS)

    Paunoiu, V.; Teodor, V.; Susac, F.

    2015-11-01

    The lightweighting with aluminum offers the potential for using unconventional fabrication technologies such as sheet hydroforming. Triform process is an unconventional sheet forming technology where the blank sheet is placed under a flexible rubber pad and is deformed under the action of the hydraulic pressure applied from the top of the equipment. The part shape is given by the shape of the die located at the bottom of the equipment. In the paper are presented the experimental results, regarding the influence of the fluid pressure towards the parts properties. The parts quality is evaluated in terms of springback variation. The results could lead to the implementation of the designed procedure for triform die and equipment.

  12. Process for producing gallium-containing solution from the aluminum smelting dust

    SciTech Connect

    Era, A.; Matsui, S.; Ikeda, H.

    1988-03-01

    A process is described for producing a gallium-containing solution from aluminum smelting dust comprising leaching aluminum smelting dust with a mineral acid selected from the group consisting of sulfuric acid, hydrochloric acid and nitric acid, and adding an oxidizing agent to the aluminum smelting dust at the time of leaching to preferentially leach and extract gallium from the aluminum smelting dust without extracting aluminum from the aluminum smelting dust. The oxidizing agent is selected from the group consisting of potassium permanganate, manganese dioxide, hydrogen peroxide, ozone, potassium chromate, potassium dichromate, ammonium persulfate, sodium hydrochlorite, sodium chlorite and sodium chlorate. The leached aluminum smelting dust is filtered to obtain a gallium-containing solution of dissolved gallium.

  13. Measurement of the thermal contact conductance and thermal conductivity of anodized aluminum coatings

    SciTech Connect

    Peterson, G.P.; Fletcher, L.S. )

    1990-08-01

    An experimental investigation was conducted to determine the thermal contact conductance and effective thermal conductivity of anodized coatings. One chemically polished Aluminum 6061-T6 test specimen and seven specimens with anodized coatings varying in thickness from 60.9 {mu}m to 163.8 {mu}m were tested while in contact with a single unanodized aluminum surface. Measurements of the overall joint conductance, composed of the thermal contact conductance between the anodized coating and the bare aluminum surface and the bulk conductance of the coating material, indicated that the overall joint conductance decreased with increasing thickness of the anodized coating and increased with increasing interfacial load. Using the experimental data, a dimensionless expression was developed that related the overall joint conductance to the coating thickness, the surface roughness, the interfacial pressure, and the properties of the aluminum substrate. By subtracting the thermal contact conductance from the measured overall joint conductance, estimations of the effective thermal conductivity of the anodized coating as a function of pressure were obtained for each of the seven anodized specimens. At an extrapolated pressure of zero, the effective thermal conductivity was found to be approximately 0.02 W/m-K. In addition to this extrapolated value, a single expression for predicting the effective thermal conductivity as a function of both the interface pressure and the anodized coating thickness was developed and shown to be within {plus minus}5 percent of the experimental data over a pressure range of 0 to 14 MPa.

  14. A method for studying weld fusion boundary microstructure evolution in aluminum alloys

    SciTech Connect

    Kostrivas, A.; Lippold, J.C.

    2000-01-01

    Aluminum alloys may exhibit a variety of microstructures within the fusion zone adjacent to the fusion boundary. Under conventional weld solidification conditions, epitaxial nucleation occurs off grains in the heat-affected zone (HAZ) and solidification proceeds along preferred growth directions. In some aluminum alloys, such as those containing Li and Zr, a nondendritic equiaxed grain zone (EQZ) has been observed along the fusion boundary that does not nucleate epitaxially from the HAZ substrate. The EQZ has been the subject of considerable study because of its susceptibility to cracking during initial fabrication and repair. The motivation of this investigation was to develop a technique that would allow the nature and evolution of the fusion boundary to be studied under controlled thermal conditions. A melting technique was developed to simulate the fusion boundary of aluminum alloys using the Gleeble{reg{underscore}sign} thermal simulator. Using a steel sleeve to contain the aluminum, samples wee heated to incremental temperatures above the solidus temperature of a number of alloys. In Alloy 2195, a 4Cu-1Li alloy, an EQZ could be formed by heating in the temperature range approximately from 630--640 C. At temperatures above 640 C, solidification occurred by the normal epitaxial nucleation and growth mechanism. Fusion boundary behavior was also studied in Alloys 5454-H34, 6061-T6 and 2219-T8. Nucleation in these alloys was observed to be epitaxial. Details of the technique and its effectiveness for performing controlled melting experiments at incremental temperatures above the solidus are described.

  15. The New Alusuisse Process for Producing Coarse Aluminum Hydrate in the Bayer Process

    NASA Astrophysics Data System (ADS)

    Tschamper, Otto

    1982-04-01

    The liquor productivity in the American Bayer process, with a maximum of about 55 g Al2O3 per liter, compares very unfavorably with that obtained in the European process of up to 80 g Al2O3 per liter. By the new Alusuisse process a liquor productivity can be obtained nearing that of the European process, but consisting of a coarse aluminum hydroxide typical of the American process. The process has been used for the conversion from floury to sandy aluminas at the Gove Alumina Plant with a nominal capacity of 1.0 million tons per year. The modified plant has been running since November 1979 at the increased nominal capacity of 1.1 million tons per year, producing an aluminum hydrate of about 5% smaller than 45µm.

  16. Ballistic Experiments with Titanium and Aluminum Targets

    SciTech Connect

    Gogolewski, R.; Morgan, B.R.

    1999-11-23

    During the course of the project we conducted two sets of fundamental experiments in penetration mechanics in the LLNL Terminal Ballistics Laboratory of the Physics Directorate. The first set of full-scale experiments was conducted with a 14.5mm air propelled launcher. The object of the experiments was to determine the ballistic limit speed of 6Al-4V-alloy titanium, low fineness ratio projectiles centrally impacting 2024-T3 alloy aluminum flat plates and the failure modes of the projectiles and the targets. The second set of one-third scale experiments was conducted with a 14.5mm powder launcher. The object of these experiments was to determine the ballistic limit speed of 6Al-4V alloy titanium high fineness ratio projectiles centrally impacting 6Al-4V alloy titanium flat plates and the failure modes of the projectiles and the target. We employed radiography to observe a projectile just before and after interaction with a target plate. Early on, we employed a non-damaging ''soft-catch'' technique to capture projectiles after they perforated targets. Once we realized that a projectile was not damaged during interaction with a target, we used a 4-inch thick 6061-T6-alloy aluminum witness block with a 6.0-inch x 6.0-inch cross-section to measure projectile residual penetration. We have recorded and tabulated below projectile impact speed, projectile residual (post-impact) speed, projectile failure mode, target failure mode, and pertinent comments for the experiments. The ballistic techniques employed for the experiments are similar to those employed in an earlier study.

  17. Compressive strength, plastic flow properties, and surface frictional effects of 1100, 3003 and 6061 aluminum alloys

    SciTech Connect

    Pinkerton, G.W.

    1993-12-31

    The purpose of this study is to find aluminum alloys that are effective for use as wire vacuum seals in the 800MeV particle accelerator located at the Louis Anderson Meson Physics Facility (LAMPF) in Los Alamos, NM. Three alloys, Al 1100, Al 3003, and Al 6061, are investigated under uniaxial compression to determine stresses for a given height reduction from 0 to 70 percent, and to find plastic flow and surface interaction effects. Right-circular cylindrical specimens are compressed on-end (cylindrically) and radially (for modeling as compressed wire). Aluminum 1100 and 3003 alloys are compared for length to diameter ratios of 1 and 2 for both compression types, and are then compared to results of radial compression of annealed small diameter Al 1100 wire currently used at LAMPE. The specimens are also compressed between three different platen surfaces, polished steel, etched steel, and aluminum 6061-T6, to determine effects of friction. The Al 3003 alloy exhibits 20 to 25% lower stresses at all height reductions than Al 1100 for both cylindrical and radial compression.

  18. High quality optically polished aluminum mirror and process for producing

    NASA Technical Reports Server (NTRS)

    Lyons, III, James J. (Inventor); Zaniewski, John J. (Inventor)

    2002-01-01

    A new technical advancement in the field of precision aluminum optics permits high quality optical polishing of aluminum monolith, which, in the field of optics, offers numerous benefits because of its machinability, lightweight, and low cost. This invention combines diamond turning and conventional polishing along with india ink, a newly adopted material, for the polishing to accomplish a significant improvement in surface precision of aluminum monolith for optical purposes. This invention guarantees the precise optical polishing of typical bare aluminum monolith to surface roughness of less than about 30 angstroms rms and preferably about 5 angstroms rms while maintaining a surface figure accuracy in terms of surface figure error of not more than one-fifteenth of wave peak-to-valley.

  19. High quality optically polished aluminum mirror and process for producing

    NASA Technical Reports Server (NTRS)

    Lyons, III, James J. (Inventor); Zaniewski, John J. (Inventor)

    2005-01-01

    A new technical advancement in the field of precision aluminum optics permits high quality optical polishing of aluminum monolith, which, in the field of optics, offers numerous benefits because of its machinability, lightweight, and low cost. This invention combines diamond turning and conventional polishing along with india ink, a newly adopted material, for the polishing to accomplish a significant improvement in surface precision of aluminum monolith for optical purposes. This invention guarantees the precise optical polishing of typical bare aluminum monolith to surface roughness of less than about 30 angstroms rms and preferably about 5 angstroms rms while maintaining a surface figure accuracy in terms of surface figure error of not more than one-fifteenth of wave peak-to-valley.

  20. The corrosion protection of aluminum by various anodizing treatments

    NASA Technical Reports Server (NTRS)

    Danford, Merlin D.

    1989-01-01

    Corrosion protection to 6061-T6 aluminum, afforded by both teflon-impregnated anodized coats (Polylube and Tufram) and hard-anodized coats (water sealed and dichromate sealed), was studied at both pH 5.5 and pH 9.5, with an exposure period of 28 days in 3.5 percent NaCl solution (25 C) for each specimen. In general, corrosion protection for all specimens was better at pH 9.5 than at pH 5.5. Protection by a Tufram coat proved superior to that afforded by Polylube at each pH, with corrosion protection by the hard-anodized, water-sealed coat at pH 9.5 providing the best protection. Electrochemical work in each case was corroborated by microscopic examination of the coats after exposure. Corrosion protection by Tufram at pH 9.5 was most comparable to that of the hard-anodized samples, although pitting and some cracking of the coat did occur.

  1. Modelling hypervelocity impacts into aluminum structures based on LDEF data

    NASA Technical Reports Server (NTRS)

    Coombs, C. R.; Atkinson, D. R.; Watts, A. J.; Wagner, J. R.; Allbrooks, M. K.; Hennessy, C. J.

    1993-01-01

    Realizing and understanding the effects of the near-Earth space environment on a spacecraft during its mission lifetime is becoming more important with the regeneration of America's space program. Included among these potential effects are the following: erosion and surface degradation due to atomic oxygen impingement; ultraviolet exposure embrittlement; and delamination, pitting, cratering, and ring formation due to micrometeoroid and debris impacts. These effects may occur synergistically and may alter the spacecraft materials enough to modify the resultant crater, star crack, and/or perforation. This study concentrates on modelling the effects of micrometeoroid and debris hypervelocity impacts into aluminum materials (6061-T6). Space debris exists in all sizes, and has the possibility of growing into a potentially catastrophic problem, particularly since self-collisions between particles can rapidly escalate the number of small impactors. We have examined the morphologies of the Long Duration Exposure Facility (LDEF) impact craters and the relationship between the observed impact damage on LDEF versus the existing models for both the natural (micrometeoroid) and manmade (debris) environments in order to better define these environments.

  2. Process Development for Stamping Á-Pillar Covers with Aluminum

    SciTech Connect

    Choi, Jung-Pyung; Rohatgi, Aashish; Smith, Mark T.; Lavender, Curt A.

    2015-02-20

    In this work, performed in close collaboration with PACCAR and Magna International, a 6XXX series aluminum alloy was used for the development of A-Pillar cover for the cab of a typical heavy-duty Class-8 truck. The use of Al alloy for the A-pillar cover represents an approximately 40% weight savings over its steel or molded fiberglass composite counterpart. For the selected Al alloy, a small amount of cold work (5% tensile strain), following prior hot-forming, was found to significantly improve the subsequent age-hardening response. The role of solutionizing temperature and rate of cooling on the age-hardening response after paint-bake treatment were investigated. For the temperature range selected in this work, higher solutionizing temperature correlated with greater subsequent age-hardening and vice-versa. However, the age-hardening response was insensitive to the mode of cooling (water quench vs. air cooling). Finally, a two-step forming process was developed where, in the first step, the blank was heated to solutionizing temperature, quenched, and then partially formed at room temperature. For the second step, the pre-form was re-heated and quenched as in the first step, and the forming was completed at room temperature. The resulting A-pillars had sufficient residual ductility to be compatible with hemming and riveting

  3. Optimization study of the femtosecond laser-induced forward-transfer process with thin aluminum films

    NASA Astrophysics Data System (ADS)

    Bera, Sudipta; Sabbah, A. J.; Yarbrough, J. M.; Allen, C. G.; Winters, Beau; Durfee, Charles G.; Squier, Jeff A.

    2007-07-01

    The parameters for an effective laser-induced forward-transfer (LIFT) process of aluminum thin films using a femtosecond laser are studied. Deposited feature size as a function of laser fluence, donor film thickness, quality of focus, and the pulse duration are varied, providing a metric of the most desirable conditions for femtosecond LIFT with thin aluminum films.

  4. Fabrication process scale-up and optimization for a boron-aluminum composite radiator

    NASA Technical Reports Server (NTRS)

    Okelly, K. P.

    1973-01-01

    Design approaches to a practical utilization of a boron-aluminum radiator for the space shuttle orbiter are presented. The program includes studies of laboratory composite material processes to determine the feasibility of a structural and functional composite radiator panel, and to estimate the cost of its fabrication. The objective is the incorporation of boron-aluminum modulator radiator on the space shuttle.

  5. Ultrasonic Real-Time Quality Monitoring Of Aluminum Spot Weld Process

    NASA Astrophysics Data System (ADS)

    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

  6. Processing of Aluminum Dross: The Birth of a Closed Industrial Process

    NASA Astrophysics Data System (ADS)

    Ingason, Helgi Thor; Sigfusson, Thorsteinn I.

    2014-11-01

    This is the history of a modern aluminum dross recycling company, from its beginnings in the last years of the twentieth century to the present day. The vision of the founders was to build a local recycling plant and take full responsibility for sensitive environmental issues by recycling aluminum dross locally rather than shipping it abroad. The paper tells the history of the company from the environmental perspective, and gives an overview of some of the challenges and the decisions that followed from this vision, for instance the selection of technology. The company developed a closed industrial process for the recycling of aluminum dross, and the paper discusses some of their laboratory experiments and industrial trials. An important milestone has now been reached as the process in its present form is recognized by the environmental authorities in the country. Furthermore, it seems realistic that in the near future the final product from this process will be comparable to the product delivered in the processing of salt cake in specialized chemical plants, but at a fraction of the cost.

  7. Processing of Aluminum Dross: The Birth of a Closed Industrial Process

    NASA Astrophysics Data System (ADS)

    Ingason, Helgi Thor; Sigfusson, Thorsteinn I.

    2014-09-01

    This is the history of a modern aluminum dross recycling company, from its beginnings in the last years of the twentieth century to the present day. The vision of the founders was to build a local recycling plant and take full responsibility for sensitive environmental issues by recycling aluminum dross locally rather than shipping it abroad. The paper tells the history of the company from the environmental perspective, and gives an overview of some of the challenges and the decisions that followed from this vision, for instance the selection of technology. The company developed a closed industrial process for the recycling of aluminum dross, and the paper discusses some of their laboratory experiments and industrial trials. An important milestone has now been reached as the process in its present form is recognized by the environmental authorities in the country. Furthermore, it seems realistic that in the near future the final product from this process will be comparable to the product delivered in the processing of salt cake in specialized chemical plants, but at a fraction of the cost.

  8. Effect of low-velocity or ballistic impact damage on the strength of thin composite and aluminum shear panels

    NASA Technical Reports Server (NTRS)

    Farley, G. L.

    1985-01-01

    Impact tests were conducted on shear panels fabricated from 6061-T6 aluminum and from woven fabric prepreg of Du Pont Kevlara fiber/epoxy resin and graphite fiber/epoxy resin. The shear panels consisted of three different composite laminates and one aluminum material configuration. Three panel aspect ratios were evaluated for each material configuration. Composite panels were impacted with a 1.27-cm (0.05-in) diameter aluminum sphere at low velocities of 46 m/sec (150 ft/sec) and 67 m/sec (220 ft/sec). Ballistic impact conditions consisted of a tumbled 0.50-caliber projectile impacting loaded composite and aluminum shear panels. The results of these tests indicate that ballistic threshold load (the lowest load which will result in immediate failure upon penetration by the projectile) varied between 0.44 and 0.61 of the average failure load of undamaged panels. The residual strengths of the panels after ballistic impact varied between 0.55 and 0.75 of the average failure strength of the undamaged panels. The low velocity impacts at 67 m/sec (220 ft/sec) caused a 15 to 20 percent reduction in strength, whereas the impacts at 46 m/sec (150 ft/sec) resulted in negligible strength loss. Good agreement was obtained between the experimental failure strengths and the predicted strength with the point stress failure criterion.

  9. Process for the synthesis of nanophase dispersion-strengthened aluminum alloy

    DOEpatents

    Barbour, John C.; Knapp, James Arthur; Follstaedt, David Martin; Myers, Samuel Maxwell

    1998-12-15

    A process for fabricating dispersion-strengthened ceramic-metal composites is claimed. The process comprises in-situ interaction and chemical reaction of a metal in gaseous form with a ceramic producer in plasma form. Such composites can be fabricated with macroscopic dimensions. Special emphasis is placed on fabrication of dispersion-strengthened aluminum oxide-aluminum composites, which can exhibit flow stresses more characteristic of high strength steel.

  10. Development of plasma MIG brazing process for dissimilar metal joining of aluminum to steel

    NASA Astrophysics Data System (ADS)

    Tashiro, Shinichi; Tanaka, Manabu

    2014-08-01

    This study aims to develop a new brazing process employing plasma MIG. Because the energy density of the plasma produced by the plasma electrode is low, the base metal can be heated extensively without melting of the base metal, consequently improving the wettability of bead. This paper discussed the dissimilar metal joining of aluminum to steel by plasma MIG brazing process. Fracture occurred at the HAZ in the aluminum plate at 80 MPa.

  11. The processing and properties of discontinuously reinforced aluminum composites

    SciTech Connect

    Geiger, A.L.; Walker, J.A. )

    1991-08-01

    Discontinuously-reinforced aluminum (DRA) SiC whisker or particle-reinforced Al-alloy matrix composites produced by P/M methods have progressed toward commercial applications, supported by growing data bases and large-scale production facilities. Attention is presently given to the elastic modulus, plastic, ductile, and toughness characteristics of representative DRA formulations, as well as to the DRAs commercially available in the forms of sheets, extrusions, and optical and instrument grade structures able to supplant beryllium. 36 refs.

  12. Continuous Severe Plastic Deformation Processing of Aluminum Alloys

    SciTech Connect

    Raghavan Srinivasan; Prabir K. Chaudhury; Balakrishna Cherukuri; Qingyou Han; David Swenson; Percy Gros

    2006-06-30

    by SPD techniques. This combination of properties makes UFG metals produced by SPD very attractive as machining, forging or extrusion stock, both from the point of view of formability as well as energy and cost saving. However, prior to this work there had been no attempt to transfer these potential benefits observed in the laboratory scale to industrial shop floor. The primary reason for this was that the laboratory scale studies had been conducted to develop a scientific understanding of the processes that result in grain refinement during SPD. Samples that had been prepared in the laboratory scale were typically only about 10-mm diameter and 50-mm long (about 0.5-inch diameter and 2-inches long). The thrust of this project was three-fold: (i) to show that the ECAE/P process can be scaled up to produce long samples, i.e., a continuous severe plastic deformation (CSPD) process, (ii) show the process can be scaled up to produce large cross section samples that could be used as forging stock, and (iii) use the large cross-section samples to produce industrial size forgings and demonstrate the potential energy and cost savings that can be realized if SPD processed stock is adopted by the forging industry. Aluminum alloy AA-6061 was chosen to demonstrate the feasibility of the approach used. The CSPD process developed using the principles of chamber-less extrusion and drawing, and was demonstrated using rolling and wire drawing equipment that was available at Oak Ridge National Laboratory. In a parallel effort, ECAE/P dies were developed for producing 100-mm square cross section SPD billets for subsequent forging. This work was carried out at Intercontinental Manufacturing Co. (IMCO), Garland TX. Forging studies conducted with the ECAE/P billets showed that many of the potential benefits of using UFG material can be realized. In particular, the material yield can be increased, and the amount of material that is lost as scrap can be reduced by as much as 50%. Forging

  13. Investigation of rapidly solidified aluminum by using diamond turning and a magnetorheological finishing process

    NASA Astrophysics Data System (ADS)

    Cheng, Yuan-Chieh; Hsu, Wei-Yao; Kuo, Ching-Hsiang; Abou-El-Hossein, Khaled; Otieno, Timothy

    2015-08-01

    The metal mirror has been widely used in optical application for a longtime. Especially the aluminum 6061 is often considered the preferred material for manufacturing optical components for ground-based astronomical applications. One reason for using this material is its high specific stiffness and excellent thermal properties. However, a large amount of data exists for this material and commercially available aluminum 6061 using single point diamond turning (SPDT) and polishing process can achieve surface roughness values of approximately 2 to 4 nm, which is adequate for applications that involve the infrared spectral range, but not for the shorter spectral range. A novel aluminum material, fabricated using a rapid solidification process that is equivalent to the conventional aluminum 6061 alloy grade has been used in optical applications in recent years because of its smaller grain size. In this study, the surface quality of the rapid solidification aluminum after single point diamond turning and followed by magnetorheological finish (MRF) process is investigated and compared with conventional aluminum 6061. Both the surface roughness Ra was evaluated using white light interferometers. Finally, indicators such as optimal fabrication parameter combination and optical performance are discussed.

  14. Characterization of aluminum processed by equal channel angular extrusion: Effect of processing route

    SciTech Connect

    Rebhi, Atef; Makhlouf, Thabet; Njah, Nabil; Champion, Yannick; Couzinie, Jean-Philippe

    2009-12-15

    Equal channel angular extrusion (ECAE) of aluminum alloys leads to enhanced strength. However, the effects of processing route on the resulting properties were not extensively investigated, and sometimes neglected. In the present work, an aluminum was processed by ECAE via routes B{sub C} and C using a die formed by two channels connected at an angle {phi} = 90 deg. Coherency lengths D calculated from X-ray diffraction peaks were 85 nm after the first passage. For route B{sub C}, it was kept constant when the number of passages N was increased. For route C, an increase of D was observed when increasing N. The remaining densities of dislocations {rho} were calculated using a recently published formula. A decrease of {rho} was observed during ECAE in route C but not in route B{sub C}. Mechanical tests allowed us to relate the increase of D and the decrease of {rho} to an enhanced recovery during ECAE via route C.

  15. Monotonic and cyclic fatigue properties of automotive aluminum alloys

    SciTech Connect

    Wong, W.A.

    1984-01-01

    Monotonic and strain-controlled fatigue tests were conducted on 2014-T6, 6061-T6 and 7175-T73 hand-forgings, 5052-H32 and 6061-T6 sheet, and a 1983/84 production Chevrolet Corvette upper-control-arm-pivot shaft (UCAPS) cold-forged from 5454-H12 and 6061-T4 rolled rod (the 6061 UCAPS was artificially-aged to the -T6 temper, after forging). Various monotonic and cyclic fatigue stress-strain material properties are presented. The responses of the various alloys and product-forms in terms of cyclic hardening or softening are described.

  16. ENVIRONMENTAL CONSIDERATIONS OF SELECTED ENERGY CONSERVING MANUFACTURING PROCESS OPTIONS: VOLUME VIII. ALUMINA/ALUMINUM INDUSTRY REPORT

    EPA Science Inventory

    This study assesses the likelihood of new process technology and new practices being introduced by energy intensive industries and explores the environmental impacts of such changes. Volume 8 deals with the alumina/aluminum industry. The report examines three new process developm...

  17. Method of thermally processing superplastically formed aluminum-lithium alloys to obtain optimum strengthening

    NASA Technical Reports Server (NTRS)

    Anton, Claire E. (Inventor)

    1993-01-01

    Optimum strengthening of a superplastically formed aluminum-lithium alloy structure is achieved via a thermal processing technique which eliminates the conventional step of solution heat-treating immediately following the step of superplastic forming of the structure. The thermal processing technique involves quenching of the superplastically formed structure using static air, forced air or water quenching.

  18. Structural Damage Prediction and Analysis for Hypervelocity Impact: Properties of Largest Fragment Produced by Hypervelocity Impact of Aluminum Spheres with Thin Aluminum Sheets

    NASA Technical Reports Server (NTRS)

    Piekutowski, Andrew J.

    1995-01-01

    Results of a series of hypervelocity impact tests are presented. In these tests, 1.275-g, 9.53-mm-diameter, 2017-T4 aluminum spheres were fired at normal incidence at eight thicknesses of 6061-T6 aluminum sheet. Bumper thickness to projectile diameter (t/D) ratio ranged from 0.026 to 0.424. Nominal impact velocity was 6.7 km/s. Results of five tests using 6.35, 9.53, and 12.70-mm-diameter aluminum spheres and other aluminum alloy bumpers are also given. A large chunky fragment of projectile was observed at the center of the debris clouds produced by the impacts. The equivalent diameter of this large fragment ranged from 5.5 mm for the lowest t/D ratio to a minimum of 0.6 mm for the case where maximum breakup of the projectile occurred (t/D approximately 0.2 to 0.3). When the t/D ratio was 0.42, numerous large flaky fragments were evenly distributed in the external bubble of bumper debris. Velocity of the large central fragments decreased continuously with increasing t/D ratio, ranging from about 99 percent to less than 80 percent of the impact velocity. The change in the velocity of small fragments spalling from the rear of the projectile was used to obtain a relationship showing a linear increase in the size of the central projectile fragment with decrease in the shock-induced stress in the projectile.

  19. Numerical investigation for formability of aluminum 6016 alloy under non-isothermal warm forming process

    NASA Astrophysics Data System (ADS)

    Hu, P.; Dai, M. H.; Ying, L.; Shi, D. Y.; Zhao, K. M.; Lu, J. D.

    2013-05-01

    The warm forming technology of aluminum alloy has attracted attention from worldwide automotive engineering sector in recent years, with which the complex geometry parts can be realized at elevated temperature. A non-isothermal warm forming process for the heat treatable aluminum can quickly carry out its application on traditional production line by adding a furnace to heat up the aluminum alloy sheet. The 6000 aluminum alloy was investigated by numerical simulation and experiment using the Nakajima test model in this paper. A modified Fields-Backofen model was introduced into numerical simulation process to describe the thermo-mechanical flow behavior of a 6000 series aluminum alloy. The experimental data was obtained by conducting thermal-mechanical uniaxial tensile experiment in temperatures range of 25˜400°C to guarantee the numerical simulation more accurate. The numerical simulation was implemented with LS_DYNA software in terms of coupled dynamic explicit method for investigating the effect of initial forming temperature and the Binder Holder Force (BHF), which are critical process parameters in non-isothermal warm forming. The results showed that the optimal initial forming temperature range was 300°C˜350°C. By means of conducting numerical simulation in deep drawing box model, the forming window of BHF and temperature around the optimal initial forming temperature (275°, 300° and 325°) are investigated, which can provide guidance to actual experiment.

  20. Modelling the growth process of porous aluminum oxide film during anodization

    NASA Astrophysics Data System (ADS)

    Aryslanova, E. M.; Alfimov, A. V.; Chivilikhin, S. A.

    2015-11-01

    Currently it has become important for the development of metamaterials and nanotechnology to obtain regular self-assembled structures. One such structure is porous anodic alumina film that consists of hexagonally packed cylindrical pores. In this work we consider the anodization process, our model takes into account the influence of layers of aluminum and electrolyte on the rate of growth of aluminum oxide, as well as the effect of surface diffusion. In present work we consider those effects. And as a result of our model we obtain the minimum distance between centers of alumina pores in the beginning of anodizing process.

  1. The Development of 6061-Aluminum Windows for the MICE LiquidAbsorber

    SciTech Connect

    Lau, W.; Yang, S.Q.; Green, M.A.; Ishimoto, S.; Swanson, J.

    2005-08-24

    The thin windows for the Muon Ionization Cooling Experiment (MICE) liquid Absorber will be fabricated from 6061-T6-aluminum. The absorber and vacuum vessel thin windows are 300-mm in diameter and are 180 mm thick at the center. The windows are designed for an internal burst pressure of 0.68 MPa (100 psig) when warm. The MICE experiment design calls for changeable windows on the absorber, so a bolted window design was adopted. Welded windows offer some potential advantages over bolted windows when they are on the absorber itself. This report describes the bolted window and its seal. This report also describes an alternate window that is welded directly to the absorber body. The welded window design presented permits the weld to be ground off and re-welded. This report presents a thermal FEA analysis of the window seal-weld, while the window is being welded. Finally, the results of a test of a welded-window are presented.

  2. Investigation of surface topography effects on metal flow under lubricated hot compression of aluminum

    NASA Astrophysics Data System (ADS)

    Kurk, Justin Irvin

    An investigation was conducted to study the effects of die surface topography, specifically surface roughness and lay, on metal flow and the friction factor under lubricated hot compression. 6061-T6 aluminum rings and square bar stock specimens were compressed on H-13 tool steel platens machined with a unidirectional lay pattern to six different roughnesses between a R 0 10 and 240 muin. A lab based hydraulic press mounted with an experimental die set was used for all testing. Repeated trials were conducted using high temperature vegetable oil and boron nitride lubricants. Metal flow was quantified as a function of surface roughness, lay orientation, and die temperature. Approximate plane strain cigar test specimens were compressed at platen temperatures of 300 °F and 400 °F and at orientations of 0°, 45°, and 90° between the longitudinal axis and unidirectional platen surface lay. The friction factor was assessed using the ring compression test under varying platen roughness conditions and die temperatures between 250 °F and 400 °F. Results indicate metal flow is optimized at low platen roughnesses and orientations parallel to the surface lay of the platen. Die temperature was not found to influence metal flow within the temperature range investigated. The friction factor was observed to be minimized at lower die temperatures and platen roughnesses.

  3. A chrome-free conversion coating and sealant for aluminum and its alloys

    SciTech Connect

    Bibber, J.W.

    1999-07-01

    For over fifty years, chromates have been the standard against which other conversion coatings and/or sealants have been judged. Due to current environmental and safety concerns, they are being removed from use. This paper presents neutral salt-spray, filiform primer adhesion and electrical conductivity data on a commercial chromate-free, inorganic and non-toxic conversion coating used with a new and unique sealing emulsion. The seal is an organic water based emulsion which when dried on a permanganate based conversion coated aluminum surface will be polymerized, or cured, when heated to 250--300 F for 20 seconds or longer. The higher the temperature, or period of time, the greater the degree of polymerization. The polymerized film is as electrically conductive as chromate films and easily accepts and bonds to applied primers. For in-service repair a conventional heat-gun maybe used. For large surfaces, any other conventional heat source may be used. The 6061-T6, 7075-T6, and 2024-T3 series wrought alloys were tested and directly compared to current chromate based conversion coatings. The tests showed equivalent or superior results in all cases.

  4. Industrial process models of electricity demand. Volume 4. The aluminum industry. Final report

    SciTech Connect

    Pierce, B.L.; Coward, H.; Sparrow, F.T.; Pilati, D.A.

    1984-05-01

    The National Center for Analysis of Energy Systems at Brookhaven National Laboratory has developed a process model of the US aluminum industry. The model consists of the major process steps in the manufacture of milled and cast aluminum products and is designed to select modes of operation and energy consumption characteristics that minimize the cost of meeting projected demands for the industry's products. Domestic refineries and primary smelters are represented individually in the model. Industry structure in terms of plant ownership and allowed transfers of aluminum-bearing materials is explicitly modeled. With a growth in product demand of 4.2% per year, model results show a decline in electricity intensity of primary production.

  5. Effects of thermomechanical processing on the resulting mechanical properties of 6101 aluminum foam

    SciTech Connect

    Margevicius, R.W.; Stanek, P.W.; Jacobson, L.A.

    1998-12-01

    Porous materials represent a tremendous weight savings for light-weight structural applications. The fabrication path can play a critical role in the resulting properties. High porosity aluminum was fabricated in a number of ways. The starting material was a cast 6101 aluminum that had a relative density of 9.8%. The cast aluminum block was compressed by uniaxial, biaxial, and triaxial densification. Uniaxial compression was done at room temperature and 200 C. Biaxial compression was achieved by unidirectional rolling at room temperature and 200 C. Triaxial compression was done by cold isostatic pressing at 3.4, 6.7, and 34 MPa (0.5, 1.0, and 5.0 ksi). Metallography and mechanical test specimens were machines from the processed bars. The mechanical properties showed that the relative yield strength depended both on relative density and processing temperature.

  6. Superhydrophobic aluminum alloy surfaces by a novel one-step process.

    PubMed

    Saleema, N; Sarkar, D K; Paynter, R W; Chen, X-G

    2010-09-01

    A simple one-step process has been developed to render aluminum alloy surfaces superhydrophobic by immersing the aluminum alloy substrates in a solution containing NaOH and fluoroalkyl-silane (FAS-17) molecules. Scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS) and water contact angle measurements have been performed to characterize the morphological features, chemical composition and superhydrophobicity of the surfaces. The resulting surfaces provided a water contact angle as high as ∼162° and a contact angle hysteresis as low as ∼4°. The study indicates that it is possible to fabricate superhydrophobic aluminum surfaces easily and effectively without involving the traditional two-step processes. PMID:20812666

  7. Ni-coated SiC{sub p} reinforced aluminum composites processed by vacuum infiltration

    SciTech Connect

    Chung, W.S.; Lin, S.J.

    1996-12-01

    A vacuum infiltration process has been developed to process aluminum-base composites reinforced with particulate SiC{sub p}. Electroless nickel coating of SiC{sub p} was used to improve wetting by molten aluminum. Experimental results showed that composites of aluminum with 5.9 wt % Si and 0.23 wt % Mg containing about 50 vol % Ni-coated SiC{sub p} were completely infiltrated at a temperature above 700 C. The effects of nickel coating thickness and infiltration temperature on infiltration behavior were investigated. The infiltration rate increased and the infiltration incubation time decreased with increasing infiltration temperature or nickel coating thickness. The microstructure, nickel distribution, bending strength and fracture were also examined. Nonuniformity bending strength and fracture morphology were attributed to nickel macrosegregation.

  8. Process Modeling of Low-Pressure Die Casting of Aluminum Alloy Automotive Wheels

    NASA Astrophysics Data System (ADS)

    Reilly, C.; Duan, J.; Yao, L.; Maijer, D. M.; Cockcroft, S. L.

    2013-09-01

    Although on initial inspection, the aluminum alloy automotive wheel seems to be a relatively simple component to cast based on its shape, further insight reveals that this is not the case. Automotive wheels are in a select group of cast components that have strict specifications for both mechanical and aesthetic characteristics due to their important structural requirements and their visibility on a vehicle. The modern aluminum alloy automotive wheel continues to experience tightened tolerances relating to defects to improve mechanical performance and/or the physical appearance. Automotive aluminum alloy wheels are assessed against three main criteria: wheel cosmetics, mechanical performance, and air tightness. Failure to achieve the required standards in any one of these categories will lead to the wheel either requiring costly repair or being rejected and remelted. Manufacturers are becoming more reliant on computational process modeling as a design tool for the wheel casting process. This article discusses and details examples of the use of computational process modeling as a predictive tool to optimize the casting process from the standpoint of defect minimization with the emphasis on those defects that lead to failure of aluminum automotive wheels, namely, macroporosity, microporosity, and oxide films. The current state of applied computational process modeling and its limitations with regard to wheel casting are discussed.

  9. Penetration experiments in aluminum 1100 targets using soda-lime glass projectiles

    NASA Technical Reports Server (NTRS)

    Horz, Friedrich; Cintala, Mark J.; Bernhard, Ronald P.; Cardenas, Frank; Davidson, William E.; Haynes, Gerald; See, Thomas H.; Winkler, Jerry L.

    1995-01-01

    The cratering and penetration behavior of annealed aluminum 1100 targets, with thickness varied from several centimeters to ultra-thin foils less than 1 micrometer thick, were experimentally investigated using 3.2 mm diameter spherical soda-lime glass projectiles at velocities from 1 to 7 km/s. The objective was to establish quantitative, dimensional relationships between initial impact conditions (impact velocity, projectile diameter, and target thickness) and the diameter of the resulting crater or penetration hole. Such dimensional relationships and calibration experiments are needed to extract the diameters and fluxes of hypervelocity particles from space-exposed surfaces and to predict the performance of certain collisional shields. The cratering behavior of aluminum 1100 is fairly well predicted. However, crater depth is modestly deeper for our silicate impactors than the canonical value based on aluminum projectiles and aluminum 6061-T6 targets. The ballistic-limit thickness was also different. These differences attest to the great sensitivity of detailed crater geometry and penetration behavior on the physical properties of both the target and impactor. Each penetration experiment was equipped with a witness plate to monitor the nature of the debris plume emanating from the rear of the target. This plume consists of both projectile fragments and target debris. Both penetration hole and witness-plate spray patterns systematically evolve in response to projectile diameter/target thickness. The relative dimensions of the projectile and target totally dominate the experimental products documented in this report; impact velocity is an important contributor as well to the evolution of penetration holes, but is of subordinate significance for the witness-plate spray patterns.

  10. Processing and microstructural evolution of alumina/aluminum alloy and aluminum nitride/aluminum alloy composites by directed melt oxidation. Ph.D. Thesis

    SciTech Connect

    Crudele, S.D.

    1994-12-31

    An experimental investigation on the directed oxidation of aluminum-zinc alloys to produce alumina/aluminum alloy composites with and without alumina preforms has been conducted. It has been suggested in the literature that Al-Mg alloys grow composites by the dissolution of a magnesia surface layer and reprecipitation of alumina in the composite. The intent of this investigation is to reveal relevant distinctions in the proposed dissolution-reprecipitation process as they apply to a more commercially interesting Zn containing alloy with a reinforcing preform. The TGA behavior and microstructural observations on the oxidation of Al-10Zn-8Si alloys were coupled with a thermodynamic and kinetic analysis to develop a composite growth model. Experiments were carried out in air at 1000-1200 C. At the higher temperatures (greater than 1100 C), Al2O3/Al composites grow by dissolving a ZnAl2O4 (spinel) surface layer. The dissolution process releases oxygen that reprecipitates in the form of Al2O3 on the existing composite, and also releases Zn and Al which migrate upward through the spinel to regenerate the surface oxide. Composite growth may only occur when the surface regenerates at a rate comparable with that of the dissolution process. At the lower temperatures, 1000 C, the composite growth is limited by the spinel regeneration process, and becomes intermittent. The addition of Mg to this alloy allows normal composite growth by the dissolution of a surface (Zn,Mg)Al2O4 layer at the lower temperatures, 980-1060 C, but leads to heterogeneous microstructures with voids as the temperature increases above approximately 1060 C. The directed oxidation of an Al-Zn alloy into porous alumina preforms yields an Al2O3/Al composite matrix which fills the preform interstices. Al-10Zn-8Si-0.25Mg alloys that are oxidized from 960-1100 C, and Al-10Zn-8Si alloys that are oxidized at 800-1000 C climb up the preform particle.

  11. In-flight oxidation of aluminum in the twin-wire electric arc process

    NASA Astrophysics Data System (ADS)

    Guillen, Donna Post; Williams, Brian G.

    2006-03-01

    This paper examines the in-flight oxidation of aluminum sprayed in air using the twin-wire electric arc (TWEA) thermal spray process. Aerodynamic shear at the droplet surface increases the amount of in-flight oxidation by promoting entrainment of the surface oxides within the molten droplet and continually exposing fresh fluid available for oxidation. Mathematical predictions herein confirm experimental measurements that reveal an elevated, nearly constant surface temperature (˜2273 K) of the droplets during flight. The calculated oxide volume fraction of a “typical” droplet with internal circulation compares favorably to the experimentally determined oxide content (3.3 12.7%) for a typical TWEA-sprayed aluminum coating sprayed onto a room temperature substrate. It is concluded that internal circulation within the molten aluminum droplet is a significant source of oxidation. This effect produces an oxide content nearly two orders of magnitude larger than that of a droplet without continual oxidation.

  12. Formation and emission of brominated dioxins and furans during secondary aluminum smelting processes.

    PubMed

    Wang, Mei; Liu, Guorui; Jiang, Xiaoxu; Li, Sumei; Liu, Wenbin; Zheng, Minghui

    2016-03-01

    Secondary aluminum smelting (SAl) processes have previously been found to be important sources of polybrominated dibenzo-p-dioxins and dibenzofurans (PBDD/Fs). It is crucial that the key factors that influence the formation and emission of PBDD/Fs are identified to allow techniques for decreasing PBDD/F emissions during SAl processes to be developed. In this study, stack gas samples were collected from four typical secondary aluminum smelters that used different raw materials, and the samples were analyzed to allow differences between PBDD/F emissions from different SAl plants to be assessed. The composition of the raw materials was found to be one of the key factors influencing the amounts of PBDD/Fs emitted. The PBDD/F emission factors (per tonne of aluminum produced) for the plants using 100% (Plant1), 80% (Plant2), and 50% (Plant3) dirty aluminum scrap in the raw material feed were 180, 86, and 14 μg t(-1), respectively. The amounts of PBDD/Fs emitted at different stages of the smelting process (feeding-fusion, refining, and casting) were compared, and the feeding-fusion stage was found to be the main stage in which PBDD/Fs were formed and emitted. Effective aluminum scrap pretreatments could significantly decrease PBDD/F emissions. Much higher polybrominated dibenzofuran concentrations than polybrominated dibenzo-p-dioxin concentrations were found throughout the SAl process. The more-brominated congeners (including octabromodibenzo-p-dioxin, octabromodibenzofuran, heptabromodibenzo-p-dioxins, and heptabromodibenzofurans) were the dominant contributors to the total PBDD/F concentrations. The results could help in the development of techniques and strategies for controlling PBDD/F emissions during metallurgical processes. PMID:26706932

  13. Development and Processing Improvement of Aerospace Aluminum Alloys

    NASA Technical Reports Server (NTRS)

    Lisagor, W. Barry; Bales, Thomas T.

    2007-01-01

    This final report, in multiple presentation format, describes a comprehensive multi-tasked contract study to improve the overall property response of selected aerospace alloys, explore further a newly-developed and registered alloy, and correlate the processing, metallurgical structure, and subsequent properties achieved with particular emphasis on the crystallographic orientation texture developed. Modifications to plate processing, specifically hot rolling practices, were evaluated for Al-Li alloys 2195 and 2297, for the recently registered Al-Cu-Ag alloy, 2139, and for the Al-Zn-Mg-Cu alloy, 7050. For all of the alloys evaluated, the processing modifications resulted in significant improvements in mechanical properties. Analyses also resulted in an enhanced understanding of the correlation of processing, crystallographic texture, and mechanical properties.

  14. Cleaning process for corrugated aluminum electrical transmission line enclosure

    DOEpatents

    Bowman, Gary K.

    1984-07-24

    A process for preparing the interior of a corrugated pipe or sheath comprises the steps of placing a predetermined amount of a tumbling abrasive material into the sheath, and then rotating the sheath.

  15. Processing of aluminum 7075-T73 components after prolonged storage

    SciTech Connect

    Guilinger, T.R.; Stevenson, J.O.; Yang, R.G.; Buchheit, R.G.; Schmale, D.T.; Shin, K.; Martinez, F.E.; Webb, L.; Stimetz, C.J.

    1996-06-01

    Three years ago, production requirements for a T73-tempered aluminium 7075 (Al 7075-T73) component were curtailed and the ``in-process`` parts were stored. During recent attempts to complete processing, visible defects were discovered in this component. Defects at such an early stage in the 20+ year lifetime of the component pose reliability concerns. Chemical and microstructural analysis, mechanical testing, and corrosion evaluation were performed to determine the impact of the defects on material properties.

  16. Fusion boundary microstructure evolution in aluminum alloys

    NASA Astrophysics Data System (ADS)

    Kostrivas, Anastasios Dimitrios

    2000-10-01

    A melting technique was developed to simulate the fusion boundary of aluminum alloys using the GleebleRTM thermal simulator. Using a steel sleeve to contain the aluminum, samples were heated to incremental temperatures above the solidus temperature of a number of alloys. In alloy 2195, a 4wt%Cu-1wt%Li alloy, an equiaxed non-dendritic zone (EQZ) could be formed by heating in the temperature range from approximately 630 to 640°C. At temperatures above 640°C, solidification occurred by the normal epitaxial nucleation and growth mechanism. Fusion boundary behavior was also studied in alloys 5454-H34, 6061-T6, and 2219-T8. Additionally, experimental alloy compositions were produced by making bead on plate welds using an alloy 5454-H32 base metal and 5025 or 5087 filler metals. These filler metals contain zirconium and scandium additions, respectively, and were expected to influence nucleation and growth behavior. Both as-welded and welded/heat treated (540°C and 300°C) substrates were tested by melting simulation, resulting in dendritic and EQZ structures depending on composition and substrate condition. Orientation imaging microscopy (OIM(TM)) was employed to study the crystallographic character of the microstructures produced and to verify the mechanism responsible for EQZ formation. OIM(TM) proved that grains within the EQZ have random orientation. In all other cases, where the simulated microstructures were dendritic in nature, it was shown that epitaxy was the dominant mode of nucleation. The lack of any preferred crystallographic orientation relationship in the EQZ supports a theory proposed by Lippold et al that the EQZ is the result of heterogeneous nucleation within the weld unmixed zone. EDS analysis of the 2195 on STEM revealed particles with ternary composition consisted of Zr, Cu and Al and a tetragonal type crystallographic lattice. Microdiffraction line scans on EQZ grains in the alloy 2195 showed very good agreement between the measured Cu

  17. NBS: Nondestructive evaluation of nonuniformities in 2219 aluminum alloy plate: Relationship to processing

    NASA Technical Reports Server (NTRS)

    Swartzendruber, L.; Boettinger, W.; Ives, L.; Coriell, S.; Ballard, D.; Laughlin, D.; Clough, R.; Biancanieilo, F.; Blau, P.; Cahn, J.

    1980-01-01

    The compositional homogeneity, microstructure, hardness, electrical conductivity and mechanical properties of 2219 aluminum alloy plates are influenced by the process variables during casting, rolling and thermomechanical treatment. The details of these relationships wre investigated for correctly processed 2219 plate as well as for deviations caused by improper quenching after solution heat treatment. Primary emphasis was been placed on the reliability of eddy current electrical conductivity and hardness as NDE tools to detect variations in mechanical properties.

  18. A Process for Producing Highly Wettable Aluminum 6061 Surfaces Compatible with Hydrazine

    NASA Technical Reports Server (NTRS)

    Moore, N. R.; Ferraro, N. W.; Yue, A. F.; Estes, R. H.

    2007-01-01

    NASA's Global Precipitation Measurement (GPM) mission is an ongoing Goddard Space Flight Center (GSFC) project whose basic objective is to improve global precipitation measurements. The space-based portion of the mission architecture consists of a primary or core spacecraft and a constellation of NASA and contributed spacecrafts. The efforts described in this paper refer to the core spacecraft (hereafter referred to as simply GPM) which is to be fabricated at GSFC. It has been decided that the GPM spacecraft is to be a "design-for-demise-spacecraft." This requirement resulted in the need for a propellant tank that would also demise or ablate to an appropriate degree upon re-entry. Composite overwrapped aluminum lined propellant tanks with aluminum propellant management devices (PMD) were shown by analyses to demise and thus became the baseline configuration for GPM. As part of the GPM tank development effort, long term compatibility and wettability testing with hydrazine was performed on Al6061 and 2219 coupons fabricated and cleaned by conventional processes. Long term compatibility was confirmed. However, the wettability of the aluminum as measured by contact angle produced higher than desired angles (greater than 30 deg.) with excessive scatter. The availability of PMD materials exhibiting consistently low contact angles aids in the design of simple PMDs. Two efforts performed by Angeles Crest Engineering and funded by GSFC were undertaken to reduce the risk of using aluminum for the GPM PMD. The goal of the first effort was to develop a cleaning or treatment process to produce consistently low contact angles. The goal of the second effort was to prove via testing that the processed aluminum would retain compatibility with hydrazine and retain low contact angle after long term exposure to hydrazine. Both goals were achieved. This paper describes both efforts and the results achieved.

  19. Fatigue properties of an 1421 aluminum alloy processed by ECAE

    NASA Astrophysics Data System (ADS)

    Mogucheva, A.; Kaibyshev, R.

    2010-07-01

    Fatigue properties and fatigue crack growth rate were examined in an Al-Mg-Li-Sc-Zr allow subjected to equal channel angular extrusion (ECAE) with rectangular shape of channels up to a total strain of ~4 at a temperature of 325°C followed by solution treatment with subsequent oil quenching with aging. After this processing the fraction recrystallized was ~80pct; the deformed microstructure remains essentially unchanged under solution treatment due to high density of Al3Sc coherent dispersoids playing a role of effective pinning agents. It was shown that the fatigue limit of this material attained a value of ~185 MPa. Thermomechanical processing provided a decrease in fatigue crack propagation growth rate and an increase in the stress intensity factor, K1c, in comparison with extruded bar. However, characteristics of crack propagation resistance did not attain values suitable for application of this alloy for critical aircraft components.

  20. Optimization of chlorine fluxing process for magnesium removal from molten aluminum

    NASA Astrophysics Data System (ADS)

    Fu, Qian

    High-throughput and low operational cost are the keys to a successful industrial process. Much aluminum is now recycled in the form of used beverage cans and this aluminum is of alloys that contain high levels of magnesium. It is common practice to "demag" the metal by injecting chlorine that preferentially reacts with the magnesium. In the conventional chlorine fluxing processes, low reaction efficiency results in excessive reactive gas emissions. In this study, through an experimental investigation of the reaction kinetics involved in this process, a mathematical model is set up for the purpose of process optimization. A feedback controlled chlorine reduction process strategy is suggested for demagging the molten aluminum to the desired magnesium level without significant gas emissions. This strategy also needs the least modification of the existing process facility. The suggested process time will only be slightly longer than conventional methods and chlorine usage and emissions will be reduced. In order to achieve process optimization through novel designs in any fluxing process, a system is necessary for measuring the bubble distribution in liquid metals. An electro-resistivity probe described in the literature has low accuracy and its capability to measure bubble distribution has not yet been fully demonstrated. A capacitance bubble probe was designed for bubble measurements in molten metals. The probe signal was collected and processed digitally. Higher accuracy was obtained by higher discrimination against corrupted signals. A single-size bubble experiment in Belmont metal was designed to reveal the characteristic response of the capacitance probe. This characteristic response fits well with a theoretical model. It is suggested that using a properly designed deconvolution process, the actual bubble size distribution can be calculated. The capacitance probe was used to study some practical bubble generation devices. Preliminary results on bubble distribution

  1. X-ray and neutron diffraction measurements of dislocation density and subgrain size in a friction stir welded aluminum alloy

    SciTech Connect

    Claussen, Bjorn; Woo, Wanchuck; Zhili, Feng; Edward, Kenik; Ungar, Tamas

    2009-01-01

    The dislocation density and subgrain size were determined in the base material and friction-stir welds of 6061-T6 aluminum alloy. High-resolution X-ray diffraction measurement was performed in the base material. The result of the line profile analysis of the X-ray diffraction peak shows that the dislocation density is about 4.5 x 10{sup 14} m{sup 02} and the subgrain size is about 200 nm. Meanwhile, neutron diffraction measurements have been performed to observe the diffraction peaks during friction-stir welding (FSW). The deep penetration capability of the neutron enables us to measure the peaks from the midplane of the Al plate underneath the tool shoulder of the friction-stir welds. The peak broadening analysis result using the Williamson-Hall method shows the dislocation density of about 3.2 x 10{sup 15} m{sup -2} and subgrain size of about 160 nm. The significant increase of the dislocation density is likely due to the severe plastic deformation during FSW. This study provides an insight into understanding the transient behavior of the microstructure under severe thermomechanical deformation.

  2. Salt Spray Test to Determine Galvanic Corrosion Levels of Electroless Nickel Connectors Mounted on an Aluminum Bracket

    NASA Technical Reports Server (NTRS)

    Rolin, T. D.; Hodge, R. E.; Torres, P. D.; Jones, D. D.; Laird, K. R.

    2014-01-01

    During preliminary vehicle design reviews, requests were made to change flight termination systems from an electroless nickel (EN) connector coating to a zinc-nickel (ZN) plating. The reason for these changes was due to a new NASA-STD-6012 corrosion requirement where connectors must meet the performance requirement of 168 hr of exposure to salt spray. The specification for class F connectors, MIL-DTL-38999, certifies the EN coating will meet a 48-hr salt spray test, whereas the ZN is certified to meet a 168-hr salt spray test. The ZN finish is a concern because Marshall Space Flight Center has no flight experience with ZN-finished connectors, and MSFC-STD-3012 indicates that zinc and zinc alloys should not be used. The purpose of this test was to run a 168-hr salt spray test to verify the electrical and mechanical integrity of the EN connectors and officially document the results. The salt spray test was conducted per ASTM B117 on several MIL-DTL-38999 flight-like connectors mounted to an aluminum 6061-T6 bracket that was alodined. The configuration, mounting techniques, electrical checks, and materials used were typical of flight and ground support equipment.

  3. Conical shaped charge pressed powder, metal liner jet characterization and penetration in aluminum

    SciTech Connect

    Vigil, M.G.

    1997-05-01

    This work was conducted as part of a Near-wellbore Mechanics program at Sandia National Laboratories. An understanding of the interaction of the perforator jet from an explosive shaped charge with the fluid filled porous sandstone media is of basic importance to the completion of oil wells. Tests were conducted using the five-head Flash X-ray Test Site to measure the jet tip velocities and jet geometry for the OMNI and CAPSULE Conical Shaped Charge (CSC) oil well perforator jets fired into air. These tests were conducted to generate jet velocity and geometry information to be used in validating the CTH hydrocode modeling/simulation development of pressed powder, metal liner jets in air. Ten tests were conducted to determine the CSC jet penetration into 6061-T6 aluminum targets. Five tests were conducted with the OMNI CSC at 0.25, 6.0, and 19 inch standoffs from the target. Five tests were conducted with the CAPSULE CSC at 0.60, 5.0, 10.0, and 19 inch standoffs from the target. These tests were conducted to generate jet penetration into homogeneous target information for use in validating the CTH code modeling/simulation of pressed powder, metal liner jets penetrating aluminum targets. The Flash X-ray radiographs, jet velocities, jet diameters, and jet lengths data for jets fired into air are presented in this report. The jet penetration into aluminum and penetration hole profile data are also presented for the OMNI and CAPSULE perforators. Least Squares fits are presented for the measured jet velocity and jet penetration data.

  4. Porous aluminum room temperature anodizing process in a fluorinated-oxalic acid solution

    NASA Astrophysics Data System (ADS)

    Dhahri, S.; Fazio, E.; Barreca, F.; Neri, F.; Ezzaouia, H.

    2016-08-01

    Anodizing of aluminum is used for producing porous insulating films suitable for different applications in electronics and microelectronics. Porous-type aluminum films are most simply realized by galvanostatic anodizing in aqueous acidic solutions. The improvement in application of anodizing technique is associated with a substantial reduction of the anodizing voltage at appropriate current densities as well as to the possibility to carry out the synthesis process at room temperature in order to obtain a self-planarizing dielectric material incorporated in array of super-narrow metal lines. In this work, the anodizing of aluminum to obtain porous oxide was carried out, at room temperature, on three different substrates (glass, stainless steel and aluminum), using an oxalic acid-based electrolyte with the addition of a relatively low amount of 0.4 % of HF. Different surface morphologies, from nearly spherical to larger porous nanostructures with smooth edges, were observed by means of scanning electron microscopy. These evidences are explained by considering the formation, transport and adsorption of the fluorine species which react with the Al3+ ions. The behavior is also influenced by the nature of the original substrate.

  5. Effects of Forging Process Parameters on Microstructure Evolution of Aluminum Alloy 7050

    SciTech Connect

    Yi Youping; Shi Yan; Yang Jihui; Lin Yongcheng

    2007-04-07

    The objective of this work is to investigate the behavior of microstructure evolution of aluminum alloy 7050 under the condition of different forging process parameters by means of combining materials physical model with finite element code. For the purpose of establishing constitutive equation and physical model of microstructure evolution, the isothermal compression test were performed by machine Gleeble 1500 on the condition of temperatures ranging from 250 deg. C to 450 deg. C and constant strain rates of 0.01s-1, 0.1s-1, 1s-1 and 10s-1. The behaviors of microstructure evolutions of aluminum alloy 7050 under difference process parameters were studied by metallographic observations. The experiment results showed that recrystallization during forming process occurred at the critical strain and the volume fraction of recrystallization changed with the temperature and strain rate. According to the results of isothermal compression test, a constitutive equation and an empirical model of DRX were obtained. A finite element code DEFORM 3D was used to analyze the influence of different forging process parameters on the behavior of microstructure evolution in details. The present model and simulation method can be served as a useful tool to predict and control the properties and shape of aluminum alloy 7050 components during forging.

  6. Metallurgical Evaluations of Depainting Processes on Aluminum Substrate

    NASA Technical Reports Server (NTRS)

    McGill, Preston

    1999-01-01

    In December 1993, the Environmental Protection Agency (EPA) Emission Standards Division and the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center (MSFC) signed an Interagency Agreement (IA) initiating a task force for the technical assessment of alternative technologies for aerospace depainting operations. The United States Air Force (USAF) joined the task force in 1994. The mandates of the task force were: (1) To identify available alternative depainting systems that do not rely on methylene chloride or other ozone-depleting, chlorinated, and volatile organic carbon solvents. (2) To determine the viability, applicability, and pollution prevention potential of each identified alternative. (3) To address issues of safety, environmental impact, reliability, and maintainability. Through a Technical Implementation Committee (TIC), the task force selected and evaluated eight alternative paint stripping technologies: chemical stripping, carbon dioxide (CO2) blasting, xenon flashlamp and CO2 coatings removal (FLASHJET(R)), CO2 laser stripping, plastic media blasting (PMB), sodium bicarbonate wet stripping, high-pressure water blasting (WaterJet), and wheat starch abrasive blasting (Enviro-Strip(R)). (The CO2 blasting study was discontinued after the first depainting sequence.) This final report presents the results of the Joint EPA/NASA/USAF Interagency Depainting Study. Significant topics include: (1) Final depainting sequence data for the chemical stripping, PMB, sodium bicarbonate wet stripping, and WaterJet processes. (2) Strip rates for all eight technologies. (3) Sequential comparisons of surface roughness measurements for the seven viable depainting technologies. (4) Chronological reviews of and lessons learned in the conduct of all eight technologies. (5) An analysis of the surface roughness trends for each of the seven technologies. (6) Metallurgic evaluations of panels Summaries of corrosion and hydrogen embrittlement

  7. Chemical and Electrochemical Processing of Aluminum Dross Using Molten Salts

    NASA Astrophysics Data System (ADS)

    Yan, Xiao Y.

    2008-04-01

    A novel molten salt process was investigated, where Al, as metal or contained in Al2O3 and AlN, was recovered from Al dross by chemical or direct electrochemical reduction in electrolytic cells. Electrolysis experiments were carried out under argon at temperatures from 1123 to 1243 K. In order to better understand the reduction behavior, the as-received Al dross was simulated using simplified systems, including pure Al2O3, pure AlN, an Al2O3/AlN binary mixture, and an Al2O3/AlN/Al ternary mixture. The reduction of the as-received dross was also studied experimentally. The studies showed that solid Al2O3 was chemically reduced by the Ca in a Ca-saturated Ca-CaCl2 melt to form Al2Ca or electrochemically reduced to Al-rich Al-Ca alloys and that the Al value in the Al2O3 was easily recovered from the Al drosses. It was found experimentally that solid AlN in the drosses could not be calciothermically reduced to any extent, consistent with thermodynamic evaluations. It was also found that the direct electrochemical reduction of the AlN in the drosses was confined to three phase boundaries (3PBs) between the AlN, the electrolyte, and the current collector and could not be enhanced by using the LiCl-containing chloride melt or the chloride-fluoride melts studied. The presence of Al powder in the Al2O3/AlN mixture facilitated the direct electrochemical reduction of both Al2O3 and AlN. The reduction mechanisms are discussed based upon the present experimental observations. Flow sheets for recovering the metallic Al and the Al in the Al2O3 and AlN from Al dross are finally proposed.

  8. Production of Gas-Solid Structures in Aluminum and Nickel Alloys by Gasar Processing

    SciTech Connect

    Apprill, J.M.; Baldwin, M.D.; Maguire, M.C.; Miszkiel, M.E.; Shapovalov, V.I.

    1999-01-06

    Experimental data on directional and bulk solidification of hydrogen-charged samples of aluminum alloy A356 and nickel alloy Inconel 718 are discussed. The solidification structure of the porous zone is shown to be dependent on many process variables. Of these variables, hydrogen content in the melt prior to solidification, and furnace atmospheric pressure during solidification play the decisive role. Also important are the furnace atmosphere composition, the solidification velocity, and the temperature distribution of the liquid metal inside the mold.

  9. DOWNSTREAM IMPACTS OF SLUDGE MASS REDUCTION VIA ALUMINUM DISSOLUTION ON DWPF PROCESSING OF SAVANNAH RIVER SITE HIGH LEVEL WASTE - 9382

    SciTech Connect

    Pareizs, J; Cj Bannochie, C; Michael Hay, M; Daniel McCabe, D

    2009-01-14

    The SRS sludge that was to become a major fraction of Sludge Batch 5 (SB5) for the Defense Waste Processing Facility (DWPF) contained a large fraction of H-Modified PUREX (HM) sludge, containing a large fraction of aluminum compounds that could adversely impact the processing and increase the vitrified waste volume. It is beneficial to reduce the non-radioactive fraction of the sludge to minimize the number of glass waste canisters that must be sent to a Federal Repository. Removal of aluminum compounds, such as boehmite and gibbsite, from sludge can be performed with the addition of NaOH solution and heating the sludge for several days. Preparation of SB5 involved adding sodium hydroxide directly to the waste tank and heating the contents to a moderate temperature through slurry pump operation to remove a fraction of this aluminum. The Savannah River National Laboratory (SRNL) was tasked with demonstrating this process on actual tank waste sludge in our Shielded Cells Facility. This paper evaluates some of the impacts of aluminum dissolution on sludge washing and DWPF processing by comparing sludge processing with and without aluminum dissolution. It was necessary to demonstrate these steps to ensure that the aluminum removal process would not adversely impact the chemical and physical properties of the sludge which could result in slower processing or process upsets in the DWPF.

  10. Development and Processing of Novel Aluminum Powder Metallurgy Materials for Heat Sink Applications

    NASA Astrophysics Data System (ADS)

    Smith, L. J. B.; Corbin, S. F.; Hexemer, R. L.; Donaldson, I. W.; Bishop, Donald Paul

    2014-02-01

    The objective of this research was to design aluminum powder metallurgy (PM) alloys and processing strategies that yielded sintered products with thermal properties that rivaled those of the cast and wrought aluminum alloys traditionally employed in heat sink manufacturing. Research has emphasized PM alloys within the Al-Mg-Sn system. In one sub-theme of research, the general processing response of each PM alloy was investigated through a combination of sintering trials, sintered density measurements, and microstructural assessments. In the second, the thermal properties of sintered products were studied in detail. Thermal conductivity was first determined using a calculated approach through discrete measurements of specific heat capacity, thermal diffusivity, and density and subsequently verified using a transient plane source technique on larger specimens. Experimental PM alloys achieved >99 pct theoretical density and exhibited thermal conductivity that ranged from 179 to 225 W/m K. Thermal performance was largely dominated by the amount of magnesium present within the aluminum grains and, in turn, bulk alloy chemistry. Data confirmed that the novel PM alloys were highly competitive with even the most advanced heat sink materials such as wrought 6063 and 6061.

  11. Defluoridation of groundwater using aluminum-coated bauxite: Optimization of synthesis process conditions and equilibrium study.

    PubMed

    Salifu, Abdulai; Petrusevski, Branislav; Mwampashi, Emmanuel S; Pazi, Iddi A; Ghebremichael, Kebreab; Buamah, Richard; Aubry, Cyril; Amy, Gary L; Kenedy, Maria D

    2016-10-01

    There is no known effective treatment for fluoride-related health disorders, hence prevention through water defluoridation is necessary. This study explored the possibility of modifying the physico-chemical properties of bauxite, a locally available material in many countries including Ghana, by thermal treatment and an aluminum coating, for water defluoridation. The study mainly focused on investigating the effects of varying synthesis process conditions on the defluoridation efficiency of Granular Aluminum Coated Bauxite (GACB). GACB performed better than raw bauxite (RB) and was able to reduce fluoride concentration in groundwater from 5 ± 0.2 mg/L to ≤ 1.5 mg/L, World Health Organization (WHO) guideline. Based on nonlinear Chi-square (χ(2)) analysis, the best-fitting isotherm model for the fluoride-GACB system was in the order: Freundlich > Redlich-Perterson ≈ Langmuir > Temkin. The fluoride adsorption capacity of GACB (qmax = 12.29 mg/g) based on the Langmuir model was found to be either comparable or higher than the capacities of some reported fluoride adsorbents. Aluminum (Al) coating procedures optimized in this study could therefore be a useful approach for synthesizing an effective fluoride adsorbent using bauxite, a locally available material. Kinetic and isotherm analysis, thermodynamic calculations, as well as FTIR and Raman analysis suggested the mechanism of fluoride adsorption onto GACB was complex and involved both physical adsorption and chemisorption processes. PMID:27327859

  12. Method for processing aluminum spent potliner in a graphite electrode ARC furnace

    DOEpatents

    O'Connor, William K.; Turner, Paul C.; Addison, Gerald W.

    2002-12-24

    A method of processing spent aluminum pot liner containing carbon, cyanide compositions, fluorides and inorganic oxides. The spent aluminum pot liner is crushed iron oxide is added to form an agglomerated material. The agglomerated material is melted in an electric arc furnace having the electrodes submerged in the molten material to provide a reducing environment during the furnace operation. In the reducing environment, pot liner is oxidized while the iron oxides are reduced to produce iron and a slag substantially free of cyanide compositions and fluorides. An off-gas including carbon oxides and fluorine is treated in an air pollution control system with an afterburner and a scrubber to produce NaF, water and a gas vented to the atmosphere free of cyanide compositions, fluorine and CO.

  13. Method for processing aluminum spent potliner in a graphite electrode arc furnace

    DOEpatents

    O'Connor, William K.; Turner, Paul C.; Addison, G.W.

    2002-12-24

    A method of processing spent aluminum pot liner containing carbon, cyanide compositions, fluorides and inorganic oxides. The spend aluminum pot liner is crushed, iron oxide is added to form an agglomerated material. The agglomerated material is melted in an electric arc furnace having the electrodes submerged in the molten material to provide a reducing environment during the furnace operation. In the reducing environment, pot liner is oxidized while the iron oxides are reduced to produce iron and a slag substantially free of cyanide compositions and fluorides. An off-gas including carbon oxides and fluorine is treated in an air pollution control system with an afterburner and a scrubber to produce NaF, water and a gas vented to the atmosphere free of cyanide compositions, fluorine, and CO.

  14. Process for producing gallium-containing solution from aluminum smelting dust

    SciTech Connect

    Ikeda, H.; Matsui, S.; Era, A.

    1988-02-16

    A process for producing a gallium-containing solution from aluminum smelting dust is described comprising mixing aluminum smelting dust with 5 to 50% by weight of an alkaline flux selected from the group consisting of sodium carbonate, sodium hydroxide, potassium carbonate, potassium hydroxide and mixtures thereof, heating the mixture to a temperature sufficient to roast the mixture without fusing the mixture, leaching the roasted mixture at a temperature of 80/sup 0/C. to 100/sup 0/C. with a mineral acid selected from the group consisting of sulfuric acid, hydrochloric acid, nitric acid and mixtures thereof to preferentially solubilize gallium from other material in the roasted mixture, and filtering the leached mixture to separate the solubilized gallium solution therefrom.

  15. Recrystallization Phenomena During Friction Stir Processing of Hypereutectic Aluminum-Silicon Alloy

    NASA Astrophysics Data System (ADS)

    Rao, A. G.; Ravi, K. R.; Ramakrishnarao, B.; Deshmukh, V. P.; Sharma, A.; Prabhu, N.; Kashyap, B. P.

    2013-03-01

    Microstructural evolution and related dynamic recrystallization phenomena were investigated in overlapping multipass friction stir processing (FSP) of hypereutectic Al-30 pct Si alloy. FSP resulted in the elimination of porosities along with the refinement of primary silicon particles and alpha aluminum grains. These alpha aluminum grains predominantly exhibit high angle boundaries with various degrees of recovered substructure and dislocation densities. The substructure and grain formation during FSP take place primarily by annihilation and reorganization of dislocations in the grain interior and at low angle grain boundary. During multipass overlap FSP, small second phase particles were observed to form, which are accountable for pinning the grain boundaries and thus restricting their growth. During the multipass overlap FSP, the microstructure undergoes continuous dynamic recrystallization by formation of the subgrain boundary and subgrain growth to the grain structure comprising of mostly high angle grain boundaries.

  16. Design, process development, manufacture, test and evaluation of boron-aluminum for space shuttle components

    NASA Technical Reports Server (NTRS)

    Garrett, R. A.; Niemann, J. T.; Otto, O. R.; Brown, N. M.; Heinrich, R. E.

    1973-01-01

    A multi phase boron-aluminum design and evaluation program for space shuttle components was conducted, culminating in the fabrication of a 1.22 m (48 inch) x 1.83 m (72 inch) boron-aluminum compression panel capable of distributing a point load of 1555 kN (350,000 lbs) into a uniform running load at a temperature of 589 K (600 F). This panel was of the skin-stringer construction with two intermediate frame supports; seven unidirectional stringers varied in thickness from 5 plies to 52 plies and the skin was contoured to thicknesses ranging from 10 plies to 62 plies. Both the stringers and the skin incorporated Ti-6Al-4V titanium interleaves to increase bearing and in-plane shear strength. The discrete program phases were materials evaluation, design studies, process technology development, fabrication and assembly, and test and evaluation.

  17. CHARACTERIZATION OF TANK 11H AND TANK 51H POST ALUMINUM DISSOLUTION PROCESS SAMPLES

    SciTech Connect

    Hay, M; Daniel McCabe, D

    2008-05-16

    A dip sample of the liquid phase from Tank 11H and a 3-L slurry sample from Tank 51H were obtained and sent to Savannah River National Laboratory for characterization. These samples provide data to verify the amount of aluminum dissolved from the sludge as a result of the low temperature aluminum dissolution process conducted in Tank 51H. The characterization results for the as-received Tank 11H and Tank 51H supernate samples and the total dried solids of the Tank 51H sludge slurry sample appear quite good with respect to the precision of the sample replicates and minimal contamination present in the blank. The two supernate samples show similar concentrations for the major components as expected.

  18. An investigation on diffusion bonding of aluminum to copper using equal channel angular extrusion process.

    PubMed

    Eslami, P; Taheri, A Karimi

    2011-06-30

    A new method for production of bimetallic rods, utilizing the equal channel angular extrusion (ECAE) process has been introduced before by previous researchers, but no attempt has been made to assess the effect of different temperatures and holding times in order to achieve a diffusional bond between the mating surfaces. In present research copper sheathed aluminum rods have been ECAEed at room temperature and subsequently held at a constant ECAE pressure, at different temperatures and holding times to produce a diffusional bond between the copper sheath and the aluminum core. The bonding quality of the joints was examined by shear strength test and a sound bonding interface was achieved. Based on the results, a bonding temperature of 200 °C and holding time of 60-80 min yielded the highest shear strength value. PMID:21760654

  19. Welding Phenomenon and Removal Mechanism of Aluminum-Oxide Films by Space GHTA Welding Process in Vacuum

    NASA Astrophysics Data System (ADS)

    Suita, Yoshikazu; Ekuni, Tomohide; Kamei, Misa; Tsukuda, Yoshiyuki; Terajima, Noboru; Yamashita, Masahiro; Imagawa, Kichiro; Masubuchi, Koichi

    Aluminum alloys have been widely used in constructing various space structures including the ISS (International Space Station) and launch vehicles. In order to apply the welding technology in space, welding experiments on aluminum alloy were performed using by the GHTA (Gas Hollow Tungsten Arc) welding processes using an inverter controlled DC/AC GTA welding machine in vacuum. We observed the removal mechanism of aluminum-oxide films on molten metal in detail during the welding using a high-speed video camera. As a result, it is clarified that the impact arc pressure produced by pulsed current mechanically crushes and removes aluminum-oxide films on the molten pool. This removal mechanism of aluminum-oxide films is completely different from a removal mechanism by cleaning action.

  20. Determination of Ideal Broth Formulations Needed to Prepare Hydrous Aluminum Oxide Microspheres via the Internal Gelation Process

    SciTech Connect

    Collins, Jack Lee; Pye, S. L.

    2009-02-01

    A simple test-tube methodology was used to determine optimum process parameters for preparing hydrous aluminum oxide microspheres by the internal gelation process. Broth formulations of aluminum, hexamethylenetetramine, and urea were found that can be used to prepare hydrous aluminum oxide gel spheres in the temperature range of 60-90 C. A few gel-forming runs were made in which microspheres were prepared with some of these formulations in order to equate the test-tube gelation times with actual gelation times. These preparations confirmed that the test-tube methodology is reliable for determining the ideal broths.

  1. Processing and characterization of in-situ aluminum bronze titanium carbide composites

    NASA Astrophysics Data System (ADS)

    Pillai, Balathandan S.

    The present study was carried out to develop a process for manufacturing in-situ aluminum bronze titanium carbide (TiC) friction drums using the centrifugal casting method and to characterize the material under optimum performance. The in-situ method of manufacturing is based on the reactive gas injection technique (RGI). The gas used in this study is high purity methane (CH 4). It was found that the methane gas injection time into the molten bath of aluminum bronze alloyed with titanium promotes the formation of titanium carbide (TiC) in the bronze matrix. The maximum amount of TiC incorporated in the matrix was 3.1 wt.%. This lead to 11.5 wt.% incorporation of TiC in the inner diameter of centrifugal castings as carbide particles drifted towards this region due to the centrifugal forces and their relatively low density. The hardness and strength of these composites when compared with the as cast condition was improved by heat treatment. However, the alloy ductility was decreased at the expense of the strength. It was found that the wear resistance properties of the composites were superior to those of pure cast and heat treated aluminum bronze currently in use. Optical and Scanning Electron Microscopy indicated that the composite surfaces did not scratch deeply when wearing against a hardened 4340 steel. The wear resistance of the as cast aluminum bronze was inferior to that of heat treated one. Moreover, the heat treated aluminum bronze showed a lack of high abrasion resistance. The frictional coefficient was relatively low for the as cast aluminum bronze as a result of adhesive wear behavior for the load and speed chosen in this present investigation. The corrosion studies showed that these composites do not lead to improved corrosion resistance in marine water environments. Apparently, there is a galvanic corrosion of TiC to bronze. In addition, pitting was observed on the corroded surfaces and increased with the volume fraction of TiC. Model validation was

  2. Properties of Aluminum Deposited by a High-Velocity Oxygen-Fueled Process

    SciTech Connect

    Chow, R; Decker, T A; Gansert, R V; Gansert, D; Lee, D

    2001-06-12

    Aluminum coatings deposited by a HVOF process have been demonstrated and relevant coating properties evaluated according to two deposition parameters, the spray distance and the oxygen-to-fuel flow ratio. The coating porosity, surface roughness, and microhardness are measured. The coating properties are fairly insensitive to spray distance, the distance between the nozzle and the workpiece, and fuel ratios, the oxygen-to-fuel flow. Increasing the fuel content does appear to improve the process productivity in terms of surface roughness. Minimization of nozzle loading is discussed.

  3. Growth process of nanosized aluminum thin films by pulsed laser deposition for fluorescence enhancement.

    PubMed

    Abdellaoui, N; Pillonnet, A; Berndt, J; Boulmer-Leborgne, C; Kovacevic, E; Moine, B; Penuelas, J; Pereira, A

    2015-03-20

    Pulsed laser deposition was used to deposit aluminum thin films of various thicknesses (tAl) ranging from 5 to 40 nm and to investigate their growth process when they are deposited onto SiO2 and Y2O3. Atomic force microscopy and x-ray reflectivity measurements show that the structure of the Al films are related to the wettability properties of the underlaying layer. Onto SiO2, ultra-smooth layers of aluminum are obtained, due to a perfect wetting of SiO2 by Al. In contrast when deposited onto Y2O3, percolated Al layers are observed with apparent pore size decreasing from 200 to 82 nm as t(Al) is increased from 5 to 40 nm, respectively. This particular morphology is related to partial dewetting of Al on Y2O3. These two different growth mechanisms of aluminum depend therefore on the surface properties of SiO2 and Y2O3. The plasmon resonance of such Al nanostructures in the UV region was then analyzed by studying the coupling between Eu(3+) rare earth emitters and Al. PMID:25712708

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

    NASA Astrophysics Data System (ADS)

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

    2001-04-01

    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°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 8×10 -6 mm3/ Nm and contact angles ranged from 156° to 127°.

  5. Characterization of ultrafine-grained aluminum tubes processed by Tube Cyclic Extrusion–Compression (TCEC)

    SciTech Connect

    Babaei, A. Mashhadi, M.M.

    2014-09-15

    Tube Cyclic Extrusion–Compression as a novel severe plastic deformation technique for tubes was utilized for processing ultrafine grained 1050 aluminum alloy for the first time. In this method, aluminum tube is fully constrained and deformed between mandrel and chamber with a small neck zone. The material deformation during Tube Cyclic Extrusion–Compression processing analyzed and the grain refinement mechanism were described. The capability of Tube Cyclic Extrusion–Compression in grain refinement of the aluminum alloy was demonstrated by transmission electron microscopy observations and X-ray diffraction line profile analysis. The micrographs of the evolved microstructure show grain size of 850 nm and 550 nm after the first and second processing cycles of Tube Cyclic Extrusion–Compression, respectively. Mechanical properties of the initial and processed specimens were extracted from ring-hoop tensile tests. The documented results confirm grain refinement by showing remarkable increase in the yield and ultimate strengths. The main increase in strength and decrease in elongation take place after the first cycle. The microhardness assessments illustrate increase from the initial value of 29 Hv to 44 and 49 Hv respectively after the first and second cycles of Tube Cyclic Extrusion–Compression. There is a good homogeneity in peripheral microhardness and microhardness across the tube thickness. - Highlights: • Tubes of AA1050 for the first time were successfully SPD processed by TCEC. • The grain size was refined to 550 nm after two cycles of TCEC. • Notable increase in the strength and decrease in the elongation were documented. • The microhardness increased to 49 Hv from the initial value of 29 Hv. • Good homogeneity in the microhardness distribution was recorded.

  6. Computer-assisted Rheo-forging Processing of A356 Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Kim, H. H.; Kang, C. G.

    2010-06-01

    Die casting process has been used widely for complex automotive products such as the knuckle, arm and etc. Generally, a part fabricated by casting has limited strength due to manufacturing defects by origin such as the dendrite structure and segregation. As an attempt to offer a solution to these problems, forging has been used as an alternative process. However, the forging process provides limited formability for complex shape products. Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes. In order to produce semi-solid materials of the desired microstructure, a stirring process is applied during solidification of A356 aluminum molten state. This paper presents the results of an A356 aluminum alloy sample, which were obtained by experiment and by simulation using DEFORM 3D V6.1. Samples of metal parts were subsequently fabricated by using hydraulic press machinery. In order to compare the influence of loading method, two types of samples were fabricated: (1) samples fabricated under direct loading die sets (2) those fabricated under indirect loading die sets. The formability and defects, which were predicted by FEM simulation, were similar to those of samples used in practice.

  7. Computer-assisted Rheo-forging Processing of A356 Aluminum Alloys

    SciTech Connect

    Kim, H. H.; Kang, C. G.

    2010-06-15

    Die casting process has been used widely for complex automotive products such as the knuckle, arm and etc. Generally, a part fabricated by casting has limited strength due to manufacturing defects by origin such as the dendrite structure and segregation. As an attempt to offer a solution to these problems, forging has been used as an alternative process. However, the forging process provides limited formability for complex shape products. Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes. In order to produce semi-solid materials of the desired microstructure, a stirring process is applied during solidification of A356 aluminum molten state. This paper presents the results of an A356 aluminum alloy sample, which were obtained by experiment and by simulation using DEFORM 3D V6.1. Samples of metal parts were subsequently fabricated by using hydraulic press machinery. In order to compare the influence of loading method, two types of samples were fabricated: (1) samples fabricated under direct loading die sets (2) those fabricated under indirect loading die sets. The formability and defects, which were predicted by FEM simulation, were similar to those of samples used in practice.

  8. Use of aluminum phosphate as the dehydration catalyst in single step dimethyl ether process

    DOEpatents

    Peng, Xiang-Dong; Parris, Gene E.; Toseland, Bernard A.; Battavio, Paula J.

    1998-01-01

    The present invention pertains to a process for the coproduction of methanol and dimethyl ether (DME) directly from a synthesis gas in a single step (hereafter, the "single step DME process"). In this process, the synthesis gas comprising hydrogen and carbon oxides is contacted with a dual catalyst system comprising a physical mixture of a methanol synthesis catalyst and a methanol dehydration catalyst. The present invention is an improvement to this process for providing an active and stable catalyst system. The improvement comprises the use of an aluminum phosphate based catalyst as the methanol dehydration catalyst. Due to its moderate acidity, such a catalyst avoids the coke formation and catalyst interaction problems associated with the conventional dual catalyst systems taught for the single step DME process.

  9. X-Ray and Neutron Diffraction Measurements of Dislocation Density and Subgrain Size in a Friction-Stir-Welded Aluminum Alloy

    SciTech Connect

    Woo, Wan Chuck; Ungar, Prof Tomas; Feng, Zhili; Kenik, Edward A; Clausen, B

    2009-01-01

    The dislocation density and subgrain size were determined in the base material and friction-stir welds of 6061-T6 aluminum alloy. High-resolution X-ray diffraction measurement was performed in the base material. The result of the line profile analysis of the X-ray diffraction peak shows that the dislocation density is about 4.5 x 10{sup 14} m{sup -2} and the subgrain size is about 200 nm. Meanwhile, neutron diffraction measurements have been performed to observe the diffraction peaks during friction-stir welding (FSW). The deep penetration capability of the neutron enables us to measure the peaks from the midplane of the Al plate underneath the tool shoulder of the friction-stir welds. The peak broadening analysis result using the Williamson-Hall method shows the dislocation density of about 3.2 x 10{sup 15} m{sup -2} and subgrain size of about 160 nm. The significant increase of the dislocation density is likely due to the severe plastic deformation during FSW. This study provides an insight into understanding the transient behavior of the microstructure under severe thermomechanical deformation.

  10. X-Ray and Neutron Diffraction Measurements of Dislocation Density and Subgrain Size in a Friction-Stir-Welded Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Woo, Wanchuck; Ungár, Tamás; Feng, Zhili; Kenik, Edward; Clausen, Bjørn

    2010-05-01

    The dislocation density and subgrain size were determined in the base material and friction-stir welds of 6061-T6 aluminum alloy. High-resolution X-ray diffraction measurement was performed in the base material. The result of the line profile analysis of the X-ray diffraction peak shows that the dislocation density is about 4.5 × 1014 m-2 and the subgrain size is about 200 nm. Meanwhile, neutron diffraction measurements have been performed to observe the diffraction peaks during friction-stir welding (FSW). The deep penetration capability of the neutron enables us to measure the peaks from the midplane of the Al plate underneath the tool shoulder of the friction-stir welds. The peak broadening analysis result using the Williamson-Hall method shows the dislocation density of about 3.2 × 1015 m-2 and subgrain size of about 160 nm. The significant increase of the dislocation density is likely due to the severe plastic deformation during FSW. This study provides an insight into understanding the transient behavior of the microstructure under severe thermomechanical deformation.

  11. Optimization of magnetically accelerated, ultra-high velocity aluminum flyer plates for use in plate impact, shock wave experiments.

    SciTech Connect

    Cochrane, Kyle Robert; Knudson, Marcus D.; Slutz, Stephen A.; Lemke, Raymond William; Davis, J. P.; Harjes, Henry Charles III; Giunta, Anthony Andrew; Bliss, David Emery

    2005-05-01

    The intense magnetic field produced by the 20 MA Z accelerator is used as an impulsive pressure source to accelerate metal flyer plates to high velocity for the purpose of performing plate impact, shock wave experiments. This capability has been significantly enhanced by the recently developed pulse shaping capability of Z, which enables tailoring the rise time to peak current for a specific material and drive pressure to avoid shock formation within the flyer plate during acceleration. Consequently, full advantage can be taken of the available current to achieve the maximum possible magnetic drive pressure. In this way, peak magnetic drive pressures up to 490 GPa have been produced, which shocklessly accelerated 850 {micro}m aluminum (6061-T6) flyer plates to peak velocities of 34 km/s. We discuss magnetohydrodynamic (MHD) simulations that are used to optimize the magnetic pressure for a given flyer load and to determine the shape of the current rise time that precludes shock formation within the flyer during acceleration to peak velocity. In addition, we present results pertaining to plate impact, shock wave experiments in which the aluminum flyer plates were magnetically accelerated across a vacuum gap and impacted z-cut, {alpha}-quartz targets. Accurate measurements of resulting quartz shock velocities are presented and analyzed through high-fidelity MHD simulations enhanced using optimization techniques. Results show that a fraction of the flyer remains at solid density at impact, that the fraction of material at solid density decreases with increasing magnetic pressure, and that the observed abrupt decrease in the quartz shock velocity is well correlated with the melt transition in the aluminum flyer.

  12. The NBS: Processing/Microstructure/Property Relationships in 2024 Aluminum Alloy Plates

    NASA Technical Reports Server (NTRS)

    Ives, L. K.; Swartzendruber, W. J.; Boettinger, W. J.; Rosen, M.; Ridder, S. D.

    1983-01-01

    As received plates of 2024 aluminum alloy were examined. Topics covered include: solidification segregation studies; microsegregation and macrosegregation in laboratory and commercially cast ingots; C-curves and nondestructive evaluation; time-temperature precipitation diagrams and the relationships between mechanical properties and NDE measurements; transmission electron microscopy studies; the relationship between microstructure and properties; ultrasonic characterization; eddy-current conductivity characterization; the study of aging process by means of dynamic eddy current measurements; and Heat flow-property predictions, property degradations due to improve quench from the solution heat treatment temperature.

  13. Simulation of the Process of Grain-Boundary Melting in Aluminum

    NASA Astrophysics Data System (ADS)

    Weckman, A. V.; Demyanov, B. F.; Dragunov, A. S.

    2016-04-01

    An MD-simulation of the process of grain-boundary (GB) melting in aluminum is performed. General- and special-type GBs with the [100]-, [110]- and [111]-misorientations are investigated. It is shown that most GBs have lower melting temperatures than that of the single crystal. Grain-boundary melting occurs within the temperature interval from 0.75Tmelt to 0.95Tmelt. Low-angle boundaries and a special Σ11(113) boundary are found to be high-melting.

  14. Simulation of the Process of Grain-Boundary Melting in Aluminum

    NASA Astrophysics Data System (ADS)

    Weckman, A. V.; Demyanov, B. F.; Dragunov, A. S.

    2016-04-01

    An MD-simulation of the process of grain-boundary (GB) melting in aluminum is performed. General- and special-type GBs with the [100]-, [110]- and [111]-misorientations are investigated. It is shown that most GBs have lower melting temperatures than that of the single crystal. Grain-boundary melting occurs within the temperature interval from 0.75 Tmelt to 0.95 Tmelt. Low-angle boundaries and a special Σ11(113) boundary are found to be high-melting.

  15. Effect of Process Variables on the Formation of Streak Defects on Anodized Aluminum Extrusions: An Overview

    NASA Astrophysics Data System (ADS)

    Zhu, Hanliang; Couper, Malcolm J.; Dahle, Arne K.

    2012-04-01

    Streak defects are often present on anodized extrusions of 6xxx series aluminum alloys, increasing the fabrication cost of these products. Moreover, streaking often only becomes visible after etching and anodizing treatments, rather than in the as-extruded condition, making it difficult to identify the original causes and influencing factors of these defects. In this paper, various process variables that influence the formation of streak defects on anodized aluminium extrusions are reviewed on the basis of a literature review, industrial practice and experimental results. The influencing factors involved in various processing steps such as billet quality, extrusion process, die design and etching process are considered. Effective measures for preventing the formation of streak defects in industrial extrusion products are discussed.

  16. Selection of thermodynamic data for a novel carbothermic smelting process for aluminum

    NASA Astrophysics Data System (ADS)

    Sayad-Yaghoubi, Y.

    2011-05-01

    For the carbothermic production of aluminum, thermodynamic data are required for the condensed compounds and gas phase involved in the Al2O3-C or Al2O3-Al4C3 systems. The data for Al2O3(s, l), Al4C3(s), CO(g), C(s, g), Al(s, l, g), Al2O(g) and AlO(g) in different databases is in accord. For a novel carbothermic aluminum smelting process, currently in development, the published JANAF Thermochemical Tables were selected for calculations. However, the JANAF Tables do not include data for oxycarbides. Thus a literature review was conducted. Data from different sources was collated and found to be in accord for Al4O4C over the 1,600-2,200 K temperature range. These data, together with the data from JANAF Tables, agree very well with the experimental results obtained during the carbothermic process. However, a commercially available computational thermodynamic software package called HSC provides results which contradict the experimental results obtained, while its thermodynamics data is also significantly different from other data available in the literature.

  17. Tribocorrosion Behavior of Aluminum/Alumina Composite Manufactured by Anodizing and ARB Processes

    NASA Astrophysics Data System (ADS)

    Jamaati, Roohollah; Toroghinejad, Mohammad Reza; Szpunar, Jerzy A.; Li, Duanjie

    2011-12-01

    In the present work, tribocorrosion behavior of Al/Al2O3 composite strips manufactured by anodizing and accumulative roll bonding (ARB) processes was investigated. The alumina quantity was 0.48, 1.13, and 3.55 vol.% in the aluminum matrix. Tribocorrosion experiments were conducted using a ball-on-plate tribometer, where the sliding contact was fully immersed in 1 wt.% NaCl solution. The composite sample served as a working electrode and its open circuit potential (OCP) was monitored before, during, and after sliding. In order to characterize the electrochemical behavior of the surface before and after sliding electrochemical impedance spectroscopy (EIS) was used and wear was also measured. Furthermore, the influence of quantity and distribution of reinforcement particles in the matrix on OCP and EIS was evaluated. It was found that the quantity, shape, size, and dispersion of alumina particles in the aluminum matrix strongly affected the measured tribocorrosion characteristics. The results showed that inhomogeneous, lower quantity, fine, and acicular-shape alumina particles cause serious materials loss in tribocorrosion process.

  18. Effect of temperature on the anodizing process of aluminum alloy AA 5052

    NASA Astrophysics Data System (ADS)

    Theohari, S.; Kontogeorgou, Ch.

    2013-11-01

    The effect of temperature (10-40 °C) during the anodizing process of AA 5052 for 40 min in 175 g/L sulfuric acid solution at constant voltage (15 V) was studied in comparison with pure aluminum. The incorporated magnesium species in the barrier layer result in the further increase of the minimum current density passed during anodizing, as the temperature increases, by about 42% up to 30 °C and then by 12% up to 40 °C. Then during the anodizing process for 40 min a blocking effect on oxide film growth was gradually observed as the temperature increased until 30 °C. The results of EDAX analysis on thick films reveal that the mean amount of the magnesium species inside the film is about 50-70% less than that in the bulk alloy, while it is higher at certain locations adjacent to the film surface at 30 °C. The increase of anodizing temperature does not influence the porosity of thin films (formed for short times) on pure aluminum, while it reduces it on the alloy. At 40 °C the above mentioned blocking effects disappear. It means that the presence of magnesium species causes an impediment to the effect of temperature on iss, on the film thickness and on the porosity of thin films, only under conditions where film growth takes place without significant loss of the anodizing charge to side reactions.

  19. Effects of chloride ions on electro-coagulation-flotation process with aluminum electrodes for algae removal.

    PubMed

    Gao, Shanshan; Du, Maoan; Tian, Jiayu; Yang, Jianyu; Yang, Jixian; Ma, Fang; Nan, Jun

    2010-10-15

    Electro-coagulation-flotation (ECF) is one of the most promising technologies that offers an attractive alternative to conventional coagulation and flotation. In this study, the effectiveness and mechanisms of algae removal by ECF process using aluminum electrodes was investigated in the presence of Cl(-) ions. The results showed that the addition of Cl(-) ions (1.0, 3.0, 5.0 and 8.0 mM) had a promoting effect on the algae removal in terms of both the cell density and chlorophyll-a, which could be attributed to the following two reasons. Firstly, active chlorine could be generated in the ECF when Cl(-) ions were present. The electrochemically generated active chlorine was demonstrated to be effective for the inactivation of algae cells with the aid of the electric field in the ECF. Secondly, the Cl(-) ions in the algae solution could enhance the release of Al(3+) from the aluminum electrodes in the ECF. Through SEM-EDX analysis, pitting corrosion and alleviated formation of oxide film by Cl(-) ions were observed on the anode surface. When considering that Cl(-) ions are universally present in natural waters, the effects of Cl(-) on ECF process for algae removal are of great significance. PMID:20667652

  20. Copper-Carbon and Aluminum-Carbon Composites Fabricated by Powder Metallurgy Processes

    NASA Astrophysics Data System (ADS)

    Silvain, Jean-François; Veillère, Amélie; Lu, Yongfeng

    2014-07-01

    The increase in both power and packing densities in power electronic devices has led to an increase in the market demand for effective heat-dissipating materials, with high thermal conductivity and thermal- expansion coefficient compatible with chip materials still ensuring the reliability of the power modules. In this context, metal matrix composites: carbon fibers and diamond-reinforced copper and aluminum matrix composites among them are considered very promising as a next generation of thermal-management materials in power electronic packages. These composites exhibit enhanced thermal properties compared to pure copper combined with lower density. This article presents the fabrication techniques of copper/carbon fibers and copper/diamond and aluminum/carbon fibers composite films by powder metallurgy and hot pressing. The thermal analyses clearly indicate that interfacial treatments are required in these composites to achieve high thermomechanical properties. Interfaces (through novel chemical and processing methods), when selected carefully and processed properly will form the right chemical/mechanical link between metal and carbon, enhancing all the desired thermal properties while minimizing the deleterious effect.

  1. Processing, Dynamic Deformation and Fragmentation of Heterogeneous Materials (Aluminum-Tungsten Composites and Aluminum-Nickel Laminates)

    NASA Astrophysics Data System (ADS)

    Chiu, Po-Hsun

    Two types of heterogeneous reactive materials, Aluminum-Tungsten composites and Aluminum-Nickel laminates were investigated. The current interest in these materials is their ability to combine the high strength and energy output under critical condition of the mechanical deformation which may include their fragmentation. Mesoscale properties of reactive materials are very important for the generation of local hot spots to ignite reactions and generate critical size of debris suitable for fast oxidation kinetics. Samples with different mesostructures (e.g., coarse vs. fine W particles, bonded vs. non-bonded Al particles, W particles vs. W wires and concentric vs. corrugated Al-Ni laminates) were prepared by Cold Isostatic Pressing, Hot Isostatic Pressing and Swaging. Several dynamic tests were utilized including Split Hopkinson Pressure Bar, Drop Weight Test, Explosively Driven Fragmentation Test, and Thick-Walled Cylinder Method. A high speed camera was used to record images of the in situ behavior of materials under dynamic loading. Pre- and post-experiment analyses and characterization were done using Optical Microscopy, Scanning Electron Microscopy, X-ray Powder Diffraction, and Laser Diffraction. The numerical simulations were conducted to monitor the in situ dynamic behavior of materials and elucidate the mesoscale mechanisms of the plastic strain accommodation under high-strain, high-strain-rate conditions in investigated heterogeneous m aterials. Several interesting results should be specifically mentioned. They include observation that the fracture and dynamic properties of the Al-W composites are sensitive to porosity of samples, particles sizes of rigid inclusions (W particles or wires), and bonding strength between Al particles in the matrix. Soft Al particles were heavily deformed between the rigid W particles/wires during dynamic tests. Three plastic strain accommodation mechanisms are observed in Al-Ni laminates. They depend on the initial

  2. The development of a fluidized bed process for the heat treatment of aluminum alloys

    NASA Astrophysics Data System (ADS)

    Keist, Jay

    2005-04-01

    Heat treating of aluminum alloys is often necessary to achieve the mechanical properties required for a part. With conventional furnaces, though, the heat-treating process requires several hours and manufacturers have traditionally utilized off-line, batch heat-treating operations. The long cycle times required for heat treating with conventional systems go contrary to lean manufacturing where the goal is to reduce the time a part spends in the factory. The fluidized bed technology offers rapid heating rates and excellent temperature control that allows one to significantly reduce the time required for heat treating by an order of magnitude. Technomics developed a fluidized bed conveying system that allows the manufacturer to bring the heat-treating system in-line with the casting or forging operation, obtaining a true lean manufacturing process.

  3. Butt Welding Joint of Aluminum Alloy by Space GHTA Welding Process in Vacuum

    NASA Astrophysics Data System (ADS)

    Suita, Yoshikazu; Shinike, Shuhei; Ekuni, Tomohide; Terajima, Noboru; Tsukuda, Yoshiyuki; Imagawa, Kichiro

    Aluminum alloys have been used widely in constructing various space structures including the International Space Station (ISS) and launch vehicles. For space applications, welding experiments on aluminum alloy were performed using the GHTA (Gas Hollow Tungsten Arc) welding process using a filler wire feeder in a vacuum. We investigated the melting phenomenon of the base metal and filler wire, bead formation, and the effects of wire feed speed on melting characteristics. The melting mechanism in the base metal during the bead on a plate with wire feed was similar to that for the melt run without wire feed. We clarified the effects of wire feed speed on bead sizes and configurations. Furthermore, the butt welded joint welded using the optimum wire feed speed, and the joint tensile strengths were evaluated. The tensile strength of the square butt joint welded by the pulsed DC GHTA welding with wire feed in a vacuum is nearly equal to that of the same joint welded by conventional GTA (Gas Tungsten Arc) welding in air.

  4. Effect of Processing Parameters on Pore Structure and Thickness of Anodic Aluminum Oxide (AAO) Tubular Membranes.

    PubMed

    Belwalkar, A; Grasing, E; Van Geertruyden, W; Huang, Z; Misiolek, W Z

    2008-07-01

    Nanoporous anodic aluminum oxide (AAO) tubular membranes were fabricated from aluminum alloy tubes in sulfuric and oxalic acid electrolytes using a two-step anodization process. The membranes were investigated for characteristics such as pore size, interpore distance and thickness by varying applied voltage and electrolyte concentration. Morphology of the membranes was examined using light optical and scanning electron microscopy and characterized using ImageJ software. Results showed that membranes having narrow pore size and uniform pore distribution with parallel channel arrays were obtained. The pore sizes were ranging from 14 to 24 nm and the wall thicknesses as high as 76 microm. It was found that the pore size increased in direct proportion with the applied voltage and inversely with the electrolyte concentration while the interpore distance increased linearly with the applied voltage. It was also observed that increase in acid concentration increased tubular membrane wall thickness that improved mechanical handling. By using anodic alumina technology, robust ceramic tubes with uniformly distributed pore-structure and parallel nano-channels of lengths and sizes practical for industrial applications were reliably produced in quantity. PMID:19578471

  5. Effect of Processing Parameters on Pore Structure and Thickness of Anodic Aluminum Oxide (AAO) Tubular Membranes

    PubMed Central

    Belwalkar, A.; Grasing, E.; Huang, Z.; Misiolek, W.Z.

    2008-01-01

    Nanoporous anodic aluminum oxide (AAO) tubular membranes were fabricated from aluminum alloy tubes in sulfuric and oxalic acid electrolytes using a two-step anodization process. The membranes were investigated for characteristics such as pore size, interpore distance and thickness by varying applied voltage and electrolyte concentration. Morphology of the membranes was examined using light optical and scanning electron microscopy and characterized using ImageJ software. Results showed that membranes having narrow pore size and uniform pore distribution with parallel channel arrays were obtained. The pore sizes were ranging from 14 to 24 nm and the wall thicknesses as high as 76 µm. It was found that the pore size increased in direct proportion with the applied voltage and inversely with the electrolyte concentration while the interpore distance increased linearly with the applied voltage. It was also observed that increase in acid concentration increased tubular membrane wall thickness that improved mechanical handling. By using anodic alumina technology, robust ceramic tubes with uniformly distributed pore-structure and parallel nano-channels of lengths and sizes practical for industrial applications were reliably produced in quantity. PMID:19578471

  6. Effects of Processing Parameters on the Fabrication of Copper Cladding Aluminum Rods by Horizontal Core-Filling Continuous Casting

    NASA Astrophysics Data System (ADS)

    Su, Ya-Jun; Liu, Xin-Hua; Huang, Hai-You; Wu, Chun-Jing; Liu, Xue-Feng; Xie, Jian-Xin

    2011-02-01

    Copper cladding aluminum (CCA) rods with a diameter of 30 mm and a sheath thickness of 3 mm were fabricated by horizontal core-filling continuous casting (HCFC) technology. The effects of key processing parameters, such as the length of the mandrel tube of composite mold, aluminum casting temperature, flux of the secondary cooling water, and mean withdrawing speed were optimized based on some quality criteria, including the uniformity of the sheath thickness, integrality of the rods, and thickness of the interface. The causes of internal flaws formation of CCA rods were also discussed. The results showed that the continuity of the liquid aluminum core-filling process and the interface reaction control between solid copper and liquid aluminum were two key problems that strongly affected the stability of the casting process and the product quality. Our research indicated that for the CCA rod with the previously mentioned size, the optimal length of mandrel tube was 210 mm. A shorter mandrel tube allowed of easier erosion at the interface, which led to a nonuniform sheath thickness. Conversely, it tended to result in a discontinuous filling process of liquid aluminum, which causes shrinkage or cold shuts. The optimal casting temperatures of copper and aluminum were 1503 K (1230 °C) and 1043 K to 1123 K (770 °C to 850 °C), respectively. When the casting temperature of aluminum was below 1043 K (770 °C), the casting process would be discontinuous, resulting in shrinkages or cold shuts. Nevertheless, when the casting temperature of aluminum was higher than 1123 K (850 °C), a severe interface reaction between solid copper and liquid aluminum would occur. The proper flux of the secondary cooling water and the mean withdrawing speed were determined as 600 to 800 L/h and 60 to 87 mm/min, respectively. In the previously mentioned proper ranges of processing parameters, the interfacial shear strengths of CCA rods were 40.5 to 67.9 MPa.

  7. Processing and Characterizing Alumina/Aluminum Composites with Tailored Microstructures Formed by Reactive Metal Penetration

    SciTech Connect

    Corral, E.; Ellerby, D.; Ewsuk, K.; Fahrenholtz, B.; Loehman, R.

    1999-01-28

    In industry, the need to maximize energy efficiency depends on the availability of suitable advanced materials. Ceramic composites are exemplary materials for many advanced engineering applications because they exhibit good thermal stability, oxidation resistance and enhanced toughness. Presently, ceramic composite fabrication processes are costly, often requiring high temperatures and pressures to achieve reasonable densities. Our research is focused on developing a processing technique, that will allow production of alumina/aluminum composites using relatively low temperatures and without the application of an external force, thus reducing the processing costs. Our composites were formed using Reactive Metal Penetration (RMP), which is a process involving the reaction of molten Al with a dense ceramic preform. The result is a near net shape ceramic/metal composite with interpenetrating phases. The volume fraction of metal in the composites was varied by doping an aluminosilicate ceramic preform with silica. For this study we fabricated composites using pure mullite and mullite doped with 23 and 42 weight percent silica, yielding 18, 25, and 30 volume percent metal in the composites, respectively. Optical and Scanning Electron Microscopy were used to characterize the homogeneity and scale of the microstructure. The scale of the microstructure varied with preform composition, the reaction temperature and with secondary heat treatments. Four-point bend testing was used to evaluate the influence of microstructure on strength and reliability. During these studies a gradient in the microstructure was observed, which we further characterized using microhardness testing. Alumina/aluminum composites formed by RMP show higher toughness then monolithic alumina and have the potential for improved reliability when compared to monolithic ceramics.

  8. Characterization of aluminum hydroxide particles from the Bayer process using neural network and Bayesian classifiers.

    PubMed

    Zaknich, A

    1997-01-01

    An automatic process of isolating and characterizing individual aluminum hydroxide particles from the Bayer process in scanning electron microscope gray-scale images of samples is described. It uses image processing algorithms, neural nets and Bayesian classifiers. As the particles are amorphous and different greatly, there were complex nonlinear decisions and anomalies. The process is in two stages; isolation of particles, and classification of each particle. The isolation process correctly identifies 96.9% of the objects as complete and single particles after a 15.5% rejection of questionable objects. The sample set had a possible 2455 particles taken from 384 256x256-pixel images. Of the 15.5%, 14.2% were correctly rejected. With no rejection the accuracy drops to 91.8% which represents the accuracy of the isolation process alone. The isolated particles are classified by shape, single crystal protrusions, texture, crystal size, and agglomeration. The particle samples were preclassified by a human expert and the data were used to train the five classifiers to embody the expert knowledge. The system was designed to be used as a research tool to determine and study relationships between particle properties and plant parameters in the production of smelting grade alumina by the Bayer process. PMID:18255695

  9. Development of Aluminum-Lithium 2195 Gores by the Stretch Forming Process

    NASA Technical Reports Server (NTRS)

    Volz, M. P.; Chen, P. S.; Gorti, S.; Salvail, P.

    2014-01-01

    Aluminum-Lithium alloy 2195 exhibits higher mechanical properties and lower density than aluminum alloy 2219, which is the current baseline material for Space Launch System (SLS) cryogenic tank components. Replacement of Al 2219 with Al-Li 2195 would result in substantial weight savings, as was the case when this replacement was made on the shuttle external tank. A key component of cryogenic tanks are the gores, which are welded together to make the rounded ends of the tanks. The required thicknesses of these gores depend on the specific SLS configuration and may exceed the current experience base in the manufacture of such gores by the stretch forming process. Here we describe the steps taken to enhance the formability of Al-Li 2195 by optimizing the heat treatment and stretch forming processes for gore thicknesses up to 0.75", which envelopes the maximum expected gore thicknesses for SLS tanks. An annealing treatment, developed at Marshall Space Flight Center, increased the forming range and strain hardening exponent of Al-Li 2195 plates. Using this annealing treatment, one 0.525" thick and two 0.75" thick gores were manufactured by the stretch forming process. The annealing treatment enabled the stretch forming of the largest ever cross sectional area (thickness x width) of an Al-Li 2195 plate achieved by the manufacturer. Mechanical testing of the gores showed greater than expected ultimate tensile strength, yield strength, modulus, and elongation values. The gores also exhibited acceptable fracture toughness at room and LN2 temperatures. All of the measured data indicate that the stretch formed gores have sufficient material properties to be used in flight domes.

  10. Investigation of Aluminum Site Changes of Dehydrated Zeolite H-Beta during a Rehydration Process by High Field Solid State NMR

    SciTech Connect

    Zhao, Zhenchao; Xu, Suochang; Hu, Mary Y.; Bao, Xinhe; Peden, Charles HF; Hu, Jian Z.

    2015-01-22

    Aluminum site changes for dehydrated H-Beta zeolite during rehydration process are systematically investigated by ²⁷Al MAS and MQ MAS NMR at high magnetic fields up to 19.9 T. Benefiting from the high magnetic field, more detailed information is obtained from the considerably broadened and overlapped spectra of dehydrated H-beta zeolite. Dynamic changes of aluminum sites are demonstrated during rehydration process. In completely dehydrated H-Beta, invisible aluminum can reach 29%. The strength of quadrupole interactions for framework aluminum sites decreases gradually during water adsorption processes. The number of extra-framework aluminum (EFAL) species, i.e., penta- (34 ppm) and octa- (4 ppm) coordinated aluminum atoms rises initially with increasing water adsorption, and finally change into either tetra-coordinated framework or extra-framework aluminum in saturated water adsorption samples, with the remaining octa-coordinated aluminum lying at 0 and -4 ppm, respectively. Quantitative ²⁷Al MAS NMR analysis combined with ¹H MAS NMR indicates that some active EFAL species formed during calcination can reinsert into the framework during this hydration process. The assignment of aluminum at 0 ppm to EFAL cation and -4 ppm to framework aluminum is clarified for H-Beta zeolite.

  11. Microstructure characterization of the stir zone of submerged friction stir processed aluminum alloy 2219

    SciTech Connect

    Feng, Xiuli; Liu, Huijie; Lippold, John C.

    2013-08-15

    Aluminum alloy 2219-T6 was friction stir processed using a novel submerged processing technique to facilitate cooling. Processing was conducted at a constant tool traverse speed of 200 mm/min and spindle rotation speeds in the range from 600 to 800 rpm. The microstructural characteristics of the base metal and processed zone, including grain structure and precipitation behavior, were studied using optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Microhardness maps were constructed on polished cross sections of as-processed samples. The effect of tool rotation speed on the microstructure and hardness of the stir zone was investigated. The average grain size of the stir zone was much smaller than that of the base metal, but the hardness was also lower due to the formation of equilibrium θ precipitates from the base metal θ′ precipitates. Stir zone hardness was found to decrease with increasing rotation speed (heat input). The effect of processing conditions on strength (hardness) was rationalized based on the competition between grain refinement strengthening and softening due to precipitate overaging. - Highlights: • SZ grain size (∼ 1 μm) is reduced by over one order of magnitude relative to the BM. • Hardness in the SZ is lower than that of the precipitation strengthened BM. • Metastable θ′ in the base metal transforms to equilibrium θ in the stir zone. • Softening in the SZ results from a decrease of precipitation strengthening.

  12. Numerical Simulation and Experimental Characterization of a Binary Aluminum Alloy Spray - Application to the Spray Rolling Process

    SciTech Connect

    S. B. Johnson; J.-P. Delplanque; Y. Lin; Y. Zhou; E. J. Lavernia; K. M. McHugh

    2005-02-01

    A stochastic, droplet-resolved model has been developed to describe the behavior of a binary aluminum alloy spray during the spray-rolling process. In this process, a molten aluminum alloy is atomized and the resulting spray is depostied on the rolls of a twin-roll caster to produce aluminum strip. The one-way coupled spray model allows the prediction of spray characteristics such as enthalph and solid fraction, and their distribution between the nozzle and the depostion surface. This paper outlines the model development and compares the predicted spray dynamics to PDI measurements performed in a controlled configuration. Predicted and measured droplet velocity and size distributions are presented for two points along the spray centerline along with predicted spray averaged specific enthalph and solid fraction curves.

  13. Tension-Compression Asymmetry of Creep and Unilateral Creep Damage in Aluminum for Isothermal and Nonisothermal Processes

    NASA Astrophysics Data System (ADS)

    Zolochevsky, Alexander; Obataya, Yoichi

    A constitutive model is proposed to describe the damage development in aluminum alloys under creep conditions for both isothermal and nonisothermal processes. Special emphasis is laid on four specific phenomena: tension-compression asymmetry of creep, damage induced anisotropy, unilateral creep damage and damage deactivation. Within the framework of the phenomenological approach in the Continuum Damage Mechanics, the nonlinear tensor constitutive equation for creep deformation and damage evolution equation are proposed to account for different orientation of microcracks in aluminum alloys under tensile and compressive loading types. After a determination of the material parameters in the obtained constitutive equation and damage growth equation, the proposed model is applied to the describing creep behavior of the aluminum alloy under uniaxial nonproportional and multiaxial nonproportional loading for both isothermal and nonisothermal processes.

  14. Processing and properties of chromate-free conversion coatings on aluminum

    SciTech Connect

    Buchheit, R.G.; Drewien, C.A.; Martinez, M.A.; Stoner, G.E.

    1994-12-31

    A conversion coating method has been developed based on precipitation of Li{sub 2}[Al{sub 2}(OH){sub 6}]{sub 2}{center_dot}CO{sub 3}{center_dot}3H{sub 2}O from alkaline lithium salt solutions. The process is procedurally similar to chromate conversion coating but does not use or produce hazardous chemicals. The coating that forms is polycrystalline, continuous and conformal. The coating meets the MIL-C-5541E corrosion resistance, electrical contact resistance and paint adhesion requirements for certain aluminum alloys, but does not match the levels of performance exhibited by chromate conversion coatings. In this paper, methods for producing the coating are described. Corrosion resistance has been characterized using electrochemical impedance spectroscopy and salt spray exposure. The structural, compositional and property changes attending post-coating thermal exposure are discussed. Performance in standardized corrosion, electrical and paint adhesion tests is also presented.

  15. Structure and Hardness of 01570 Aluminum Alloy Friction Stir Welds Processed Under Different Conditions

    NASA Astrophysics Data System (ADS)

    Il'yasov, R. R.; Avtokratova, E. V.; Markushev, M. V.; Predko, P. Yu.; Konkevich, V. Yu.

    2015-10-01

    Structure and hardness of the 01570 aluminum alloy joints processed by friction stir welding at various speeds are investigated. It is shown that increasing the traverse tool speed lowers the probability of macrodefect formation in the nugget zone; however, this can lead to anomalous grain growth in the zone of contact with the tool shoulder. Typical "onion-like" structure of the weld consisting of rings that differ by optical contrast is formed for all examined welding regimes. It is demonstrated that this contrast is caused by the difference in the grain sizes in the rings rather than by their chemical or phase composition. Mechanisms of transformation of the alloy structure during friction stir welding are discussed.

  16. Experimental and analytical investigation of the fracture processes of boron/aluminum laminates containing notches

    NASA Technical Reports Server (NTRS)

    Johnson, W. S.; Bigelow, C. A.; Bahei-El-din, Y. A.

    1983-01-01

    Experimental results for five laminate orientations of boron/aluminum composites containing either circular holes or crack-like slits are presented. Specimen stress-strain behavior, stress at first fiber failure, and ultimate strength were determined. Radiographs were used to monitor the fracture process. The specimens were analyzed with a three-dimensional elastic-elastic finite-element model. The first fiber failures in notched specimens with laminate orientation occurred at or very near the specimen ultimate strength. For notched unidirectional specimens, the first fiber failure occurred at approximately one-half of the specimen ultimate strength. Acoustic emission events correlated with fiber breaks in unidirectional composites, but did not for other laminates. Circular holes and crack-like slits of the same characteristic length were found to produce approximately the same strength reduction. The predicted stress-strain responses and stress at first fiber failure compared very well with test data for laminates containing 0 deg fibers.

  17. How to avoid the `invisible gorilla' in aluminum smelting process control: Visual guidelines

    NASA Astrophysics Data System (ADS)

    Gao, Yashuang; Taylor, Mark P.; Chen, John J. J.; Hautus, Michael J.

    2011-08-01

    Over the last three decades, process control in aluminum smelters has improved significantly as it is the biggest leverage for cost and energy reduction in production and product quality improvement, as well as for meeting environmental compliance. The implementation of computerized automatic control systems two decades ago was a step change in improvement in the state of the art of process control. However, the complex and dynamic nature of the process requires human monitoring, diagnosis, and intervention from time to time. This study investigates the use of the supervisory screen of the control system of a smelter, as well as the effectiveness of visual guidelines to help the operators to identify process abnormalities. The results show that visual guidelines such as voltage patterns which are used as a reference improve the performance of the operators. Detection time and falsealarm rates were reduced in addition to increasing detection sensitivities. It is proposed that a higher level of human and system interaction would improve the overall performance process control.

  18. A Highly Controllable Electrochemical Anodization Process to Fabricate Porous Anodic Aluminum Oxide Membranes

    NASA Astrophysics Data System (ADS)

    Lin, Yuanjing; Lin, Qingfeng; Liu, Xue; Gao, Yuan; He, Jin; Wang, Wenli; Fan, Zhiyong

    2015-12-01

    Due to the broad applications of porous alumina nanostructures, research on fabrication of anodized aluminum oxide (AAO) with nanoporous structure has triggered enormous attention. While fabrication of highly ordered nanoporous AAO with tunable geometric features has been widely reported, it is known that its growth rate can be easily affected by the fluctuation of process conditions such as acid concentration and temperature during electrochemical anodization process. To fabricate AAO with various geometric parameters, particularly, to realize precise control over pore depth for scientific research and commercial applications, a controllable fabrication process is essential. In this work, we revealed a linear correlation between the integrated electric charge flow throughout the circuit in the stable anodization process and the growth thickness of AAO membranes. With this understanding, we developed a facile approach to precisely control the growth process of the membranes. It was found that this approach is applicable in a large voltage range, and it may be extended to anodization of other metal materials such as Ti as well.

  19. Wear characteristics of severely deformed aluminum sheets by accumulative roll bonding (ARB) process

    SciTech Connect

    Talachi, A. Kazemi; Eizadjou, M. Manesh, H. Danesh; Janghorban, K.

    2011-01-15

    Wear behavior of severely deformed aluminum sheets by accumulative roll bonding (ARB) process was characterized using a pin on disc wear machine at different conditions. The sheets were processed up to eight ARB cycles in order to induce a high strain ({approx} 6.4) to the samples. EBSD results showed that after eight cycles of ARB, sheets were found to contain ultrafine grains with high fraction of high angle grain boundaries. Wear experiments were conducted under different loading and operating conditions, including dry and immersion lubrication, and rotation speeds. Wear was continuously monitored by measuring the wear rates and morphologies of worn surfaces by scanning electron microscope (SEM). Contrary to expectation, the wear resistance of the ARBed Al sheets was less than the non-processed sheets. Wear rates of the ARBed Al sheets increased by increasing wear load and rotation speed, while, immersion lubrication decreased the wear rate significantly. Based on the observation and results, a model for the wear of the ARBed Al was proposed. - Research Highlights: {yields}The wear rate of the ARBed Al was higher than that of the non-processed alloy. {yields}This unexpected behavior was related to the low strain hardening capability and evolution of the ARB subsurface microstructure during the wear process. {yields}Sliding wear of the ARBed Al proceeded by surface deformation, and progressed by delamination of the deformed surface layer. {yields}The wear rate of ARBed Al increased by increasing applied load and sliding speed.

  20. A Highly Controllable Electrochemical Anodization Process to Fabricate Porous Anodic Aluminum Oxide Membranes.

    PubMed

    Lin, Yuanjing; Lin, Qingfeng; Liu, Xue; Gao, Yuan; He, Jin; Wang, Wenli; Fan, Zhiyong

    2015-12-01

    Due to the broad applications of porous alumina nanostructures, research on fabrication of anodized aluminum oxide (AAO) with nanoporous structure has triggered enormous attention. While fabrication of highly ordered nanoporous AAO with tunable geometric features has been widely reported, it is known that its growth rate can be easily affected by the fluctuation of process conditions such as acid concentration and temperature during electrochemical anodization process. To fabricate AAO with various geometric parameters, particularly, to realize precise control over pore depth for scientific research and commercial applications, a controllable fabrication process is essential. In this work, we revealed a linear correlation between the integrated electric charge flow throughout the circuit in the stable anodization process and the growth thickness of AAO membranes. With this understanding, we developed a facile approach to precisely control the growth process of the membranes. It was found that this approach is applicable in a large voltage range, and it may be extended to anodization of other metal materials such as Ti as well. PMID:26706687

  1. Development of an Optimization Methodology for the Aluminum Alloy Wheel Casting Process

    NASA Astrophysics Data System (ADS)

    Duan, Jianglan; Reilly, Carl; Maijer, Daan M.; Cockcroft, Steve L.; Phillion, Andre B.

    2015-08-01

    An optimization methodology has been developed for the aluminum alloy wheel casting process. The methodology is focused on improving the timing of cooling processes in a die to achieve improved casting quality. This methodology utilizes (1) a casting process model, which was developed within the commercial finite element package, ABAQUS™—ABAQUS is a trademark of Dassault Systèms; (2) a Python-based results extraction procedure; and (3) a numerical optimization module from the open-source Python library, Scipy. To achieve optimal casting quality, a set of constraints have been defined to ensure directional solidification, and an objective function, based on the solidification cooling rates, has been defined to either maximize, or target a specific, cooling rate. The methodology has been applied to a series of casting and die geometries with different cooling system configurations, including a 2-D axisymmetric wheel and die assembly generated from a full-scale prototype wheel. The results show that, with properly defined constraint and objective functions, solidification conditions can be improved and optimal cooling conditions can be achieved leading to process productivity and product quality improvements.

  2. Advanced Process Heater for the Steel, Aluminum and Chemical Industries of the Future

    SciTech Connect

    Thomas D. Briselden

    2007-10-31

    The Roadmap for Process Heating Technology (March 16, 2001), identified the following priority R&D needs: “Improved performance of high temperature materials; improved methods for stabilizing low emission flames; heating technologies that simultaneously reduce emissions, increase efficiency, and increase heat transfer”. Radiant tubes are used in almost every industry of the future. Examples include Aluminum re-heat furnaces; Steel strip annealing furnaces, Petroleum cracking/ refining furnaces, Metal Casting/Heat Treating in atmosphere and fluidized bed furnaces, Glass lair annealing furnaces, Forest Products infrared paper driers, Chemical heat exchangers and immersion heaters, and the indirect grain driers in the Agriculture Industry. Several common needs among the industries are evident: (1) Energy Reductions, (2) Productivity Improvements, (3) Zero Emissions, and (4) Increased Component Life. The Category I award entitled “Proof of Concept of an Advanced Process Heater (APH) for Steel, Aluminum, and Petroleum Industries of the Future” met the technical feasibility goals of: (1) doubling the heat transfer rates (2) improving thermal efficiencies by 20%, (3) improving temperature uniformity by 100oF (38 oC) and (4) simultaneously reducing NOx and CO2 emissions. The APH addresses EERE’s primary mission of increasing efficiency/reducing fuel usage in energy intensive industries. The primary goal of this project was to design, manufacture and test a commercial APH prototype by integrating three components: (1) Helical Heat Exchanger, (2) Shared Wall Radiant U-tube, and (3) Helical Flame Stabilization Element. To accomplish the above, a near net shape powder ceramic Si-SiC low-cost forming process was used to manufacture the components. The project defined the methods for making an Advanced Process Heater that produced an efficiency between 70% to 80% with temperature uniformities of less than 5oF/ft (9oC/m). Three spin-off products resulted from this

  3. Process for Producing a Cast Article from a Hypereutectic Aluminum-Silicon Alloy

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A. (Inventor); Chen, Po-Shou (Inventor)

    2003-01-01

    A process for making a cast article from an aluminum alloy includes first casting an article from an alloy having the following composition, in weight percent: Silicon (Si) 14.0-25.0, Copper (CU) 5.5-8.0, Iron (Fe) 0-0.8, Magnesium (Mg) 0.5-1.5, Nickel (Ni) 0.05-1.2, Manganese (Mn) 0-1.0, Titanium (Ti) 0.05-1.2, Zirconium (Zr) 0.12-1.2, Vanadium (V) 0.05-1.2, Zinc (Zn) 0-0.9, Phosphorus (P) 0.001-0.1, Aluminum, balance. In this alloy the ration of Si:Mg is 15-35, and the ratio of Cu:Mg is 4-15. After an article is cast from the alloy, the cast article is aged at a temperature within the range of 400 F to 500 F for a time period within the range of four to 16 hours. It has been found especially advantageous if the cast article is first exposed to a solutionizing step prior to the aging step. This solutionizing step is carried out by exposing the cast article to a temperature within the range of 875 F to 1025 F for a time period of fifteen minutes to four hours. It has also been found to be especially advantageous if the solutionizing step is followed directly with a quenching step, wherein the cast article is quenched in a quenching medium such as water at a temperature within the range of 120 F to 300 F. The resulting cast article is highly suitable in a number of high temperature applications, such as heavy-duty pistons for internal combustion engines.

  4. Self-supported aluminum thin films produced by vacuum deposition process

    NASA Technical Reports Server (NTRS)

    Neff, J. E.; Timme, R. W.

    1966-01-01

    Self-supported aluminum thin film is produced by vacuum depositing the film on a polyvinyl formal resin film and then removing the resin by radiant heating in the vacuum. The aluminum film can be used as soon as the resin is eliminated.

  5. Effect of processing parameters on the corrosion behaviour of friction stir processed AA 2219 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Surekha, K.; Murty, B. S.; Prasad Rao, K.

    2009-04-01

    The effect of processing parameters (rotation speed and traverse speed) on the corrosion behaviour of friction stir processed high strength precipitation hardenable AA 2219-T87 alloy was investigated. The results indicate that the rotation speed has a major influence in determining the rate of corrosion, which is attributed to the breaking down and dissolution of the intermetallic particles. Corrosion resistance of friction stir processed alloy was studied by potentiodynamic polarization, electrochemical impedance spectroscopy, salt spray and immersion tests.

  6. Functionally Graded Aluminum Foam Fabricated by Friction Powder Sintering Process with Traversing Tool

    NASA Astrophysics Data System (ADS)

    Hangai, Yoshihiko; Morita, Tomoaki; Koyama, Shinji; Kuwazuru, Osamu; Yoshikawa, Nobuhiro

    2016-07-01

    Functionally graded aluminum foam (FG Al foam) is a new class of Al foam in which the pore structure varies over the foam, resulting in corresponding variations in the mechanical properties of the foam. In this study, FG Al foam plates were fabricated by a friction powder sintering (FPS) process with a traversing tool that is based on a previously developed sintering and dissolution process. The variation of the mechanical properties was realized by setting the volume fraction φ of NaCl in the mixture to 60, 70, and 80%. Long FG Al foam plates were fabricated with a length equal to the tool traversing length with φ varying in the tool traversing direction. From x-ray computed tomography observation, it was shown that the density of the Al foam decreased with increasing φ. In contrast, almost uniform pore structures were obtained in each area. According to the results of compression tests on each area, the plateau stress and energy absorption tended to decrease with increasing φ. Therefore, it was shown that FG Al foam plates with varying mechanical properties can be fabricated by the FPS process with the traversing tool.

  7. Fluxless Tin and␣Silver-Indium Bonding Processes for␣Silicon onto␣Aluminum

    NASA Astrophysics Data System (ADS)

    Lee, Chin C.; Hsu, Shou-Jen; Wu, Yuan-Yun

    2014-01-01

    The high thermal conductivity, light weight, and low cost of aluminum (Al) make it a promising material for use in high-power electronic packaging. The challenges are its high coefficient of thermal expansion (CTE) of 23 × 10-6/°C and difficulty in soldering. In this research, we surmounted these challenges by bonding large Si chips to Al boards using fluxless Sn and Ag-In processes, respectively. Despite the large CTE mismatch, the bonded structures were strong as determined by fracture force measured by shear test machine. The reference is the fracture force specified in MIL-STD-883H method 2019.8. The microstructure and composition of the joints were examined using scanning electron microscopy (SEM) and energy-dispersive x-ray (EDX) analysis. The resulting Sn joint is almost pure Sn with thin intermetallic layer. The Ag-In joint consists of Ag/(Ag)/Ag2In/(Ag)/Ag that has a melting temperature higher than 695°C even though the bonding process was performed at 180°C. These bonding processes are entirely fluxless. The fluxless feature greatly helps reduce voids in the joints, which in turn increases the joint strength. These preliminary but encouraging results should open up new applications of Al boards in electronic packaging where Al was avoided because of its high CTE and difficulty in bonding.

  8. Microstructure Analysis on 6061 Aluminum Alloy after Casting and Diffuses Annealing Process

    NASA Astrophysics Data System (ADS)

    Wang, H. Q.; Sun, W. L.; Xing, Y. Q.

    One factory using semi-continuous casting process produce the ф200×6000 mm 6061 aluminium alloy barstock, and then rotary forged for car wheels. 6061 distorting aluminium alloy is an forged aluminum alloy, and mainly containing Mg, Si, Cu and other alloying elements. The main strengthening phase is Mg2Si, and also has few phase of (FeMn) 3Si2Al15. In order to eliminate the segregation and separation which present in the crystal boundary, and make the distortion to be uniform, and does not present ear and fracture defects after the forging. So the 6061 distorting aluminium alloy adopt the diffusion annealing heat treatment before the forging process.According to the current conditions, we use the diffusion annealing which have the different heating temperature and different holding time.The best process we can obtain from the test which can improve the production efficiency and reduce the material waste, improve the mechanical properties, and eliminate the overheated film on the surface.Then,we using OM,SEM and EDS to analyse the microstructure and the chemical composition of compound between the surface and centre. The result shows that the amount of segregation were different in the surface and in the center, and the different diffusion annealing can cause the phase change in the surface and the center.

  9. Characterization of ironing in the hole-flanging process of an aluminum alloy

    NASA Astrophysics Data System (ADS)

    Kacem, A.; Krichen, A.; Manach, P. Y.

    2011-08-01

    Hole-flanging is a sheet metal forming process which is often used to produce a flange around holes. Many industrial applications require a longer flange that can be used for example to increase bearing surface or to increase the number of threads that will fit in a tapped hole. Ironing is usually used during such process to increase the flange height. Due to the thinning of the flange caused by edge stretching, some difficulties arise when trying to set a clearance value for which the process is performed with ironing. Therefore, the occurrence of ironing needs to be more clarified. It is also important to quantify the effect of ironing intensity in the flange geometry. In the present work, FE simulations and experiments are performed to investigate hole-flanging with and without ironing. For this purpose, hole-flanging is carried out by varying the clearance between the punch and the die while keeping constant the other parameters. The aim is to identify the occurrence of ironing by the determination of a limit between the hole-flanging with ironing and the hole-flanging without ironing. Attention is focused on studying the effect of the hole-flanging conditions on the punch load, the forming kinematics and the final shape. The experiments are carried out to check the FE results on an aluminum alloy.

  10. Carbothermic Aluminum Production Using Scrap Aluminum As A Coolant

    DOEpatents

    LaCamera, Alfred F.

    2002-11-05

    A process for producing aluminum metal by carbothermic reduction of alumina ore. Alumina ore is heated in the presence of carbon at an elevated temperature to produce an aluminum metal body contaminated with about 10-30% by wt. aluminum carbide. Aluminum metal or aluminum alloy scrap then is added to bring the temperature to about 900-1000.degree. C. and precipitate out aluminum carbide. The precipitated aluminum carbide is filtered, decanted, or fluxed with salt to form a molten body having reduced aluminum carbide content.

  11. Processing and response of aluminum-lithium alloy composites reinforced with copper-coated silicon carbide particulates

    SciTech Connect

    Khor, K.A.; Cao, Y.; Boey, F.Y.C.; Hanada, K.; Murakoshi, Y.; Sudarshan, T.S.; Srivatsan, T.S.

    1998-02-01

    Lithium-containing aluminum alloys have shown promise for demanding aerospace applications because of their light weight, high strength, and good damage tolerance characteristics. Additions of ceramic reinforcements to an aluminum-lithium alloy can significantly enhance specific strength, and specific modulus while concurrently offering acceptable performance at elevated temperatures. The processing and fabrication of aluminum-lithium alloy-based composites are hampered by particulate agglomeration or clustering and the existence of poor interfacial relationships between the reinforcing phase and the matrix. The problem of distribution of the reinforcing phase in the metal matrix can be alleviated by mechanical alloying. This article presents the results of a study aimed at addressing and improving the interfacial relationship between the host matrix and the reinforcing phase. Copper-coated silicon carbide particulates are introduced as the particulate reinforcing phase, and the resultant composite mixture is processed by conventional milling followed by hot pressing and hot extrusion. The influence of extrusion ration and extrusion temperature on microstructure and mechanical properties was established. Post extrusion processing by hot isostatic pressing was also examined. Results reveal the increase in elastic modulus of the aluminum-lithium alloy matrix reinforced with copper-coated SiC to be significantly more than the mechanically alloyed Al-Li/SiC counterpart. This suggests the possible contributions of interfacial strengthening on mechanical response in direct comparison with a uniform distribution of the reinforcing ceramic particulates.

  12. Ultrasonic Spot and Torsion Welding of Aluminum to Titanium Alloys: Process, Properties and Interfacial Microstructure

    NASA Astrophysics Data System (ADS)

    Balle, Frank; Magin, Jens

    Hybrid lightweight structures shape the development of future vehicles in traffic engineering and the aerospace industry. For multi-material concepts made out of aluminum and titanium alloys, the ultrasonic welding technique is an alternative effective joining technology. The overlapped structures can be welded in the solid state, even without gas shielding. In this paper the conventional ultrasonic spot welding with longitudinal oscillation mode is compared to the recent ultrasonic torsion welding with a torsional mode at 20 kHz working frequency. For each technique the process parameters welding force, welding energy and oscillation amplitude were optimized for the hybrid joints using design of experiments. Relationships between the process parameters, mechanical properties and related welding zone should be understood. Central aspects of the research project are microscopic studies of the joining zone in cross section and extensive fracture surface analysis. Detailed electron microscopy and spectroscopy of the hybrid interface help to understand the interfacial formation during ultrasonic welding as well as to transfer the gained knowledge for further multi-metal joints.

  13. Characteristics of aluminum and magnesium based nanocomposites processed using hybrid microwave sintering.

    PubMed

    Eugene, Wong Wai Leong; Gupta, Manoj

    2010-01-01

    Powder metallurgy is one of the highly established methods to synthesize metals, alloys and composites. Sintering is one of the important steps in powder metallurgy methodology and is usually realized through conventional resistance furnaces. The sintering usually takes a few hours to realize density in excess of 90%. The present study highlights the use of energy efficient and environment friendly microwave sintering route to synthesize pure aluminum, magnesium and magnesium based nanocomposites. Three reinforcements were targeted: a) silicon carbide, a microwave susceptor, b) alumina, a microwave transparent material and c) copper, a conducting material. Composites were prepared using blend - compact - microwave sintering - extrusion methodology. Process evaluation revealed that microwave assisted sintering can lead to a reduction of 86% in sintering time and energy savings of 96% when compared to conventional sintering. Moreover, microwave assisted sintering of metal compacts in this study was carried out in air, in the absence of any protective atmosphere, without compromising the mechanical properties of the materials. Results revealed that properties of magnesium can be convincingly enhanced using the said processing methodology and the materials formulations selected. Most importantly, the study established the viability of microwave sintering approach used in place of conventional sintering for magnesium based formulations. PMID:21721326

  14. Aluminum phosphide

    Integrated Risk Information System (IRIS)

    Aluminum phosphide ; CASRN 20859 - 73 - 8 Human health assessment information on a chemical substance is included in the IRIS database only after a comprehensive review of toxicity data , as outlined in the IRIS assessment development process . Sections I ( Health Hazard Assessments for Noncarcinoge

  15. Salt-soda sinter process for recovering aluminum from fly ash

    DOEpatents

    McDowell, William J.; Seeley, Forest G.

    1981-01-01

    A method for recovering aluminum values from fly ash comprises sintering the fly ash with a mixture of NaCl and Na.sub.2 CO.sub.3 to a temperature in the range 700.degree.-900.degree. C. for a period of time sufficient to convert greater than 90% of the aluminum content of the fly ash into an acid-soluble fraction and then contacting the thus-treated fraction with an aqueous solution of nitric or sulfuric acid to effect dissolution of aluminum and other metal values in said solution.

  16. Process development and fabrication of space station type aluminum-clad graphite epoxy struts

    NASA Technical Reports Server (NTRS)

    Ring, L. R.

    1990-01-01

    The manufacture of aluminum-clad graphite epoxy struts, designed for application to the Space Station truss structure, is described. The strut requirements are identified, and the strut material selection rationale is discussed. The manufacturing procedure is described, and shop documents describing the details are included. Dry graphite fiber, Pitch-75, is pulled between two concentric aluminum tubes. Epoxy resin is then injected and cured. After reduction of the aluminum wall thickness by chemical milling the end fittings are bonded on the tubes. A discussion of the characteristics of the manufactured struts, i.e., geometry, weight, and any anomalies of the individual struts is included.

  17. Salt-soda sinter process for recovering aluminum from fly ash

    DOEpatents

    McDowell, W.J.; Seeley, F.G.

    A method for recovering aluminum values from fly ash comprises sintering the fly ash with a mixture of NaCl and Na/sub 2/CO/sub 3/ to a temperature in the range 700/sup 0/ to 900/sup 0/C for a period of time sufficient to convert greater than 90% of the aluminum content of the fly ash into an acidsoluble fraction and then contacting the thus-treated fraction with an aqueous solution of nitric or sulfuric acid to effect dissolution of aluminum and other metal values in said solution.

  18. Processing of Silver-Implanted Aluminum Nitride for Energy Harvesting Devices

    NASA Astrophysics Data System (ADS)

    Alleyne, Fatima Sierre

    One of the more attractive sources of green energy has roots in the popular recycling theme of other green technologies, now known by the term "energy scavenging." In its most promising conformation, energy scavenging converts cyclic mechanical vibrations in the environment or random mechanical pressure pulses, caused by sources ranging from operating machinery to human footfalls, into electrical energy via piezoelectric transducers. While commercial piezoelectrics have evolved to favor lead zirconate titanate (PZT) for its combination of superior properties, the presence of lead in these ceramic compounds raises resistance to their application in anything "green" due to potential health implications during their manufacturing, recycling, or in-service application, if leaching occurs. Therefore in this study we have pursued the application of aluminum nitride (AlN) as a non-toxic alternative to PZT, seeking processing pathways to augment the modest piezoelectric performance of AlN and exploit its compatibility with complementary-metal-oxide semiconductor (CMOS) manufacturing. Such piezoelectric transducers have been categorized as microelectromechanical systems (MEMS), which despite more than a decade of research in this field, is plagued by delamination at the electrode/piezoelectric interface. Consequently the electric field essential to generate and sustain the piezoelectric response of these devices is lost, resulting in device failure. Working on the hypothesis that buried conducting layers can both mitigate the delamination problem and generate sufficient electric field to engage the operation of resonator devices, we have undertaken a study of silver ion implantation to experimentally assess its feasibility. As with most ion implantation procedures employed in semiconductor fabrication, the implanted sample is subjected to a thermal treatment, encouraging diffusion-assisted precipitation of the implanted species at high enough concentrations. The objective

  19. Processing of Silver-Implanted Aluminum Nitride for Energy Harvesting Devices

    NASA Astrophysics Data System (ADS)

    Alleyne, Fatima Sierre

    One of the more attractive sources of green energy has roots in the popular recycling theme of other green technologies, now known by the term "energy scavenging." In its most promising conformation, energy scavenging converts cyclic mechanical vibrations in the environment or random mechanical pressure pulses, caused by sources ranging from operating machinery to human footfalls, into electrical energy via piezoelectric transducers. While commercial piezoelectrics have evolved to favor lead zirconate titanate (PZT) for its combination of superior properties, the presence of lead in these ceramic compounds raises resistance to their application in anything "green" due to potential health implications during their manufacturing, recycling, or in-service application, if leaching occurs. Therefore in this study we have pursued the application of aluminum nitride (AlN) as a non-toxic alternative to PZT, seeking processing pathways to augment the modest piezoelectric performance of AlN and exploit its compatibility with complementary-metal-oxide semiconductor (CMOS) manufacturing. Such piezoelectric transducers have been categorized as microelectromechanical systems (MEMS), which despite more than a decade of research in this field, is plagued by delamination at the electrode/piezoelectric interface. Consequently the electric field essential to generate and sustain the piezoelectric response of these devices is lost, resulting in device failure. Working on the hypothesis that buried conducting layers can both mitigate the delamination problem and generate sufficient electric field to engage the operation of resonator devices, we have undertaken a study of silver ion implantation to experimentally assess its feasibility. As with most ion implantation procedures employed in semiconductor fabrication, the implanted sample is subjected to a thermal treatment, encouraging diffusion-assisted precipitation of the implanted species at high enough concentrations. The objective

  20. Finite Element Simulation of Plastic Joining Processes of Steel and Aluminum Alloy Sheets

    SciTech Connect

    Mori, K.; Abe, Y.; Kato, T.

    2007-05-17

    Various high tensile strength steel sheets and an aluminum alloy sheet were joined with a self-piercing rivet. It is not easy to weld the aluminum alloy sheet and high tensile strength sheets by means of conventional resistance welding because of very different melting points. To obtain optimum joining conditions, joining defects were categorized into separation of the sheets and an inner fracture. The joining range of ultra high tensile strength steel and aluminum alloy sheets was extended by means of dies optimized by finite element simulation. The joint strength is greatly influenced by not only the strength of the sheets and rivets but also the ratio of the thickness of the lower sheet to the total thickness. In addition, mechanical clinching of high strength steel and aluminum alloy sheets was simulated.

  1. Finite Element Simulation of Plastic Joining Processes of Steel and Aluminum Alloy Sheets

    NASA Astrophysics Data System (ADS)

    Mori, K.; Abe, Y.; Kato, T.

    2007-05-01

    Various high tensile strength steel sheets and an aluminum alloy sheet were joined with a self-piercing rivet. It is not easy to weld the aluminum alloy sheet and high tensile strength sheets by means of conventional resistance welding because of very different melting points. To obtain optimum joining conditions, joining defects were categorized into separation of the sheets and an inner fracture. The joining range of ultra high tensile strength steel and aluminum alloy sheets was extended by means of dies optimized by finite element simulation. The joint strength is greatly influenced by not only the strength of the sheets and rivets but also the ratio of the thickness of the lower sheet to the total thickness. In addition, mechanical clinching of high strength steel and aluminum alloy sheets was simulated.

  2. In-process oxidation protection in fluxless brazing or diffusion bonding of aluminum alloys

    NASA Technical Reports Server (NTRS)

    Okelly, K. P.; Featherston, A. B.

    1974-01-01

    Aluminum is cleaned of its oxide coating and is sealed immediately with polymeric material which makes it suitable for fluxless brazing or diffusion bonding. Time involved between cleaning and brazing is no longer critical factor.

  3. A correlation between salt spray and electrochemical impedance spectroscopy test results for conversion-coated aluminum alloys

    SciTech Connect

    Buchheit, R.G.; Cunningham, M.; Jensen, H.; Kendig, M.W.; Martinez, M.A.

    1998-01-01

    The corrosion resistance of 33 inorganic conversion coatings applied to five aluminum alloys was tested by salt spray exposure and electrochemical impedance spectroscopy (EIS). Results were evaluated to determine if a relationship existed. Individual salt spray test panels, with an area of 30 in.{sup 2} (194 cm{sup 2}), were inspected visually at regular intervals up to 168 h of exposure. At each inspection interval, panels were assigned a pass rank if <5 pits were observed, or a fail rank if >5 pits were observed. EIS data were analyzed using a simple equivalent circuit which yielded a coating resistance (R{sub c}), which was used as a figure of merit to assess coating performance. Examination of the data showed both tests could be sensitive discriminators of corrosion protection, but that EIS was more discriminating in the extremes of coating performance. Analysis showed the probability of achieving a passing salt spray result increased as R{sub c} increased. In the regimes where both tests were sensitive, regression analysis showed a linear relationship existed for each alloy substrate between the log of R{sub c} and the probability of a coating meeting the pass/fail criterion in salt spray. Based upon these relationships, threshold R{sub c} values were proposed to define the minimum value for which a given coating can be expected to attain a passing result in a 168-h salt spray test. These values were 2 {times} 10{sup 6} {Omega}-cm{sup 2} to 5 {times} 10{sup 6} {Omega}-cm{sup 2} for Al 356 (UNS A13560), Al 2024-T3 (UNS A92024), and Al 6061-T6 (UNS A96061); 1.5 {times} 10{sup 7} for Al 7075-T6 (UNS A97075); and 2.3 {times} 10{sup 6} {Omega}-cm{sup 2} for Al 3003 (UNS A93003).

  4. Multiscale Modeling of Damage Processes in Aluminum Alloys: Grain-Scale Mechanisms

    NASA Technical Reports Server (NTRS)

    Hochhalter, J. D.; Veilleux, M. G.; Bozek, J. E.; Glaessgen, E. H.; Ingraffea, A. R.

    2008-01-01

    This paper has two goals related to the development of a physically-grounded methodology for modeling the initial stages of fatigue crack growth in an aluminum alloy. The aluminum alloy, AA 7075-T651, is susceptible to fatigue cracking that nucleates from cracked second phase iron-bearing particles. Thus, the first goal of the paper is to validate an existing framework for the prediction of the conditions under which the particles crack. The observed statistics of particle cracking (defined as incubation for this alloy) must be accurately predicted to simulate the stochastic nature of microstructurally small fatigue crack (MSFC) formation. Also, only by simulating incubation of damage in a statistically accurate manner can subsequent stages of crack growth be accurately predicted. To maintain fidelity and computational efficiency, a filtering procedure was developed to eliminate particles that were unlikely to crack. The particle filter considers the distributions of particle sizes and shapes, grain texture, and the configuration of the surrounding grains. This filter helps substantially reduce the number of particles that need to be included in the microstructural models and forms the basis of the future work on the subsequent stages of MSFC, crack nucleation and microstructurally small crack propagation. A physics-based approach to simulating fracture should ultimately begin at nanometer length scale, in which atomistic simulation is used to predict the fundamental damage mechanisms of MSFC. These mechanisms include dislocation formation and interaction, interstitial void formation, and atomic diffusion. However, atomistic simulations quickly become computationally intractable as the system size increases, especially when directly linking to the already large microstructural models. Therefore, the second goal of this paper is to propose a method that will incorporate atomistic simulation and small-scale experimental characterization into the existing multiscale

  5. Fatigue-crack propagation in aluminum-lithium alloys processed by power and ingot metallurgy

    SciTech Connect

    Venkateswara Rao, K.T.; Ritchie, R.O. ); Kim, N.J. ); Pizzo, P.P. )

    1990-04-01

    Fatigue-crack propagation behavior in powder-metallurgy (P/M) aluminum-lithium alloys, namely, mechanically-alloyed (MA) Al-4.0Mg-1.5Li-1.1C-0.80{sub 2} (Inco 905-XL) and rapid-solidification-processed (RSP) Al-2.6Li-1.0Cu-0.5Mg-0.5Zr (Allied 644-B) extrusions, has been studied, and results compared with data on an equivalent ingot-metallurgy (I/M) Al-Li alloy, 2090-T81 plate. Fatigue-crack growth resistance of the RSP Al-Li alloy is found to be comparable to the I/M Al-Li alloy; in contrast, crack velocities in MA 905-XL extrusions are nearly three orders of magnitude faster. Growth-rate response in both P/M Al-Li alloys, however, is high anisotropic. Results are interpreted in terms of the microstructural influence of strengthening mechanism, slip mode, grain morphology and texture on the development of crack-tip shielding from crack-path deflection and crack closure. 14 refs., 7 figs., 2 tabs.

  6. Effect of Orifice Diameter on Bubble Generation Process in Melt Gas Injection to Prepare Aluminum Foams

    NASA Astrophysics Data System (ADS)

    Yuan, Jianyu; Li, Yanxiang; Wang, Ningzhen; Cheng, Ying; Chen, Xiang

    2016-06-01

    The bubble generation process in conditioned A356 alloy melt through submerged spiry orifices with a wide diameter range (from 0.07 to 1.0 mm) is investigated in order to prepare aluminum foams with fine pores. The gas flow rate and chamber pressure relationship for each orifice is first determined when blowing gas in atmospheric environment. The effects of chamber pressure ( P c) and orifice diameter ( D o) on bubble size are then analyzed separately when blowing gas in melt. A three-dimensional fitting curve is obtained illustrating both the influences of orifice diameter and chamber pressure on bubble size based on the experimental data. It is found that the bubble size has a V-shaped relationship with orifice diameter and chamber pressure neighboring the optimized parameter ( D o = 0.25 mm, P c = 0.4 MPa). The bubble generation mechanism is proposed based on the Rayleigh-Plesset equation. It is found that the bubbles will not be generated until a threshold pressure difference is reached. The threshold pressure difference is dependent on the orifice diameter, which determines the time span of pre-formation stage and bubble growth stage.

  7. The effect of process parameters on the internal quality of an aluminum die casting

    NASA Astrophysics Data System (ADS)

    Dewit, M. C. A. J.

    1986-01-01

    The influence of process parameters on the porosity of an aluminum die casting was investigated. Two types of die one of which had an interchangeable gate and two alloys, AlSi8Cu3 and AlSi7, were used. During the solidification phase of a die casting, air entrapment can occur; the air remains in the die casting under high pressure after solidification. The Rayleigh number which contains the velocity in the gate, the gate diameter, and the liquid metal surface tension, determines the air entrapment. It appears that there are two types of filling: solid front filling at low velocities, and standard spray filling at high velocities. With the former type, the castings contain no air, but the shrinkage is concentrated in big holes; with the latter type the castings contain much air, and the shrinkage is distributed over fine holes. The first phase velocity has no significant influence on the porosity; a decrease of the third phase velocity increases the porosity. Variations of the changeover point between the first and second phase have little influence.

  8. Substrate-dependent thermal conductivity of aluminum nitride thin-films processed at low temperature

    SciTech Connect

    Belkerk, B. E.; Bensalem, S.; Soussou, A.; Carette, M.; Djouadi, M. A.; Scudeller, Y.; Al Brithen, H.

    2014-12-01

    In this paper, we report on investigation concerning the substrate-dependent thermal conductivity (k) of Aluminum Nitride (AlN) thin-films processed at low temperature by reactive magnetron sputtering. The thermal conductivity of AlN films grown at low temperature (<200 °C) on single-crystal silicon (Si) and amorphous silicon nitride (SiN) with thicknesses ranging from 100 nm to 4000 nm was measured with the transient hot-strip technique. The k values for AlN films on SiN were found significantly lower than those on Silicon consistently with their microstructures revealed by X-ray diffraction, high resolution scanning electron microscopy, and transmission electron microscopy. The change in k was due to the thermal boundary resistance found to be equal to 10 × 10{sup −9} Km{sup 2}W{sup −1} on SiN against 3.5 × 10{sup −9} Km{sup 2}W{sup −1} on Si. However, the intrinsic thermal conductivity was determined with a value as high as 200 Wm{sup −1}K{sup −1} whatever the substrate.

  9. Low-resolution FTIR continuous monitoring/process control system to minimize HCl emissions in aluminum casting operations

    NASA Astrophysics Data System (ADS)

    Dunder, Thomas A.

    1999-12-01

    In a Department of Energy funded project, a low resolution Fourier Transform IR Continuous Emissions Monitoring (FTIR CEM) and Process Control system was developed and evaluated for use in minimizing HCl emissions during aluminum casting operations. In the casting process, molten aluminum is treated by fluxing with chlorine to remove alkali and hydrogen impurities. The industry has traditionally used a stoichiometric excess of chlorine to ensure metal quality, with resulting atmospheric emissions of HCl. The FTIR system can potentially be used to reduce emission when employed as a closed-loop process control device to monitor the HCl concentration and thereby reduce chlorine usage while maintaining product quality. In the initial project phase, tests were conducted under varying process conditions at a pilot-scale casting facility. The goals of these test included demonstrating that the FTIR monitor could provide closed-loop control of chlorine use, correlating HCl emission with metal quality, and verifying that the instrumentation could operate under harsh casting facility conditions. The system will subsequently be tested at two aluminum production facilities. This paper summarizes the results from the initial evaluation of the FTIR CEM/Process Control system.

  10. Purifying Aluminum by Vacuum Distillation

    NASA Technical Reports Server (NTRS)

    Du Fresne, E. R.

    1985-01-01

    Proposed method for purifying aluminum employs one-step vacuum distillation. Raw material for process impure aluminum produced in electrolysis of aluminum ore. Impure metal melted in vacuum. Since aluminum has much higher vapor pressure than other constituents, boils off and condenses on nearby cold surfaces in proportions much greater than those of other constituents.

  11. Ion-enhanced oxidation of aluminum as a fundamental surface process during target poisoning in reactive magnetron sputtering

    SciTech Connect

    Kuschel, Thomas; Keudell, Achim von

    2010-05-15

    Plasma deposition of aluminum oxide by reactive magnetron sputtering (RMS) using an aluminum target and argon and oxygen as working gases is an important technological process. The undesired oxidation of the target itself, however, causes the so-called target poisoning, which leads to strong hysteresis effects during RMS operation. The oxidation occurs by chemisorption of oxygen atoms and molecules with a simultaneous ion bombardment being present. This heterogenous surface reaction is studied in a quantified particle beam experiment employing beams of oxygen molecules and argon ions impinging onto an aluminum-coated quartz microbalance. The oxidation and/or sputtering rates are measured with this microbalance and the resulting oxide layers are analyzed by x-ray photoelectron spectroscopy. The sticking coefficient of oxygen molecules is determined to 0.015 in the zero coverage limit. The sputtering yields of pure aluminum by argon ions are determined to 0.4, 0.62, and 0.8 at 200, 300, and 400 eV. The variation in the effective sticking coefficient and sputtering yield during the combined impact of argon ions and oxygen molecules is modeled with a set of rate equations. A good agreement is achieved if one postulates an ion-induced surface activation process, which facilitates oxygen chemisorption. This process may be identified with knock-on implantation of surface-bonded oxygen, with an electric-field-driven in-diffusion of oxygen or with an ion-enhanced surface activation process. Based on these fundamental processes, a robust set of balance equations is proposed to describe target poisoning effects in RMS.

  12. An optimizing process of profiled cross-sectional aluminum alloy porthole die extrusion using response surface methodology

    NASA Astrophysics Data System (ADS)

    Zhou, Fujian; Li, Feng; Shi, Liansheng; Jiang, Hongwei

    2016-03-01

    The porthole die extrusion process of profiled cross-section hollow aluminum alloy is influenced by numerous factors, which brings inconvenience to the process design. In this paper, 7075 aluminum alloy is taken as an example, the fitting model of the ultimate load is analyzed by variance and regression analysis using response surface method (RSM). The influences of extrusion speed, friction factor and initial temperature on the change of extruded ultimate load are investigated systematically, and the important influence factors (initial temperature > friction factor > extrusion speed) to the load are determined eventually. By comparison, the error between the ultimate load model obtained after fitting and the calculated value is only 2.4%, further verifying the reliability of this model. The optimal objective is to minimize the ultimate load, then the optimum technological parameters are obtained by optimizing the process, where the initial temperature, the extrusion speed and the friction factor are 430∘C, 2.28mm/s and 0.31, respectively. The results provide a theoretical basis for the scientific design of the porthole die extrusion process of profiled cross-section hollow aluminum alloy.

  13. Aluminum reference electrode

    DOEpatents

    Sadoway, Donald R.

    1988-01-01

    A stable reference electrode for use in monitoring and controlling the process of electrolytic reduction of a metal. In the case of Hall cell reduction of aluminum, the reference electrode comprises a pool of molten aluminum and a solution of molten cryolite, Na.sub.3 AlF.sub.6, wherein the electrical connection to the molten aluminum does not contact the highly corrosive molten salt solution. This is accomplished by altering the density of either the aluminum (decreasing the density) or the electrolyte (increasing the density) so that the aluminum floats on top of the molten salt solution.

  14. Aluminum reference electrode

    DOEpatents

    Sadoway, D.R.

    1988-08-16

    A stable reference electrode is described for use in monitoring and controlling the process of electrolytic reduction of a metal. In the case of Hall cell reduction of aluminum, the reference electrode comprises a pool of molten aluminum and a solution of molten cryolite, Na[sub 3]AlF[sub 6], wherein the electrical connection to the molten aluminum does not contact the highly corrosive molten salt solution. This is accomplished by altering the density of either the aluminum (decreasing the density) or the electrolyte (increasing the density) so that the aluminum floats on top of the molten salt solution. 1 fig.

  15. Mechanical behavior and processing of aluminum metal-matrix composites. Final report, 1 Jan 89-31 Dec 91

    SciTech Connect

    Lavernia, E.J.; Mohamed, F.A.

    1992-02-21

    The objectives of the present three year research program were threefold. First the program sought to explore the potential of using spray atomization and deposition to process aluminum metal matrix composites, not only with improved mechanical properties, but also with specifications suitable for applications of interest to the Army; these applications include light weight armor vehicles, helicopter engines and other structural components. Second, the research program sought to develop an in-depth understanding of the various physical phenomena that occur during spray atomization and deposition of aluminum metal matrix composites. Third, the program sought to provide insight the fundamental mechanisms governing the elevated temperature deformation behavior, not only of metal matrix composites processed by spray atomization and deposition, but also of metal matrix composites in general.

  16. Identification of non-thermal and thermal processes in femtosecond laser-ablated aluminum

    NASA Astrophysics Data System (ADS)

    Bashir, Shazia; Shahid Rafique, M.; Husinsky, Wolfgang

    2013-12-01

    Non-thermal and thermal processes due to femtosecond laser ablation of aluminum (Al) at low, moderate, and high-fluence regimes are identified by Atomic Force Microscope (AFM) surface topography investigations. For this purpose, surface modifications of Al by employing 25 fs Ti: sapphire laser pulses at the central wavelength of 800 nm have been performed to explore different nano- and microscale features such as hillocks, bumps, pores, and craters. The mechanism for the formation of these diverse kinds of structures is discussed in the scenario of three ablation regimes. Ultrafast electronic and non-thermal processes are dominant in the lower fluence regime, whereas slow thermal processes are dominant at the higher fluence regime. Therefore, by starting from the ablation threshold three different fluence regimes have been chosen: a lower fluence regime (0.06-0.5 J cm-2 single-shot irradiation under ultrahigh vacuum condition and 0.25-2.5 J cm-2 single-shot irradiation in ambient condition), a moderate-fluence regime (0.25-1.5 J cm-2 multiple-shot irradiation), and a high-fluence regime 2.5-3.5 J cm-2 multiple-shot irradiation. For the lower fluence (gentle ablation) regime, around the ablation threshold, the unique appearance of individual, localized Nano hillocks typically a few nanometers in height and less than 100 nm in diameter are identified. These Nano hillock-like features can be regarded as a nonthermal, electronically induced phase transition process due to localized energy deposition as a result of Coulomb explosion or field ion emission by surface optical rectification. At a moderate-fluence regime, slightly higher than ablation threshold multiple-pulse irradiation produces bump-formation and is attributed to ultrafast melting (plasma formation). The high-fluence regime results in greater rates of material removal with highly disturbed and chaotic surface of Al with an appearance of larger protrusions at laser fluence well above the ablation threshold

  17. Material Failure and the Growth of Instabilities in Hollow Cylindrical Samples of Aluminum Shocked to 14Gpa and 50Gpa (U)

    SciTech Connect

    Stokes, J.; Fulton, R.D.; Morgan, D.V.; Obst, A.W.; Oro, D.M.; Oona, H.; Anderson, W.E.

    1999-11-20

    Understanding the surface stability of metals undergoing dynamic fracture at shock breakout is important to several applications in metals processing. The advantages of using the Pegasus II facility to investigate the phenomena occurring at shock break out are described. As an example of the data collected, we concentrate on brief descriptions of two experiments that compared the tensile failure, i.e. ''spall'', patterns in the presence of sinusoidal perturbations seeded on the free inner surface of cylindrical samples made of structural grade Al 6061.T6. These samples were subjected to ramped waves with shock pressures of 14 GPa and 50 GPa to observe the effect of pressure on the production of a type of volumetric failure that is mentioned here ''microspall.'' This failed region behind the exiting surface of the shock wave is comprised of a significant volume of low-density, probably granular, material. The failure mechanism, combined with the forces that cause inertial instability, leads to rapid pattern growth in the failed material, observable as density variations, as well as to pattern growth on the surface. Pattern growth was observed to vary with perturbation amplitude, wavelength, and shock pressure. Both increased pressure and increased amplitude were shown to destabilize a stable perturbation. Increasing the wavelength by a factor of 3 was shown to result in significantly slower growth of the pattern within the failed volume. The mechanisms leading to the formation of the spall volume and to the patterns are discussed briefly.

  18. Application of the Pegasus II Pulsed-Power Facility to the Study of Inertial Instability and Fracture of Cylindrical Tubes of Solid Aluminum

    SciTech Connect

    Chandler, E.A.; Stokes, J.; Fulton, R.D.; Morgan, D.V.; Obst, A.W.; Oro, D.M.; Oona, H.; Anderson, W.E.

    1999-06-23

    Understanding the surface stability of metals undergoing dynamic fracture at shock breakout is important to several applications in metals processing. The advantages of using the Pegasus II facility to investigate the phenomena occurring at shock break out are described. As an example of the data collected, we concentrate on brief descriptions of two experiments that compared the tensile failure, i.e. ''spall'', patterns in the presence of sinusoidal perturbations seeded on the free inner surface of cylindrical samples of 3 types of Al. These samples were composed variously of soft Al 1100-O, structural grade Al 6061-T6, and ultra-pure 99.99% Al and were subjected to Taylor waves with shock pressures of 14 GPa. We show that the material behind the exiting surface undergoes a type of failure termed here ''microspall'', resulting in the production of a significant volume of low-density, probably granular, material. The failure mechanism, combined with the forces that cause inertial instability, leads to rapid pattern growth in the failed material and subsequent pattern growth on the surface. Pattern growth was studied as a function of perturbation wavelength and amplitude. The different Al samples vary by an order of magnitude in yield strength, and some increase in pattern instability was observed at lower yield strength. The ultra-pure Al has exceptionally large grain size, in the mm range. No appreciable variation of spall pattern was observed due to grain size.

  19. Influence of Sulfur Species on Current Efficiency in the Aluminum Smelting Process

    NASA Astrophysics Data System (ADS)

    Meirbekova, Rauan; Haarberg, Geir Martin; Thonstad, Jomar; Saevarsdottir, Gudrun

    2016-04-01

    Anode impurities are the major source of sulfur in aluminum electrolysis. Sulfur in anodes is mainly found as organic compounds. Alumina also introduces small quantities of sulfur, typically in the form of sulfates. The scarcity and cost of low-sulfur raw materials and the possibility of sulfur removal from the cell by means of flue gas may make high-sulfur content anodes a viable option. However, some anode impurities are known to affect current efficiency in aluminum production and caution must be exercised. The effect of increased sulfur content in the aluminum electrolysis electrolyte must be studied. This paper explores the effect of increased sulfur concentration in the electrolyte on current efficiency in a laboratory cell. Sodium sulfate was added to the electrolyte as a source of sulfur at regular time intervals to maintain a constant sulfur concentration. Current efficiency decreased by 1.1 pct per each 100 mg/kg (ppm) increase in sulfur concentration in the electrolyte.

  20. Tailoring Microstructure and Properties of Hierarchical Aluminum Metal Matrix Composites Through Friction Stir Processing

    NASA Astrophysics Data System (ADS)

    Sohn, Y. H.; Patterson, T.; Hofmeister, C.; Kammerer, C.; Mohr, W.; van den Bergh, M.; Shaeffer, M.; Seaman, J.; Cho, K.

    2012-02-01

    The fabrication of hierarchical aluminum metal matrix composites (MMCs) begins with the cryomilling of inert gas-atomized AA5083 Al powders with B4C particles, which yields agglomerates of nanocrystalline (NC) Al grains containing a uniform dispersion of solidly bonded, submicron B4C particles. The cryomilled agglomerates are size classified, blended with coarse-grain Al (CG-Al) powders, vacuum degassed at an elevated temperature, and consolidated to form the bulk composite. This hierarchical Al MMCs have low weight and high strength/stiffness attributable to the (A) Hall-Petch strengthening from NC-Al (5083) grains, (B) Zener pinning effects from B4C particulate reinforcement and dispersoids in both the NC-Al and CG-Al, (C) the interface characteristics between the three constituents, and (D) a high dislocation density. The hierarchical Al MMCs exhibit good thermal stability and microstructural characteristics that deflect or blunt crack propagation. A significant change in the microstructure of the composite was observed after friction stir processing (FSP) in the thermomechanically affected zone (TMAZ) due to the mechanical mixing, particularly in the advancing side of the stir zone (SZ). The NC-Al grains in the TMAZ grew during FSP. Evidence of CG-Al size reduction was also documented since CG-Al domain was absent by optical observation. Given the proper control of the microstructure, FSP has demonstrated its potential to increase both strength and ductility, and to create functionally tailored hierarchical MMCs through surface modification, graded structures, and other hybrid microstructural design.

  1. Power ultrasound irradiation during the alkaline etching process of the 2024 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Moutarlier, V.; Viennet, R.; Rolet, J.; Gigandet, M. P.; Hihn, J. Y.

    2015-11-01

    Prior to any surface treatment on an aluminum alloy, a surface preparation is necessary. This commonly consists in performing an alkaline etching followed by acid deoxidizing. In this work, the use of power ultrasound irradiation during the etching step on the 2024 aluminum alloy was studied. The etching rate was estimated by weight loss, and the alkaline film formed during the etching step was characterized by glow discharge optical emission spectrometry (GDOES) and scanning electron microscope (SEM). The benefit of power ultrasound during the etching step was confirmed by pitting potential measurement in NaCl solution after a post-treatment (anodizing).

  2. Thermodynamic investigation of the effect of alkali metal impuries on the processing of aluminum and magnesium alloys

    NASA Astrophysics Data System (ADS)

    Zhang, Shengjun

    2006-12-01

    Aluminum and magnesium alloys are widely used in the automobile and aerospace industries as structural materials due to their light weight, high specific strength and good formability. However, they suffer from the poor hot rolling characteristics due to undesired impurities like calcium, potassium, lithium and sodium. They increase the hydrogen solubility in the melt and promote the formation of porosity in aluminum castings. During fabrication of aluminum alloys, they cause the hot-shortness and embrittlement due to cracking. They also led to "blue haze" corrosion which promotes the discoloration of aluminum under humid condition. The removal of these elements increases overall melt loss of aluminum alloys when aluminum products are remelted and recast. Na is one of the common impurities in the Al and Mg alloys. In industry, primary Al is produced by the Hall-Heroult process, through the electrolysis of the mixture of molten alumina and cryolite (Al2O3+Na 3AlF6), the latter being added to lower the melting point. Therefore, Al inevitably contains some Na (>0.002%) without further treatment. The Na content in Al is influenced by the thermodynamics and kinetics of the electrolysis. Similarly, in the electrolytic production and subsequent processing of Mg, Mg is commonly in contact with molten salt mixtures of NaCl and MgCl 2. Consequently, 2--20 wt. ppm Na is often found in Mg alloys. Besides originating from the industrial production process, Na can be introduced in laboratory experiments from alumina crucibles by the reaction between the molten Al-Mg alloys and the Na2O impurity in the alumina crucible. The trace element K plays a similar role in Al alloys although it is seldom discussed. No systematic theoretic research has been carried out to investigate the behavior of these impurities during the processing of aluminum alloys. The thermodynamic description of the Al-Ca-K-Li-Mg-Na system is needed to understand the effects of Ca, K, Li and Na on phase stability

  3. Development and Processing Improvement of Aerospace Aluminum Alloys-Development of AL-Cu-Mg-Ag Alloy (2139)

    NASA Technical Reports Server (NTRS)

    Cho, Alex; Lisagor, W. Barry; Bales, Thomas T.

    2007-01-01

    This final report supplement in presentation format describes a comprehensive multi-tasked contract study to continue the development of the silver bearing alloy now registered as aluminum alloy 2139 by the Aluminum Association. Two commercial scale ingots were processed into nominal plate gauges of two, four and six inches, and were extensively characterized in terms of metallurgical and crystallographic structure, and resulting mechanical properties. This report includes comparisons of the property combinations for this alloy and 2XXX and 7XXX alloys more widely used in high performance applications. Alloy 2139 shows dramatic improvement in all combinations of properties, moreover, the properties of this alloy are retained in all gauge thicknesses, contrary to typical reductions observed in thicker gauges of the other alloys in the comparison. The advancements achieved in this study are expected to result in rapid, widespread use of this alloy in a broad range of ground based, aircraft, and spacecraft applications.

  4. Material Flow Tracking for Various Tool Geometries During the Friction Stir Spot Welding Process

    NASA Astrophysics Data System (ADS)

    Lin, Yuan-Ching; Liu, Ju-Jen; Chen, Jiun-Nan

    2013-12-01

    This study applied powder-tracing techniques to mount Cu and W powders on A6061-T6 aluminum sheets to investigate the material flow mechanism of friction stir spot welding (FSSW) using various geometric tools. The experimental results showed that the geometry of the tools plays a crucial role and determines the entrances of material flow during FSSW. It was believed that instantaneous voids were filled up with material flow in all directions for triangular pins, and the voids were located at the pin bottom for cylindrical pins. In accordance with the plastic rule of material flow, the pressure gradient is the necessary condition to cause material flow during FSSW; therefore, the transient constraint space (TCS) is required to generate pressure in this space. Enlargement of the TCS accompanies the evolution of the stir zone (SZ). A generated void causes a steep pressure gradient, which is regarded as the entrance of material flow. A tool with screw threads causes downward driving force, which determines the intermixing behavior between the upper and lower sheets, and also affects the size of the SZs.

  5. Performance characterization of fiber Bragg grating thermal response in space vacuum thermal environment

    NASA Astrophysics Data System (ADS)

    Jiang, Junfeng; Song, Luyao; Liu, Tiegen; Zhang, Jingchuan; Liu, Kun; Wang, Shuang; Yin, Jinde; Zhao, Peng; Xie, Jihui; Wu, Fan; Zhang, Xuezhi

    2013-12-01

    We investigated the fiber Bragg grating (FBG) thermal response in space vacuum thermal environment. The FBGs were packaged with 6061-T6 aluminum. The liquid nitrogen immersion experiment results show that its wavelength shift standard deviation is 0.76 pm for 217 h. The combination effect of vacuum and cryogenic temperature was studied by thermal cycling process in space environment simulator. The FBG sensors show accuracy better than 2% full scale, and the hysteresis errors are below 1%. It proves that these metal packaged FBG sensors can survive and meet the requirement of space measurement.

  6. Performance characterization of fiber Bragg grating thermal response in space vacuum thermal environment.

    PubMed

    Jiang, Junfeng; Song, Luyao; Liu, Tiegen; Zhang, Jingchuan; Liu, Kun; Wang, Shuang; Yin, Jinde; Zhao, Peng; Xie, Jihui; Wu, Fan; Zhang, Xuezhi

    2013-12-01

    We investigated the fiber Bragg grating (FBG) thermal response in space vacuum thermal environment. The FBGs were packaged with 6061-T6 aluminum. The liquid nitrogen immersion experiment results show that its wavelength shift standard deviation is 0.76 pm for 217 h. The combination effect of vacuum and cryogenic temperature was studied by thermal cycling process in space environment simulator. The FBG sensors show accuracy better than 2% full scale, and the hysteresis errors are below 1%. It proves that these metal packaged FBG sensors can survive and meet the requirement of space measurement. PMID:24387420

  7. Processing, properties, and ballistic performance of titanium-aluminum titanium metal-intermetallic laminate (MIL) composites

    NASA Astrophysics Data System (ADS)

    Harach, David John

    2000-10-01

    A systematic investigation into the processing of Ti-Al3Ti metal-intermetallic laminate (MIL) composites from elemental titanium and aluminum foils in open air by a novel one step technique, and subsequent characterization, physical, mechanical and ballistic testing was carried out. Al3Ti is the only intermetallic phase to form, and no oxides or other phases are formed. Composites with Ti volume fractions of ˜0, 14, 20, 35, and 57 percent can be processed consistently, with measured density agreeing well with calculated density. The intermetallic reaction occurs in two parts that are linear with respect to Al3Ti growth with time: oxide controlled diffusion of Al, and the order of magnitude faster chemical reaction that occurs after the oxide layer breaks down and transient liquid phases are formed. A reaction model based on the production of Al3Ti spheroids that are ejected from the Ti reaction surface has been developed, and is titled reactive foil sintering. Quasi-static and dynamic compression tests resulted in maximum yield stresses for the 20Ti composite, and end-confined quasi-static and dynamic compression tests, tension tests, and 3-point bend tests resulted in maximum yield stresses and bending loads for the 35Ti composite. Maximum yield stresses occurred in specimens tested with layers parallel to the load. Arrester orientation R-curve testing was completed for the 14Ti composite under large-scale bridging conditions, with initiation toughness values obtained for 20Ti and 35Ti which developed cracks in the intermetallic layer growing perpendicular to the load axis. Divider orientation R-curves were obtained, with the 20Ti and 35Ti curves closely approaching calculated steady-state toughness values. Ballistics testing of bonded Ti, bonded Ti-Al, 5Ti, 14Ti, 35Ti, 57Ti, and Al3Ti at projectile velocities of 500--700 m/s resulted in the 14Ti and 35Ti having the best ballistic performance based on mass efficiency. Ballistics testing of 14Ti, 20Ti, and 35Ti

  8. Optimizing and developing a continuous separation system for the wet process separation of aluminum and polyethylene in aseptic composite packaging waste.

    PubMed

    Yan, Dahai; Peng, Zheng; Liu, Yuqiang; Li, Li; Huang, Qifei; Xie, Minghui; Wang, Qi

    2015-01-01

    The consumption of milk in China is increasing as living standards rapidly improve, and huge amounts of aseptic composite milk packaging waste are being generated. Aseptic composite packaging is composed of paper, polyethylene, and aluminum. It is difficult to separate the polyethylene and aluminum, so most of the waste is currently sent to landfill or incinerated with other municipal solid waste, meaning that enormous amounts of resources are wasted. A wet process technique for separating the aluminum and polyethylene from the composite materials after the paper had been removed from the original packaging waste was studied. The separation efficiency achieved using different separation reagents was compared, different separation mechanisms were explored, and the impacts of a range of parameters, such as the reagent concentration, temperature, and liquid-solid ratio, on the separation time and aluminum loss ratio were studied. Methanoic acid was found to be the optimal separation reagent, and the suitable conditions were a reagent concentration of 2-4 mol/L, a temperature of 60-80°C, and a liquid-solid ratio of 30 L/kg. These conditions allowed aluminum and polyethylene to be separated in less than 30 min, with an aluminum loss ratio of less than 3%. A mass balance was produced for the aluminum-polyethylene separation system, and control technique was developed to keep the ion concentrations in the reaction system stable. This allowed a continuous industrial-scale process for separating aluminum and polyethylene to be developed, and a demonstration facility with a capacity of 50t/d was built. The demonstration facility gave polyethylene and aluminum recovery rates of more than 98% and more than 72%, respectively. Separating 1t of aluminum-polyethylene composite packaging material gave a profit of 1769 Yuan, meaning that an effective method for recycling aseptic composite packaging waste was achieved. PMID:25458854

  9. Manufacturing process controls for high reliability carbon filament-wound seamless-aluminum-lined composite pressure vessels

    NASA Astrophysics Data System (ADS)

    Braun, C. A.; Haddock, R. C.

    1992-07-01

    An account is given of the manufacturing, inspection, and test-process variables associated with the production of carbon filament-wound/epoxy-matrix, seamless aluminum-lined pressure vessels, which have achieved operating pressures of the order of 10,000 psi and burst-to-operating safety factors of as low as 1.5-1.0. Attention is given to the process controls that are needed to reach current reliability requirements. Attention is given to liner surface preparation, age sensitivity, and the dangers of exposure to heat and stress.

  10. Part A - low-aluminum-content iron-aluminum alloys. Part B - commercial-scale melting and processing of FAPY alloy

    SciTech Connect

    Sikka, V.K.; Howell, C.R.; Hall, F.; Valykeo, J.

    1996-06-01

    The FAPY is a Fe-16 at. % Al alloy of nominal composition. The aluminum content of the alloy is such that it remains single phase ({alpha}) without the formation of an ordered phase (DO{sub 3}). The alloy has good oxidation resistance at temperatures up to 1000{degrees}C and has shown significantly superior performance as heating elements as compared to the commonly used nickel-based alloy, Nichrome. Although wire for the heating elements has been fabricated from small (15-1b) laboratory heats, for its commercial applications, the wire needs to be producible from large (1200 to 1500-1b) air-melted heats. The purpose of this study was to produce commercial size heats and investigate their mechanical properties and microstructure in the as-cast, hot-worked, and cold-worked conditions. The results of this study are expected to provide: (1) insight into processing steps for large heats into wire under commercial conditions, and (2) the mechanical properties data on commercial size heats in various product forms.

  11. Effect of processing variables on the structure and properties of {gamma}-glycidoxypropyltrimethoxysilane primers on aluminum substrates

    SciTech Connect

    Boerio, F.J.; Bertelsen, C.M.

    1996-12-31

    The use of silanes to improve the durability of adhesive bonds to metals such as aluminum has been extensively described in the literature. For example, Thiedman et al investigated aluminum/epoxy wedge test specimens. They found that when the aluminum substrates were pretreated with solutions of {gamma}-glycidoxypropyltrimethoxysilane ({gamma}-GPS), the crack growth rates during exposure to 96% RH and 50{degrees}C were similar to those obtained using substrates pretreated by the FPL etching process. When wedge test specimens were prepared from adherends pretreated with {gamma}-aminopropyltriethoxysilane ({gamma}-APS) solutions, the crack growth rates depended on the pH of the solutions and the way in which the pH was adjusted. When the pH was adjusted by adding HO to the solutions, the crack growth rates were similar to those obtained using substrates pretreated by FPL etching. However, when the pH was adjusted by adding acetic acid, rapid crack growth was observed. The purpose of this paper is to report results obtained using Fourier-transform infrared spectroscopy and X-ray photoelectron spectroscopy to characterize {gamma}-GPS films on aluminium subtrates. Preliminary results obtained using high performance liquid chromatography and nuclear magnetic resonance to characterize aqueous solutions of {gamma}-GPS are also reported.

  12. Oxidation Behavior of In-Flight Molten Aluminum Droplets in the Twin-Wire Electric Arc Thermal Spray Process

    SciTech Connect

    Donna Post Guillen; Brian G. Williams

    2005-05-01

    This paper examines the in-flight oxidation of molten aluminum sprayed in air using the twin-wire electric arc (TWEA) thermal spray process. The oxidation reaction of aluminum in air is highly exothermic and is represented by a heat generation term in the energy balance. Aerodynamic shear at the droplet surface enhances the amount of in-flight oxidation by: (1) promoting entrainment and mixing of the surface oxides within the droplet, and (2) causing a continuous heat generation effect that increases droplet temperature over that of a droplet without internal circulation. This continual source of heat input keeps the droplets in a liquid state during flight. A linear rate law based on the Mott-Cabrera theory was used to estimate the growth of the surface oxide layer formed during droplet flight. The calculated oxide volume fraction of an average droplet at impact agrees well with the experimentally determined oxide content for a typical TWEA-sprayed aluminum coating, which ranges from 3.3 to 12.7%. An explanation is provided for the elevated, nearly constant surface temperature (~ 2000 oC) of the droplets during flight to the substrate and shows that the majority of oxide content in the coating is produced during flight, rather than after deposition.

  13. The use of synthetic hydrocalcite as a chloride-ion getter for a barrier aluminum anodization process

    SciTech Connect

    Panitz, J.K.G.; Sharp, D.J.

    1995-11-01

    Chloride ion contamination at parts per billion concentrations plaques electrochemists studying barrier anodic aluminum oxide film growth and anodic aluminum oxide capacitor manufacturers. Chloride ion contamination slows film growth and reduces film quality. We have demonstrated that synthetic hydrocalcite substantially reduces the detrimental effects of chloride ion contamination in an aqueous electrolyte commonly used to grow barrier anodic aluminum oxide. We have determined that problems arise if precautions are not taken when using synthetic hydrocalcite as a chloride-ion getter in an aqueous electrolyte. Synthetic hydrocalcite is somewhat hydrophobic. If this powder is added directly to an aqueous electrolyte, some powder disperses; some floats to the top of the bath and forms scum that locally impedes anodic film formation. Commercially available powder contains a wide range of particle sizes including submicrometer-sized particles that can escape through filters into the electrolyte and cause processing problems. These problems can be over come if (1) the getter is placed in filter bags, (2) a piece of filter paper is used to skim trace amounts of getter floating on the top of the bath, (3) dummy runs are performed to scavenge chloride-ion loaded getter micelles dispersed in the bath, and (4) substrates are rinsed with a strong stream of deionized water to remove trace amounts of powder after anodization.

  14. Evaluation of occupational exposure to toxic metals released in the process of aluminum welding.

    PubMed

    Matczak, Wanda; Gromiec, Jan

    2002-04-01

    The objective of this study was to evaluate occupational exposure to welding fumes and its elements on aluminum welders in Polish industry. The study included 52 MIG/Al fume samples and 18 TIG/Al samples in 3 plants. Air samples were collected in the breathing zone of welders (total and respirable dust). Dust concentration was determined gravimetrically, and the elements in the collected dust were determined by AAS. Mean time-weighted average (TWA) concentrations of the welding dusts/fumes and their components in the breathing zone obtained for different welding processes were, in mg/m3: MIG/Al fumes mean 6.0 (0.8-17.8), Al 2.1 (0.1-7.7), Mg 0.2 (< 0.1-0.9), Mn 0.014 (0.002-0.049), Cu 0.011 (0.002-0.092), Zn 0.016 (0.002-0.14), Pb 0.009 (0.005-0.025), Cr 0.003 (0.002-0.007), and TIG/Al fumes 0.7 (0.3-1.4), Al 0.17 (0.07-0.50). A correlation has been found between the concentration of the main components and the fume/dust concentrations in MIG/Al and TIG/Al fumes. Mean percentages of the individual components in MIG/Al fumes/dusts were Al: 30 (9-56) percent; Mg: 3 (1-5.6) percent; Mn: 0.2 (0.1-0.3) percent; Cu: 0.2 (< 0.1-1.8) percent; Zn: 0.2 (< 0.1-0.8) percent; Pb: 0.2 (< 0.1-1) percent; Cr: < 0.1 percent. The proportion of the respirable fraction in the fumes and their constituents varied between 10 percent and 100 percent. The results showed that MIG/Al fumes concentration was 1.2 times higher than the American Conference of Governmental Industrial Hygienists (ACGIH) threshold limit value (TLV), and the index of the combined exposure to the determined agents was 2.3 (0.4-8.0), mostly because of high Al2O3 contribution. The background concentrations of the components (ca. 5-10 times lower than those in the breathing zone of the welders) did not exceed the Polish MAC value. The elemental composition of total and respirable fume/dust may differ considerably depending on welding methods, the nature of welding-related operations, and work environment conditions

  15. Corrosion resistance and durability of siloxane ceramic/polymer films for aluminum alloys in marine environments

    NASA Astrophysics Data System (ADS)

    Kusada, Kentaro

    The objective of this study is to evaluate corrosion resistance and durability of siloxane ceramic/polymer films for aluminum alloys in marine environments. Al5052-H3 and Al6061-T6 were selected as substrates, and HCLCoat11 and HCLCoat13 developed in the Hawaii Corrosion Laboratory were selected for the siloxane ceramic/polymer coatings. The HCLCoat11 is a quasi-ceramic coating that has little to no hydrocarbons in its structure. The HCLCoat13 is formulated to incorporate more hydrocarbons to improve adhesion to substrate surfaces with less active functionalities. In this study, two major corrosion evaluation methods were used, which were the polarization test and the immersion test. The polarization tests provided theoretical corrosion rates (mg/dm 2/day) of bare, HCLCoat11-coated, and HCLCoat13-coated aluminum alloys in aerated 3.15wt% sodium chloride solution. From these results, the HCLCoat13-coated Al5052-H3 was found to have the lowest corrosion rate which was 0.073mdd. The next lowest corrosion rate was 0.166mdd of the HCLCoat11-coated Al5052-H3. Corrosion initiation was found to occur at preexisting breaches (pores) in the films by optical microscopy and SEM analysis. The HCLCoat11 film had many preexisting breaches of 1-2microm in diameter, while the HCLCoat13 film had much fewer preexisting breaches of less than 1microm in diameter. However, the immersion tests showed that the seawater immersion made HCLCoat13 film break away while the HCLCoat11 film did not apparently degrade, indicating that the HCLCoat11 film is more durable against seawater than the HCLCoat13. Raman spectroscopy revealed that there was some degradation of HCLCoat11 and HCLCoat13. For the HCLCoat11 film, the structure relaxation of Si-O-Si linkages was observed. On the other hand, seawater generated C-H-S bonds in the HCLCoat13 film resulting in the degradation of the film. In addition, it was found that the HCLCoat11 coating had anti-fouling properties due to its high water contact

  16. Aluminum nitride-silicon carbide whisker composites: Processing, properties, and microstructural stability

    SciTech Connect

    Cross, M.T.

    1990-01-01

    Aluminum nitride -- silicon carbide whisker composites with up to 20 vol % whiskers were fabricated by pressureless sintering (1750{degree}--1800{degree}C) and by hot-pressing (1700{degree}--1800{degree}C). Silicon carbide whiskers were found to degrade depending on the type of protective powder bed used during sintering. Whiskers were found to degraded in high oxygen containing samples by reaction with sintering additives. Whisker degradation was also due to the formation of silicon carbide -- aluminum nitride solid solution. No whisker degradation was observed in hot-pressed samples. For these samples Young's modulus and fracture toughness were measured. A 33% increase in the fracture toughness was measured by the indentation technique for a 20 vol % whisker composite. Operative toughening mechanisms were investigated using scanning electron microscopy. Crack deflection and whisker bridging were the dominant mechanisms. It was also shown that load transfer from matrix to whiskers can be a contributing factor to toughening. 88 refs., 34 figs., 11 tabs.

  17. Studies of the Crystallization Process of Aluminum-Silicon Alloys Using a High Temperature Microscope. Thesis

    NASA Technical Reports Server (NTRS)

    Justi, S.

    1985-01-01

    It is shown that primary silicon crystals grow polyhedral in super-eutectic AlSi melts and that phosphorus additives to the melt confirm the strong seeding capacity. Primary silicon exhibits strong dendritic seeding effects in eutectic silicon phases of various silicon alloys, whereas primary aluminum does not possess this capacity. Sodium addition also produces a dendritic silicon network growth in the interior of the sample that is attributed to the slower silicon diffusion velocity during cooling.

  18. BONDING ALUMINUM METALS

    DOEpatents

    Noland, R.A.; Walker, D.E.

    1961-06-13

    A process is given for bonding aluminum to aluminum. Silicon powder is applied to at least one of the two surfaces of the two elements to be bonded, the two elements are assembled and rubbed against each other at room temperature whereby any oxide film is ruptured by the silicon crystals in the interface; thereafter heat and pressure are applied whereby an aluminum-silicon alloy is formed, squeezed out from the interface together with any oxide film, and the elements are bonded.

  19. Chloride-free processing of aluminum scrap to recover by-product materials

    SciTech Connect

    Riley, W.D.; Jong, B.W.

    1995-12-31

    The US Bureau of Mines has developed technology to recover by-product materials from aluminum scrap using engineered scavenger compounds (ESC). ESCs are structural oxides with a channel or tunnel structure that allows them to hold ions of a specific sizes and charges. The scavenging reaction is easily reversible allowing the ESC to be recharged for continued use and the ion is recovered as an electrodeposit. Key features of this novel technology are: (a) ESC systems are designed to have a high degree of selectivity for a desired ionic species. (b) The recovered material requires little or no additional reprocessing prior to reuse. Two current uses for the ESC technology that are described in this paper are the removal and recycle of lithium (Li) from lithium aluminum (Li-Al) alloys; and, using ESCs as a replacement for the conventional demaging (magnesium removal) technology used by the secondary casting industry. Research indicates that the ESC technology proposed for both these applications has either distinct economic and/or environmental advantages over previously employed methods of recovering metal values from aluminum scrap.

  20. Aluminum: Recycling of Aluminum Dross/Saltcake

    SciTech Connect

    Blazek, S.

    1999-01-29

    As this NICE3 publication details, the objective of this project is to commercialize the process technology to eliminate all landfill waste associated with black dross and saltcake generated from aluminum recycling in the United States.

  1. Electrically conductive anodized aluminum coatings

    NASA Technical Reports Server (NTRS)

    Alwitt, Robert S. (Inventor); Liu, Yanming (Inventor)

    2001-01-01

    A process for producing anodized aluminum with enhanced electrical conductivity, comprising anodic oxidation of aluminum alloy substrate, electrolytic deposition of a small amount of metal into the pores of the anodized aluminum, and electrolytic anodic deposition of an electrically conductive oxide, including manganese dioxide, into the pores containing the metal deposit; and the product produced by the process.

  2. Microstructure and Crystallographic Texture Evolution During the Friction-Stir Processing of a Precipitation-Hardenable Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Nadammal, Naresh; Kailas, Satish V.; Szpunar, Jerzy; Suwas, Satyam

    2015-05-01

    Friction-stir processing (FSP) has been proven as a successful method for the grain refinement of high-strength aluminum alloys. The most important attributes of this process are the fine-grain microstructure and characteristic texture, which impart suitable properties in the as-processed material. In the current work, FSP of the precipitation-hardenable aluminum alloy 2219 has been carried out and the consequent evolution of microstructure and texture has been studied. The as-processed materials were characterized using electron back-scattered diffraction, x-ray diffraction, and electron probe microanalysis. Onion-ring formation was observed in the nugget zone, which has been found to be related to the precipitation response and crystallographic texture of the alloy. Texture development in the alloy has been attributed to the combined effect of shear deformation and dynamic recrystallization. The texture was found heterogeneous even within the nugget zone. A microtexture analysis revealed the dominance of shear texture components, with C component at the top of nugget zone and the B and A2* components in the middle and bottom. The bulk texture measurement in the nugget zone revealed a dominant C component. The development of a weaker texture along with the presence of some large particles in the nugget zone indicates particle-stimulated nucleation as the dominant nucleation mechanism during FSP. Grain growth follows the Burke and Turnbull mechanism and geometrical coalescence.

  3. Iron and aluminum hydroxide nanoparticles in the environment: from nano-scale to the field processes

    NASA Astrophysics Data System (ADS)

    Bazilevskaya, Ekaterina

    The objective of this doctoral research was to increase scientific understanding of the behavior of Fe and Al hydroxide nanoparticles in soils. These particles are of great environmental importance due to their ability to retain and transport nutrients and contaminants. Three studies were undertaken at different scales, which are documented in three manuscripts included in this dissertation. The first study examined the rate constants for goethite (alpha-FeOOH) crystallization from nano-particulate Fe hydroxide suspensions in the absence (0% Al) and presence (2% Al) of aluminum. One of the merits of this study was the application of a multivariate curve resolution analysis (MCR) of infrared spectra to environmentally important mixed Fe-Al hydroxide colloids in order to quantify goethite content in poorly-crystalline mixtures. Obtained rate constants were found to be equal to (7.64+/-0.67)x10-7 s-1 for 0% Al and (4.5+/-0.21) x10-7 s-1 for 2% Al hydroxides. Dissolution-precipitation mechanism was dominant in the process of goethite transformation to ferrihydrite. Further growth of goethite crystals took place either by aggregation mechanism to form polycrystalline agglomerates or alternatively by Oswald ripening to form large single crystals. The presence of aqueous Al species "poisoned" goethite's surface by disrupting the formation of hydrogen bonds thus increasing the number of non-stoichiometric hydroxyls. The second study addressed changes of mineral composition in mixed Fe-Al hydroxide nanoparticles as a function of Al-substitution and reaction time. It was found that low Al concentrations (2-8 mol. %) lead to formation of moderately crystalline Al-goethite upon ageing, while at medium Al concentrations (10-20%) colloidal suspensions remained stable for the duration of the whole experiment (54 days), goethite formation was completely retarded, and less crystalline intermediate structure were formed. At 25% Al substitution, gibbsite Al(OH)3 microcrystalline

  4. Application of the rapid thermal process: Sintering the sputtered aluminum/silicon contact in silicon detector fabrication

    SciTech Connect

    Chen, Wei; Li, Zheng; Kraner, H.W.

    1991-11-01

    Rapid thermal process (RTP) sintering has been used in p{sup +}{minus}n junction detector fabrication. For the same thickness of aluminum film and at the same RTP sintering condition, the leakage current of the p{sup +}{minus}n junction detector with sputtered Al gate showed at least a 50% improvement and no spiking phenomena were observed. RTP sintering in 4% H{sub 2}/N{sub 2} ambient passivates the defects introduced by sputtering and the damage caused by the {sup 60}Co irradiation.

  5. Magnesium Recycling of Partially Oxidized, Mixed Magnesium-Aluminum Scrap through Combined Refining and Solid Oxide Membrane Electrolysis Processes

    SciTech Connect

    Xiaofei Guan; Peter A. Zink; Uday B. Pal; Adam C. Powell

    2012-01-01

    Pure magnesium (Mg) is recycled from 19g of partially oxidized 50.5wt.% Mg-Aluminum (Al) alloy. During the refining process, potentiodynamic scans (PDS) were performed to determine the electrorefining potential for magnesium. The PDS show that the electrorefining potential increases over time as the magnesium content inside the Mg-Al scrap decreases. Up to 100% percent of magnesium is refined from the Mg-Al scrap by a novel refining process of dissolving magnesium and its oxide into a flux followed by vapor phase removal of dissolved magnesium and subsequently condensing the magnesium vapor. The solid oxide membrane (SOM) electrolysis process is employed in the refining system to enable additional recycling of magnesium from magnesium oxide (MgO) in the partially oxidized Mg-Al scrap. The combination of the refining and SOM processes yields 7.4g of pure magnesium.

  6. Magnesium Recycling of Partially Oxidized, Mixed Magnesium-Aluminum Scrap Through Combined Refining and Solid Oxide Membrane (SOM) Electrolysis Processes

    SciTech Connect

    Guan, Xiaofei; Zink, Peter; Pal, Uday

    2012-03-11

    Pure magnesium (Mg) is recycled from 19g of partially oxidized 50.5wt.%Mg-Aluminum (Al) alloy. During the refining process, potentiodynamic scans (PDS) were performed to determine the electrorefining potential for magnesium. The PDS show that the electrorefining potential increases over time as the Mg content inside the Mg-Al scrap decreases. Up to 100% percent of magnesium is refined from the Mg-Al scrap by a novel refining process of dissolving magnesium and its oxide into a flux followed by vapor phase removal of dissolved magnesium and subsequently condensing the magnesium vapors in a separate condenser. The solid oxide membrane (SOM) electrolysis process is employed in the refining system to enable additional recycling of magnesium from magnesium oxide (MgO) in the partially oxidized Mg-Al scrap. The combination of the refining and SOM processes yields 7.4g of pure magnesium; could not collect and weigh all of the magnesium recovered.

  7. Influence of the surface pre-treatment of aluminum on the processes of formation of cerium oxides protective films

    NASA Astrophysics Data System (ADS)

    Andreeva, R.; Stoyanova, E.; Tsanev, A.; Stoychev, D.

    2016-03-01

    It is known that there is special interest in the contemporary investigations on conversion treatment of aluminum aimed at promoting its corrosion stability, which is focused on electrolytes on the basis of salts of metals belonging to the group of rare-earth elements. Their application is especially attractive, as it enables a successful substitution of the presently applied highly efficient, but at the same time toxic Cr6+-containing electrolytes. The present paper presents a study on the influence of the preliminary alkaline activation and acidic de-oxidation of the aluminum surface on the processes of immersion formation of protective cerium oxides films on Al 1050. The results obtained show that their deposition from simple electrolytes (containing only salts of Ce3+ ions) on the Al surface, treated only in alkaline solution, occurs at a higher rate, which leads to preparing thicker oxide films having a better protective ability. In the cases when the formation of oxide films is realized in a complex electrolyte (containing salts of Ce3+ and Cu2+ ions), better results are obtained with respect to the morphology and protective action of cerium oxides film on samples that have been consecutively activated in alkaline solution and deoxidized in acidic solution. Electrochemical investigations were carried out in a model corrosion medium (0.1 M NaCl); it was shown that the cerium protective films, deposited by immersion, have a cathodic character with regard to the aluminum support and inhibit the occurrence of the depolarizing corrosion process -- the reaction of oxygen reduction.

  8. Modeling, simulation and control of pulsed DE-GMA welding process for joining of aluminum to steel

    NASA Astrophysics Data System (ADS)

    Zhang, Gang; Shi, Yu; Li, Jie; Huang, Jiankang; Fan, Ding

    2014-09-01

    Joining of aluminum to steel has attracted significant attention from the welding research community, automotive and rail transportation industries. Many current welding methods have been developed and applied, however, they can not precisely control the heat input to work-piece, they are high costs, low efficiency and consist lots of complex welding devices, and the generated intermetallic compound layer in weld bead interface is thicker. A novel pulsed double electrode gas metal arc welding(Pulsed DE-GMAW) method is developed. To achieve a stable welding process for joining of aluminum to steel, a mathematical model of coupled arc is established, and a new control scheme that uses the average feedback arc voltage of main loop to adjust the wire feed speed to control coupled arc length is proposed and developed. Then, the impulse control simulation of coupled arc length, wire feed speed and wire extension is conducted to demonstrate the mathematical model and predict the stability of welding process by changing the distance of contact tip to work-piece(CTWD). To prove the proposed PSO based PID control scheme's feasibility, the rapid prototyping experimental system is setup and the bead-on-plate control experiments are conducted to join aluminum to steel. The impulse control simulation shows that the established model can accurately represent the variation of coupled arc length, wire feed speed and the average main arc voltage when the welding process is disturbed, and the developed controller has a faster response and adjustment, only runs about 0.1 s. The captured electric signals show the main arc voltage gradually closes to the supposed arc voltage by adjusting the wire feed speed in 0.8 s. The obtained typical current waveform demonstrates that the main current can be reduced by controlling the bypass current under maintaining a relative large total current. The control experiment proves the accuracy of proposed model and feasibility of new control scheme

  9. Process for the fabrication of aluminum metallized pyrolytic graphite sputtering targets

    DOEpatents

    Makowiecki, Daniel M.; Ramsey, Philip B.; Juntz, Robert S.

    1995-01-01

    An improved method for fabricating pyrolytic graphite sputtering targets with superior heat transfer ability, longer life, and maximum energy transmission. Anisotropic pyrolytic graphite is contoured and/or segmented to match the erosion profile of the sputter target and then oriented such that the graphite's high thermal conductivity planes are in maximum contact with a thermally conductive metal backing. The graphite contact surface is metallized, using high rate physical vapor deposition (HRPVD), with an aluminum coating and the thermally conductive metal backing is joined to the metallized graphite target by one of four low-temperature bonding methods; liquid-metal casting, powder metallurgy compaction, eutectic brazing, and laser welding.

  10. Electrical property studies on chemically processed polypyrolle/aluminum doped ZnO based hybrid heterostructures

    NASA Astrophysics Data System (ADS)

    Mohan Kumar, G.; Ilanchezhiyan, P.; Madhan Kumar, A.; Yuldashev, Sh. U.; Kang, T. W.

    2016-04-01

    A hybrid structure based on p-type polypyrolle (PPy) and n-type aluminum (Al) doped ZnO nanorods was successfully constructed. The effect of Al doping on material properties of wurtzite structured ZnO were studied using several analytical techniques. To establish the desired hybrid structure, pyrrole monomers were polymerized on hydrothermally grown Al doped ZnO nanorods by chemical polymerization. The current-voltage characteristics on the fabricated PPy/Al doped ZnO heterostructures were found to exhibit excellent rectifying characteristics under dark and illumination conditions. The obtained results augment the prescribed architecture to be highly suitable for high-sensitivity optoelectronic applications.

  11. Corrosion Behavior of Ultra-fine Grained 1050 Aluminum Alloy Fabricated by ARB Process in a Buffer Borate Solution

    NASA Astrophysics Data System (ADS)

    Fattah-alhosseini, A.; Gashti, S. O.

    2015-09-01

    Accumulative roll bonding (ARB) has been used as a severe plastic deformation process for the industrial production of ultra-fine grained (UFG) and nano-crystalline sheets with excellent mechanical properties. In the present study, the effect of the ARB process on the corrosion behavior of UFG and nano-crystalline 1050 aluminum alloy in a buffer borate solution (pH 5.5) has been investigated. The result of microhardness tests revealed that microhardness values increase with an increasing number of ARB cycles. A sharp increase in microhardness is seen after three ARB cycles, whereas moderate additional increases are observed afterward for up to nine cycles. Also, the XRD results showed that the mean crystallite size decreased to about 91 nm after nine cycles. The potentiodynamic plots show that as a result of ARB, the corrosion behavior of the UFG and nano-crystalline specimens improves, compared to the annealed 1050 aluminum alloy. Moreover, electrochemical impedance spectroscopy measurements showed that the polarization resistance increases with an increasing number of ARB cycles.

  12. Numerical simulation of melt ejection during the laser drilling process on aluminum alloy by millisecond pulsed laser

    NASA Astrophysics Data System (ADS)

    Wei, Zhang; Jin, Guangyong; Wang, Yibin

    2016-01-01

    In this paper, established a physical model to simulate the melt ejection induced by millisecond pulsed laser on aluminum alloy and use the finite element method to simulate the whole process. A semi-infinite axisymmetric model was established according to the experiment and the analytical solution of temperature in a solid phase was derived based on the thermal conduction equation. Mean while, by assuming that material was removed from the hole once it was melted, the function describing the hole's shape was obtained with the energy balance theory. This simulation is based on the interaction between single pulsed laser with different pulse-width and different peak energy and aluminum alloy material, the result of numerical simulation is that the hole's depth increases with the increase of laser energy and the hole's depth increases with the increase of laser pulse width, the keyhole depth is linearly increased with the increase of laser energy, respectively; the growth of the keyhole radius is in the trend to be gentle. By comparing the theoretical simulation data and the actual test data, we discover that: we discover that: the relative error between the theoretical values and the actual values is about 8.8%, the theoretical simulation curve is well consistent with the actual experimental curve. This research may provide the theoretical references to the understanding of the interaction between millisecond pulsed laser and many kinds of materials, as well as be beneficial to the application of the laser materials processing and military field.

  13. Investigation of the crater-like microdefects induced by laser shock processing with aluminum foil as absorbent layer

    NASA Astrophysics Data System (ADS)

    Ye, Y. X.; Xuan, T.; Lian, Z. C.; Feng, Y. Y.; Hua, X. J.

    2015-06-01

    This paper reports that 3D crater-like microdefects form on the metal surface when laser shock processing (LSP) is applied. LSP was conducted on pure copper block using the aluminum foil as the absorbent material and water as the confining layer. There existed the bonding material to attach the aluminum foil on the metal target closely. The surface morphologies and metallographs of copper surfaces were characterized with 3D profiler, the optical microscopy (OM) or the scanning electron microscopy (SEM). Temperature increases of metal surface due to LSP were evaluated theoretically. It was found that, when aluminum foil was used as the absorbent material, and if there existed air bubbles in the bonding material, the air temperatures within the bubbles rose rapidly because of the adiabatic compression. So at the locations of the air bubbles, the metal materials melted and micromelting pool formed. Then under the subsequent expanding of the air bubbles, a secondary shock wave was launched against the micromelting pool and produced the crater-like microdefects on the metal surface. The temperature increases due to shock heat and high-speed deformation were not enough to melt the metal target. The temperature increase induced by the adiabatic compression of the air bubbles may also cause the gasification of the metal target. This will also help form the crater-like microdefects. The results of this paper can help to improve the surface quality of a metal target during the application of LSP. In addition, the results provide another method to fabricate 3D crater-like dents on metal surface. This has a potential application in mechanical engineering.

  14. Degradation and biodegradability improvement of the olive mill wastewater by peroxi-electrocoagulation/electrooxidation-electroflotation process with bipolar aluminum electrodes.

    PubMed

    Esfandyari, Yahya; Mahdavi, Yousef; Seyedsalehi, Mahdi; Hoseini, Mohammad; Safari, Gholam Hossein; Ghozikali, Mohammad Ghanbari; Kamani, Hossein; Jaafari, Jalil

    2015-04-01

    Olive mill wastewater is considered as one of the most polluting effluents of the food industry and constitutes a source of important environmental problems. In this study, the removal of pollutants (chemical oxygen demand (COD), biochemical oxygen demand (BOD5), polyphenols, turbidity, color, total suspended solids (TSS), and oil and grease) from olive oil mill processing wastewater by peroxi-electrocoagulation/electrooxidation-electroflotation process with bipolar aluminum electrodes was evaluated using a pilot continuous reactor. In the electrochemical unit, aluminum (Al), stainless steel, and RuO2/Ti plates were used. The effects of pH, hydrogen peroxide doses, current density, NaCl concentrations, and reaction times were studied. Under optimal conditions of pH 4, current density of 40 mA/m(2), 1000 mg/L H2O2, 1 g/L NaCl, and 30-min reaction time, the peroxi-electrochemical method yielded very effective removal of organic pollution from the olive mill wastewater diluted four times. The treatment process reduced COD by 96%, BOD5 by 93.6%, total, polyphenols by 94.4%, color by 91.4%, turbidity by 88.7, suspended solids by 97% and oil and grease by 97.1%. The biodegradability index (BOD5/COD) increased from 0.29 to 0.46. Therefore, the peroxi-electrocoagulation/electrooxidation-electroflotation process is considered as an effective and feasible process for pre-treating olive mill wastewater, making possible a post-treatment of the effluent in a biological system. PMID:25408073

  15. Aluminum Hydroxide

    MedlinePlus

    Aluminum hydroxide is used for the relief of heartburn, sour stomach, and peptic ulcer pain and to ... Aluminum hydroxide comes as a capsule, a tablet, and an oral liquid and suspension. The dose and ...

  16. Process for the fabrication of aluminum metallized pyrolytic graphite sputtering targets

    DOEpatents

    Makowiecki, D.M.; Ramsey, P.B.; Juntz, R.S.

    1995-07-04

    An improved method is disclosed for fabricating pyrolytic graphite sputtering targets with superior heat transfer ability, longer life, and maximum energy transmission. Anisotropic pyrolytic graphite is contoured and/or segmented to match the erosion profile of the sputter target and then oriented such that the graphite`s high thermal conductivity planes are in maximum contact with a thermally conductive metal backing. The graphite contact surface is metallized, using high rate physical vapor deposition (HRPVD), with an aluminum coating and the thermally conductive metal backing is joined to the metallized graphite target by one of four low-temperature bonding methods; liquid-metal casting, powder metallurgy compaction, eutectic brazing, and laser welding. 11 figs.

  17. Microstructure Evolution of 1050 Commercial Purity Aluminum Processed by High-Strain-Rate Deformation

    NASA Astrophysics Data System (ADS)

    Yang, Yang; Chen, Yadong; Ma, Fei; Hu, Haibo; Zhang, Qingming; Tang, Tiegang; Zhang, Xiaowei

    2015-11-01

    1050 commercial purity aluminum was first deformed by split-Hopkinson pressure bar. Two means of loading methods were conducted, namely uni-directional impact and multiaxial impact. The nominal strain rates reached 1.1 ×103 and 3.0 × 103/s, respectively, with the total strain 1.6 and 3.6. TEM observations reveal that the initial coarse grains are refined significantly. The majority of the structures in the deformed state are composed of elongated grains/cells whose width/length average grain sizes are 187/411 nm. However, the grains of multiaxial impacted sample are equiaxed with an average size of 517 nm. Dynamic recovery is suppressed during high-strain-rate deformation, so the dislocation configurations could not reach equilibrium states. High densities of dislocations are generated, forming several kinds of configurations. Interactions of dislocation substructures result in the refinement of grains.

  18. Defectivity control of aluminum chemical mechanical planarization in replacement metal gate process of MOSFET

    NASA Astrophysics Data System (ADS)

    Jin, Zhang; Yuling, Liu; Chenqi, Yan; Yangang, He; Baohong, Gao

    2016-04-01

    The replacement metal gate (RMG) defectivity performance control is very challenging in high-k metal gate (HKMG) chemical mechanical polishing (CMP). In this study, three major defect types, including fall-on particles, micro-scratch and corrosion have been investigated. The research studied the effects of polishing pad, pressure, rotating speed, flow rate and post-CMP cleaning on the three kinds of defect, which finally eliminated the defects and achieved good surface morphology. This study will provide an important reference value for the future research of aluminum metal gate CMP. Project supported by the Major National Science and Technology Special Projects (No. 2009ZX02308), the Natural Science Foundation for the Youth of Hebei Province (Nos. F2012202094, F2015202267), and the Outstanding Youth Science and Technology Innovation Fund of Hebei University of Technology (No. 2013010).

  19. Analytical and experimental investigation of the dispersion process during rapid transients for the aluminum-based nuclear fuel plates

    SciTech Connect

    Georgevich, V.; Taleyarkhan, R.P.; Kim, S.H.; Fuketa, T.; Soyama, K.; Ishijima, K.

    1995-06-01

    A thermally induced fuel-plate dispersion model was developed to analyze for dispersive potential and determine the onset of fuel plate dispersion for aluminum-based research and test reactor fuels. The effect of rapid energy deposition in a fuel plate was simulated. Several data types for aluminum-based fuels tested in the Nuclear Safety Research Reactor (NSRR) facility in Japan and in the Transient Reactor Test (TREAT) facility in Idaho, US, were reviewed. Analyses of experiments show that the onset of fuel dispersion is clearly linked to a sharp rise in the predicted strain rate, which further coincides with the onset of aluminum vaporization. Analysis also shows that aluminum oxidation and exothermal chemical reaction between the fuel and aluminum can significantly affect: the energy deposition characteristics and, therefore dispersion onset connected with aluminum vaporization, and the onset of aluminum vaporization.

  20. Heat transfer simulation and retort program adjustment for thermal processing of wheat based Haleem in semi-rigid aluminum containers.

    PubMed

    Vatankhah, Hamed; Zamindar, Nafiseh; Shahedi Baghekhandan, Mohammad

    2015-10-01

    A mixed computational strategy was used to simulate and optimize the thermal processing of Haleem, an ancient eastern food, in semi-rigid aluminum containers. Average temperature values of the experiments showed no significant difference (α = 0.05) in contrast to the predicted temperatures at the same positions. According to the model, the slowest heating zone was located in geometrical center of the container. The container geometrical center F0 was estimated to be 23.8 min. A 19 min processing time interval decrease in holding time of the treatment was estimated to optimize the heating operation since the preferred F0 of some starch or meat based fluid foods is about 4.8-7.5 min. PMID:26396432

  1. Process Conditions of Forming the Surface Layer of Aluminum Powder Product by Layer-by-layer Laser Sintering

    NASA Astrophysics Data System (ADS)

    Saprykina, N. A.; Saprykin, A. A.; Ibragimov, E. A.; Arkhipova, D. A.

    2016-07-01

    The paper presents data on state of the art in selective laser sintering of products. Layer-by-layer sintering is shown to be a future-oriented technology, making it possible to synthesize products of metal powder materials. Factors, influencing the quality of a sintered product, are revealed in the paper. It presents outcomes of experiments, focused on the dependence of surface layer thickness of sintered aluminum powder PA-4 on laser processing conditions. Basic factors, influencing the quality of a sintered surface layer include laser power, speeds of scanning and moving the laser beam on the layer of powder. Thickness of the sintered layer varies from 0.74 to 1.55 mm, as the result of changing the laser processing conditions.

  2. Enhancement and improvement of the mechanical properties of aluminum extruded products by mathematical analysis and simulation process

    NASA Astrophysics Data System (ADS)

    Magid, Hani Mizhir; Sulaiman, S.; Ariffin, M. K. A.; Baharudin, B. T. H. T.

    2015-05-01

    This paper investigates a technique for solving the problems of the aluminum extrusion process, and improving the mechanical properties of the products produced by this method through a smart design, simulation and Mathematical Analysis by using F.E.M. For this purpose, the general F.E.A. Software ABAQUS was used to set up the finite element model of the warm aluminum extrusion in two dimensions (3D). Also, an iterative procedure was carried out using MATLAB at each iteration. The model was formulated as a nonlinear model. The inputs to this model were: the product geometry and its materials specifications such as density, rigidity, elasticity, thermal conductivity, and the required analytical steps. An axisymmetrical (3D) geometric model of the tooling and billet was constructed for the analysis. Data obtained from the F.E model included die-work piece contact pressure, effective stress and strain and material deformation velocity. The correlation between the calculated and collected data from (FEA) was established in this research. Then the billet and die stresses, temperature and the ram speed that closely matched with the strain rates for the desired quality were obtained.

  3. Microstructure and mechanical properties of 7075 aluminum alloy nanostructured composites processed by mechanical milling and indirect hot extrusion

    SciTech Connect

    Flores-Campos, R.; Estrada-Guel, I.; Miki-Yoshida, M.; Martinez-Sanchez, R.; Herrera-Ramirez, J.M.

    2012-01-15

    Nanostructured composites of 7075 aluminum alloy and carbon coated silver nanoparticles were produced by mechanical milling and indirect hot extrusion. The milling products were obtained in a high energy SPEX ball mill, and then were compacted by uniaxial load and pressure-less sintered under argon atmosphere. Finally, the sintered product was hot extruded. Carbon coated silver nanoparticles were well distributed in the matrix of the extruded material. Tensile tests were carried out to corroborate the hypothesis that second phase particles, well dispersed in the matrix, improve the strength of the material. High resolution transmission electron microscopy was employed to locate and make sure that the silver nanoparticles were homogeneously and finely dispersed. Highlights: Black-Right-Pointing-Pointer 7075 Al nanostructured composites can be produced by mechanical milling. Black-Right-Pointing-Pointer Carbon coated silver nanoparticles are well dispersed into aluminum matrix. Black-Right-Pointing-Pointer Ductile Ag-C NP's improve the mechanical properties of the 7075 Al-alloy. Black-Right-Pointing-Pointer Ag-C NP's content has an important effect in the particle and crystallite size. Black-Right-Pointing-Pointer Ag-C NP's keep their morphology after milling and conformation processes.

  4. Friction stir welding of thin-sheet, age-hardenable aluminum alloys: A study of process/structure/property relationships

    NASA Astrophysics Data System (ADS)

    Shukla, Alpesh Khushalchand

    Friction Stir Welding (FSW) is a relatively new joining process that, as a solid-state process, offers several advantages over conventional fusion welding. Although FSW has been used extensively for the joining of age-hardenable aluminum alloys, the detailed effects of process parameters on the microstructures and mechanical properties of these welds have not been studied, especially for thin-sheet alloys. The present study investigated the FSW of thin-sheet, age-hardenable aluminum alloys, including: the development and optimization of welding process parameters that produce high-integrity, defect-free welds; the systematic evaluation of the effect of the base metal microstructure, FSW process parameters, and corresponding weld zone thermal conditions on microstructure evolution across the weld zone; the analysis of FSW mechanical properties and fracture behavior; and the development of relationships between the process parameters, microstructure, properties, and fracture that allow the optimization of weld performance. Two alloy systems, viz., Al-Cu-Mg (2024) and Al-Cu-Li (2195) in naturally-aged and artificially-aged conditions, respectively, were studied. Process optimization in 1 mm thick 2024-T3 sheet resulted in superior properties versus those of FS welds in thick sheet and plate, and nearly 100% joint efficiency. Microstructures, hardness and tensile properties of FS welds in 2024-T3 exhibited a strong dependency on process parameters. The heat of welding promoted various weld zone microstructures that were produced via the dissolution of base metal GPB zones, the nucleation of GBP and GPB II, and the nucleation and coarsening of S phase. SZ hardness for 2024-T3 welds exhibited a strong, but unusual dependency on the FSW process parameters, which was related to different mechanisms related to GPB zone formation. The microstructures of FS welds in 1 mm thick 2195-T8 were generally insensitive to the FSW process parameters. For all weld heat inputs, FSW

  5. Influence of the fabrication process on the functionality of piezoceramic patch transducers embedded in aluminum die castings

    NASA Astrophysics Data System (ADS)

    Klassen, Alexander; Rübner, Matthias; Ilg, Jürgen; Rupitsch, Stefan J.; Lerch, Reinhard; Singer, Robert F.; Körner, Carolin

    2012-11-01

    Piezoceramic patch transducers are integrated into aluminum components using high-pressure die casting. Expanded metal has proven suitable as a supporting structure for placing the patch transducers inside the die cavity and for stabilization during the injection of molten metal. However, difficulties arise when the transducers are positioned off the neutral axis within the wall of the casting. Numerical simulations of the die filling are performed to analyse the evolution of the integration process. The asymmetric infiltration of the supporting structure is identified as the major factor contributing to the formation of cracks and perforations inside the piezoceramic transducer. By means of measurements and numerical calculations of the electrical impedance of the transducer, a close relation is established between mechanical damage patterns observed in radiographs of the patch transducers and loss of performance.

  6. Control of Crystal Morphology for Mold Flux During High-Aluminum AHSS Continuous Casting Process

    NASA Astrophysics Data System (ADS)

    GUO, Jing; SEO, Myung-Duk; SHI, Cheng-Bin; CHO, Jung-Wook; KIM, Seon-Hyo

    2016-05-01

    In the present manuscript, the efforts to control the crystal morphology are carried out aiming at improving the lubrication of lime-alumina-based mold flux for casting advanced high-strength steel with high aluminum. Jackson α factors for crystals of melt crystallization in multi-component mold fluxes are established and reasonably evaluated by applying thermodynamic databases to understand the crystal morphology control both in lime-alumina-based and lime-silica-based mold fluxes. The results show that Jackson α factor and supercooling are the most critical factors to determine the crystal morphology in a mold flux. Crystals precipitating in mold fluxes appear with different morphologies due to their different Jackson α factors and are likely to be more faceted with higher Jackson α factor. In addition, there is a critical supercooling degree for crystal morphology dendritic transition. When the supercooling over the critical value, the crystals transform from faceted shape to dendritic ones in morphology as the kinetic roughening occurs. Typically, the critical supercooling degrees for cuspidine dendritic transition in the lime-silica-based mold fluxes are evaluated to be between 0.05 and 0.06. Finally, addition of a small amount of Li2O in the mold flux can increase the Jackson α factor and decrease the supercooling for cuspidine precipitation; thus, it is favorable to enhance a faceted cuspidine crystal.

  7. Al-SiC powder preparation for electronic packaging aluminum composites by plasma spray processing

    NASA Astrophysics Data System (ADS)

    Gui, Manchang; Kang, Suk Bong; Euh, Kwangjun

    2004-06-01

    Powders of pure aluminum (Al) with 55 and 75 vol.% SiC particles were ball milled in a conventional rotating ball mill with stainless steel and ZrO2 balls for 1-10 h. The morphology and microstructure of the milled powders have been observed and analyzed by scanning electron microscopy (SEM) and energy dispersive x-ray (EDX). The milled powders were plasma sprayed onto a graphite substrate to obtain Al matrix composites with high SiC volume fraction. SiC particles in the milled powders existed in two forms; i.e., the combination of Al into composite powder and individual. Plastic Al particles were broken during ball milling, and fine Al particles can be coated onto the surface of SiC particles. Iron contamination in the milled powders occurred when stainless steel balls were used. The iron level can be effectively controlled by using ZrO2 ball media. The milling efficiency by ZrO2 balls is inferior to that by stainless steel balls. Longer milling time was required with ZrO2 balls to achieve the same effect as obtained with stainless steel balls. SiC particles in the sprayed composites from the milled powders exhibited a reasonably uniform distribution and high volume fraction.

  8. Control of Crystal Morphology for Mold Flux During High-Aluminum AHSS Continuous Casting Process

    NASA Astrophysics Data System (ADS)

    GUO, Jing; SEO, Myung-Duk; SHI, Cheng-Bin; CHO, Jung-Wook; KIM, Seon-Hyo

    2016-08-01

    In the present manuscript, the efforts to control the crystal morphology are carried out aiming at improving the lubrication of lime-alumina-based mold flux for casting advanced high-strength steel with high aluminum. Jackson α factors for crystals of melt crystallization in multi-component mold fluxes are established and reasonably evaluated by applying thermodynamic databases to understand the crystal morphology control both in lime-alumina-based and lime-silica-based mold fluxes. The results show that Jackson α factor and supercooling are the most critical factors to determine the crystal morphology in a mold flux. Crystals precipitating in mold fluxes appear with different morphologies due to their different Jackson α factors and are likely to be more faceted with higher Jackson α factor. In addition, there is a critical supercooling degree for crystal morphology dendritic transition. When the supercooling over the critical value, the crystals transform from faceted shape to dendritic ones in morphology as the kinetic roughening occurs. Typically, the critical supercooling degrees for cuspidine dendritic transition in the lime-silica-based mold fluxes are evaluated to be between 0.05 and 0.06. Finally, addition of a small amount of Li2O in the mold flux can increase the Jackson α factor and decrease the supercooling for cuspidine precipitation; thus, it is favorable to enhance a faceted cuspidine crystal.

  9. Interactions of aluminum with biochars and oxidized biochars: implications for the biochar aging process.

    PubMed

    Qian, Linbo; Chen, Baoliang

    2014-01-15

    Interactions of aluminum with primary and oxidized biochars were compared to understand the changes in the adsorption properties of aged biochars. The structural characteristics of rice straw-derived biochars, before and after oxidation by HNO3/H2SO4, were analyzed by element composition, FTIR, and XPS. The adsorption of Al to primary biochars was dominated by binding to inorganic components (such as silicon particles) and surface complexation of oxygen-containing functional groups via esterification reactions. Oxidization (aging) introduced carboxylic functional groups on biochar surfaces, which served as additional binding sites for Al(3+). At pH 2.5-3.5, the Al(3+) binding was significantly greater on oxidized biochars than primary biochars. After loading with Al, the -COOH groups anchored to biochar surfaces were transformed into COO(-) groups, and the negative surface charge diminished, which indicated that Al(3+) coordinated with COO(-). Biochar is suggested as a potential adsorbent for removing Al from acidic soils. PMID:24364719

  10. PREPARATION OF URANIUM-ALUMINUM ALLOYS

    DOEpatents

    Moore, R.H.

    1962-09-01

    A process is given for preparing uranium--aluminum alloys from a solution of uranium halide in an about equimolar molten alkali metal halide-- aluminum halide mixture and excess aluminum. The uranium halide is reduced and the uranium is alloyed with the excess aluminum. The alloy and salt are separated from each other. (AEC)

  11. Quasicrystalline particulate reinforced aluminum composite

    SciTech Connect

    Anderson, I.E.; Biner, S.B.; Sordelet, D.J.; Unal, O.

    1997-07-01

    Particulate reinforced aluminum and aluminum alloy composites are rapidly emerging as new commercial materials for aerospace, automotive, electronic packaging and other high performance applications. However, their low processing ductility and difficulty in recyclability have been the key concern. In this study, two composite systems having the same aluminum alloy matrix, one reinforced with quasicrystals and the other reinforced with the conventional SiC reinforcements were produced with identical processing routes. Their processing characteristics and tensile mechanical properties were compared.

  12. Aluminum: Reducing chloride emissions from aluminum production

    SciTech Connect

    Simon, P.

    1999-09-29

    Reynolds Metals Company (RMC), with assistance from a NICE{sup 3} grant, is developing for commercialization a closed-loop control process that greatly reduces chlorine emissions and increases plant efficiency while maintaining metal quality. The process still utilizes chlorine to remove impurities during aluminum processing, but is more effective than current methods. With the new technology chlorine in the stack is monitored and input chlorine is adjusted continuously. This optimization of chlorine use results in substantially less waste because less chlorine has to be bought or produced by aluminum manufacturers. This innovation is a significant improvement over conventional aluminum treatments, in which chlorine is injected in a more costly and wasteful manner. By the year 2010, the new technology has the potential to reduce the energy it takes to create chlorine by 8.4 billion Btu per year and to cut greenhouse gas emissions by 1,377 tons per year.

  13. Molecular-dynamics Simulation-based Cohesive Zone Representation of Intergranular Fracture Processes in Aluminum

    NASA Technical Reports Server (NTRS)

    Yamakov, Vesselin I.; Saether, Erik; Phillips, Dawn R.; Glaessgen, Edward H.

    2006-01-01

    A traction-displacement relationship that may be embedded into a cohesive zone model for microscale problems of intergranular fracture is extracted from atomistic molecular-dynamics simulations. A molecular-dynamics model for crack propagation under steady-state conditions is developed to analyze intergranular fracture along a flat 99 [1 1 0] symmetric tilt grain boundary in aluminum. Under hydrostatic tensile load, the simulation reveals asymmetric crack propagation in the two opposite directions along the grain boundary. In one direction, the crack propagates in a brittle manner by cleavage with very little or no dislocation emission, and in the other direction, the propagation is ductile through the mechanism of deformation twinning. This behavior is consistent with the Rice criterion for cleavage vs. dislocation blunting transition at the crack tip. The preference for twinning to dislocation slip is in agreement with the predictions of the Tadmor and Hai criterion. A comparison with finite element calculations shows that while the stress field around the brittle crack tip follows the expected elastic solution for the given boundary conditions of the model, the stress field around the twinning crack tip has a strong plastic contribution. Through the definition of a Cohesive-Zone-Volume-Element an atomistic analog to a continuum cohesive zone model element - the results from the molecular-dynamics simulation are recast to obtain an average continuum traction-displacement relationship to represent cohesive zone interaction along a characteristic length of the grain boundary interface for the cases of ductile and brittle decohesion. Keywords: Crack-tip plasticity; Cohesive zone model; Grain boundary decohesion; Intergranular fracture; Molecular-dynamics simulation

  14. Laser welding of aluminum alloys

    SciTech Connect

    Leong, K.H.; Sabo, K.R.; Sanders, P.G.; Spawr, W.J.

    1997-03-01

    Recent interest in reducing the weight of automobiles to increase fuel mileage has focused attention on the use of aluminum and associated joining technologies. Laser beam welding is one of the more promising methods for high speed welding of aluminum. Consequently, substantial effort has been expended in attempting to develop a robust laser beam welding process. Early results have not been very consistent in the process requirements but more definitive data has been produced recently. This paper reviews the process parameters needed to obtain consistent laser welds on 5,000 series aluminum alloys and discusses the research necessary to make laser processing of aluminum a reality for automotive applications.

  15. Aluminum-Silicon Alloy Having Improved Properties At Elevated Temperatures and Process for Producing Cast Articles Therefrom

    NASA Technical Reports Server (NTRS)

    Lee, Jonathan A. (Inventor); Chen, Po-Shou (Inventor)

    2002-01-01

    A process for making a cast article from an aluminum alloy includes first casting an article from an alloy having the following composition, in weight percent: Silicon 11.0-14.0, Copper 5.6-8.0, Iron 0-0.8, Magnesium 0.5-1.5, Nickel 0.05-0.9, Manganese 0-1.0, Titanium 0.05-1.2, Zirconium 0.12-1.2, Vanadium 0.05-1.2, Zinc 0.05-0.9, Strontium 0.001-0.1, Aluminum balance . In this alloy the ratio of silicon to magnesium is 10 to 25, and the ratio of copper to magnesium is 4 to 15. After an article is cast from the alloy, the cast article is aged at a temperature within the range of 400F to 500F for a time period within the range of four to 16 hours. It has been found especially advantageous if the cast article is first exposed to a solutionizing step prior to the aging step. This solutionizing step is carried out by exposing the cast article to a temperature within the range of 900F to 1000F for a time period of fifteen minutes to four hours. It has also been found to be especially advantageous if the solutionizing step is followed directly with a quenching step, wherein the cast article is quenched in a quenching medium such as water at a temperature within the range of 120F to 300F. The resulting cast article is suitable in a number of high temperature applications, such as heavy-duty pistons for internal combustion engines.

  16. Energy Assessment Helps Kaiser Aluminum Save Energy and Improve Productivity; DOE Software Adopted as Standard for Analyzing Plant Process Heating Systems Company-Wide

    SciTech Connect

    Not Available

    2008-07-01

    This case study describes how the Kaiser Aluminum plant in Sherman, Texas, achieved annual savings of $360,000 and 45,000 MMBtu, and improved furnace energy intensity by 11.1% after receiving a DOE Save Energy Now energy assessment and implementing recommendations to improve the efficiency of its process heating system.

  17. The Development of an Innovative Vertical Floatation Melter and Scrap Dryer for Use in the Aluminum Processing Industry

    SciTech Connect

    Robert De Saro

    2004-08-24

    The project aimed at the development of a Vertical Floatation melter, for application to the aluminum industry. This is intended to improve both the energy efficiency and environmental performance of aluminum melting furnaces. Phase I of this project dealt primarily with the initial research effort. Phase II, dealt with pilot-scale testing.

  18. Impact of aluminum chloride on process performance and microbial community structure of granular sludge in an upflow anaerobic sludge blanket reactor for natural rubber processing wastewater treatment.

    PubMed

    Thanh, Nguyen Thi; Watari, Takahiro; Thao, Tran Phuong; Hatamoto, Masashi; Tanikawa, Daisuke; Syutsubo, Kazuaki; Fukuda, Masao; Tan, Nguyen Minh; Anh, To Kim; Yamaguchi, Takashi; Huong, Nguyen Lan

    2016-01-01

    In this study, granular sludge formation was carried out using an aluminum chloride supplement in an upflow anaerobic sludge blanket (UASB) reactor treating natural rubber processing wastewater. Results show that during the first 75 days after the start-up of the UASB reactor with an organic loading rate (OLR) of 2.65 kg-COD·m(-3)·day(-1), it performed stably with a removal of 90% of the total chemical oxygen demand (COD) and sludge still remained in small dispersed flocs. However, after aluminum chloride was added at a concentration of 300 mg·L(-1) and the OLR range was increased up to 5.32 kg-COD·m(-3)·day(-1), the total COD removal efficiency rose to 96.5 ± 2.6%, with a methane recovery rate of 84.9 ± 13.4%, and the flocs began to form granules. Massively parallel 16S rRNA gene sequencing of the sludge retained in the UASB reactor showed that total sequence reads of Methanosaeta sp. and Methanosarcina sp., reported to be the key organisms for granulation, increased after 311 days of operation. This indicates that the microbial community structure of the retained sludge in the UASB reactor at the end of the experiment gave a good account of itself in not only COD removal, but also granule formation. PMID:27438256

  19. Extracting aluminum from dross tailings

    NASA Astrophysics Data System (ADS)

    Amer, A. M.

    2002-11-01

    Aluminum dross tailings, an industrial waste, from the Egyptian Aluminium Company (Egyptalum) was used to produce two types of alums: aluminum-sulfate alum [itAl2(SO4)3.12H2O] and ammonium-aluminum alum [ (NH 4)2SO4AL2(SO4)3.24H2O]. This was carried out in two processes. The first process is leaching the impurities using diluted H2SO4 with different solid/liquid ratios at different temperatures to dissolve the impurities present in the starting material in the form of solute sulfates. The second process is the extraction of aluminum (as aluminum sulfate) from the purifi ed aluminum dross tailings thus produced. The effects of temperature, time of reaction, and acid concentration on leaching and extraction processes were studied. The product alums were analyzed using x-ray diffraction and thermal analysis techniques.

  20. An equilibrium model for chloride removal from recycled cooling water using the ultra-high lime with aluminum process.

    PubMed

    Abdel-Wahab, Ahmed; Batchelor, Bill; Schwantes, Jon

    2005-01-01

    Removal of chloride from recycled cooling water is needed to reduce corrosion and prolong equipment life. Laboratory experiments have demonstrated that the ultra-high lime with aluminum (UHLA) process has the ability to achieve high chloride removal efficiency from recycled cooling water. In an effort to further understand the behavior of chloride in the UHLA process, a fundamental model of the chemical processes was developed. The purpose of this paper is to describe this equilibrium model and present values for solubility products of precipitated solids that have not been investigated previously. The model was based on PHREEQC and a new program called INVRS K was integrated with PHREEQC to calculate values of unknown or poorly defined equilibrium or kinetic constants using a Gauss-Newton nonlinear regression routine. Model predictions indicated that the results could be best described by assuming the formation of a solid solution of calcium chloroaluminate (Ca4Al2Cl2OH12), tricalcium hydroxyaluminate (Ca3Al2OH12), and tetracalcium hydroxyaluminate (Ca4Al2OH14). PMID:16381154

  1. The influence of process parameters on porosity formation in hybrid LASER-GMA welding of AA6082 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Ascari, Alessandro; Fortunato, Alessandro; Orazi, Leonardo; Campana, Giampaolo

    2012-07-01

    This paper deals with an experimental campaign carried out on AA6082 8 mm thick plates in order to investigate the role of process parameters on porosity formation in hybrid LASER-GMA welding. Bead on plate weldments were obtained on the above mentioned aluminum alloy considering the variation of the following process parameters: GMAW current (120 and 180 A for short-arc mode, 90 and 130 A for pulsed-arc mode), arc transfer mode (short-arc and pulsed-arc) and mutual distance between arc and LASER sources (0, 3 and 6 mm). Porosities occurring in the fused zone were observed by means of X-ray inspection and measured exploiting an image analysis software. In order to understand the possible correlation between process parameters and porosity formation an analysis of variance statistical approach was exploited. The obtained results pointed out that GMAW current is significant on porosity formation, while the distance between the sources do not affect this aspect.

  2. Fabrication of Machined and Shrink Fitted Impactor; Composite Liners for the Los Alamos HEDP Program

    SciTech Connect

    Randolph, B.

    1999-10-19

    Composite liners have been fabricated for the Los Alamos liner driven HEDP experiments using impactors formed by physical vapor deposition (PVD), electroplating, machining and shrink fitting. Chemical vapor deposition (CVD) has been proposed for some ATLAS liner applications. This paper describes the processes used to fabricate machined and shrink fitted impactors which have been used for copper impactors in 1100 aluminum liners and 6061 T-6 aluminum impactors in 1100 aluminum liners. The most successful processes have been largely empirically developed and rely upon a combination of shrink fitted and light press fitting. The processes used to date will be described along with some considerations for future composite liners requirements in the HEDP Program.

  3. Dust Explosion Characteristics of Aluminum, Titanium, Zinc, and Iron-Based Alloy Powders Used in Cold Spray Processing

    NASA Astrophysics Data System (ADS)

    Sakata, K.; Tagomori, K.; Sugiyama, N.; Sasaki, S.; Shinya, Y.; Nanbu, T.; Kawashita, Y.; Narita, I.; Kuwatori, K.; Ikeda, T.; Hara, R.; Miyahara, H.

    2014-01-01

    Compared to conventional thermal spray coating, cold spray processing typically employs finer, smaller-diameter metal powders. Furthermore, cold-sprayed particles exhibit fewer surface oxides than thermally sprayed particles due to the absence of particle melting during spraying. For these reasons, it is important to consider the potential for dust explosions or fires during cold spray processing, for both industrial and R&D applications. This work examined the dust explosion characteristics of metal powders typically used in cold spray coating, for the purpose of preventing dust explosions and fires and thus protecting the health and safety of workers and guarding against property damage. In order to safely make use of the new cold spray technology in industrial settings, it is necessary to manage the risks based on an appropriate assessment of the hazards. However, there have been few research reports focused on such risk management. Therefore, in this study, the dust explosion characteristics of aluminum, titanium, zinc, carbonyl iron, and eutectoid steel containing chromium at 4 wt.% (4 wt.% Cr-eutectoid steel) powders were evaluated according to the standard protocols JIS Z 8818, IEC61241-2-3(1994-09) section 3, and JIS Z 8817. This paper reports our results concerning the dust explosion properties of the above-mentioned metal powders.

  4. Effect of tool velocity ratio on tensile properties of friction stir processed aluminum based metal matrix composites

    NASA Astrophysics Data System (ADS)

    Vijayavel, P.; Balasubramanian, V.

    2016-08-01

    In friction stir processing (FSP), tool rotational speed (TRS) and tool traverse speed (TTS) are the two important parameters, known to produce significant changes in the properties of the processed material. Increasing the TRS and TTS beyond a certain level would produce undesirable results. The heat generation will increase with an increase in the TRS and decrease in TTS. Excessive heat generation results in the formation of coarse grains exhibiting poor mechanical properties. The heat generation will decrease with decrease in the TRS and increase in TTS. Low heat generation will lead to inadequate plasticization and improper material flow. Hence a perfect combination of TRS and TTS is required to attain desirable properties in FSPed material. In this investigation FSP was carried out on aluminum based metal matrix composite (LM25AA+5%SiCp) material using five different tool velocity ratios (TVR: TRS/TTS). The FSP was subjected to microstructural characterization and tensile properties, evaluation. The results revealed that the TVR of 2.6 yielded superior tensile properties compared to other conditions.

  5. Nondestructive Evaluation of the Friction Weld Process on 2195/2219 Grade Aluminum

    NASA Technical Reports Server (NTRS)

    Suits, Michael W.; Clark, Linda S.; Cox, Dwight E.

    1999-01-01

    In 1996, NASA's Marshall Space Flight Center began an ambitious program designed to find alternative methods of repairing conventional TIG (Tungsten Inert Gas) welds and VPPA (Variable Polarity Plasma Arc) welds on the Space Shuttle External Tank without producing additional heat-related anomalies or conditions. Therefore, a relatively new method, invented by The Welding Institute (TWI) in Cambridge, England, called Friction Stir Welding (FSW), was investigated for use in this application, as well as being used potentially as an initial weld process. As with the conventional repair welding processes, nondestructive evaluation (NDE) plays a crucial role in the verification of these repairs. Since it was feared that conventional NDE might have trouble with this type of weld structure (due to shape of nugget, grain structure, etc.) it was imperative that a complete study be performed to address the adequacy of the NDE process. This paper summarizes that process.

  6. Recovering aluminum from aluminum dross in a DC electric-arc rotary furnace

    NASA Astrophysics Data System (ADS)

    Tzonev, Tz.; Lucheva, B.

    2007-11-01

    The recycling of aluminum scrap and dross yields significant economic and energy savings, as well environmental benefits. The recovery of aluminum depends on many factors. The aim of this work is to experimentally investigate aluminum recovery under different conditions. In this study, aluminum dross was processed in a direct-current electric-arc rotary furnace. The presence of crushing refractory bodies during processing was found to increase the degree of aluminum recovery by about ten percent.

  7. Statistical analysis of process parameters to eliminate hot cracking of fiber laser welded aluminum alloy

    NASA Astrophysics Data System (ADS)

    Wang, Jin; Wang, Hui-Ping; Wang, Xiaojie; Cui, Haichao; Lu, Fenggui

    2015-03-01

    This paper investigates hot cracking rate in Al fiber laser welding under various process conditions and performs corresponding process optimization. First, effects of welding process parameters such as distance between welding center line and its closest trim edge, laser power and welding speed on hot cracking rate were investigated experimentally with response surface methodology (RSM). The hot cracking rate in the paper is defined as ratio of hot cracking length over the total weld seam length. Based on the experimental results following Box-Behnken design, a prediction model for the hot cracking rate was developed using a second order polynomial function considering only two factor interaction. The initial prediction result indicated that the established model could predict the hot cracking rate adequately within the range of welding parameters being used. The model was then used to optimize welding parameters to achieve cracking-free welds.

  8. Electrode patterning and annealing processes of aluminum-doped zinc oxide thin films using a UV laser system

    NASA Astrophysics Data System (ADS)

    Hsiao, Wen-Tse; Tseng, Shih-Feng; Huang, Kuo-Cheng; Chiang, Donyau

    2013-01-01

    This study presents the hybrid processing (patterning and annealing) of aluminum-doped zinc oxide (AZO) films in a one-step process using a diode-pumped-solid-state (DPSS) ultraviolet (UV) laser system. The focused laser beam had a diameter of 30 μm and the positive defocused laser beam had a diameter of 1 mm. Both beams were adjusted using a UV laser-processing system. AZO films were deposited on Corning Eagle 2000® optical glass sheets with a thickness of 0.7 mm using a sputtering method. The deposited films were approximately 200 nm. The optoelectronic properties of machined (patterning and annealing) AZO films depend on the laser pulse frequency and galvanometer scanning speed. The surface morphology, roughness, optical transmittance, and resistivity of the films after the laser patterning and annealing processes were measured using a three-dimensional confocal laser scanning microscope, a field emission scanning electron microscope (FE-SEM), a spectrophotometer, and a four-point probe instrument, respectively. Experimental results indicate that the ablation depth increased as the pulse repetition frequency increased. The ablation depth also decreased as the galvanometric scanning speed increased. The transmittance spectra of the film changes slightly after laser annealing, and the average transmittance in the visible region is approximately 83%. All resistivity values of laser-patterned and annealed AZO films decreased significantly. The structural properties grain size was calculated firm the X-ray diffraction (XRD) spectra using the Scherrer equation that increased from 7.4 nm to 12 nm as the annealing scanning speed decreased from 800 mm/s to 400 mm/s. The root mean square (RMS) values of annealed AZO films treated with a laser scanning speed of 500 mm/s with a pulse repetition frequency of 40 kHz, 55 kHz, and 70 kHz were 1.1 nm, 1.2 nm, and 1.8 nm, respectively.

  9. INDUSTRIAL PROCESS PROFILES FOR ENVIRONMENTAL USE: CHAPTER 25. PRIMARY ALUMINUM INDUSTRY

    EPA Science Inventory

    The catalog of Industrial Process Profiles for Environmental Use was developed as an aid in defining the environmental impacts of industrial activity in the United States. Entries for each industry are in consistent format and form separate chapters of the study. The primary alum...

  10. Oxide film microstructure: the link between surface preparation processes and strength/durability of adhesively bonded aluminum. Final report

    SciTech Connect

    Hsia, K. Jimmy; Pearlstein, Arne J.; Scheeline, Alexander; Shang, Jian Ku

    2000-11-30

    Strength and durability of adhesive bonding of aluminum alloys structures are intrinsically determined by the surface microstructures and interfacial failure micromechanisms. The current project presents a multidisciplinary approach to addressing critical issues controlling the strength and durability of adhesive bonds of aluminum alloys. Three main thrust areas have been pursued: surface treatment technology development to achieve desirable surface microstructures; relationship between surface structure and properties of adhesive bonds; and failure mechanisms of adhesively bonded components.

  11. Lost-Soap Aluminum Casting.

    ERIC Educational Resources Information Center

    Mihalow, Paula

    1980-01-01

    Lost-wax casting in sterling silver is a costly experience for the average high school student. However, this jewelry process can be learned at no cost if scrap aluminum is used instead of silver, and soap bars are used instead of wax. This lost-soap aluminum casting process is described. (Author/KC)

  12. Boron carbide-aluminum cermets

    SciTech Connect

    Halverson, D.C.

    1986-09-03

    We have developed boron carbide-aluminum cermets by means of thermodynamic, kinetic, and processing studies. Our research indicates that boron carbide-aluminum cermets offer ''tailorable'' microstructures with designable properties through process control. This new class of cermets has the potential to become a very important material with wide industrial applications.

  13. Dislocation processes in the deformation of nanocrystalline aluminum by molecular-dynamics simulation.

    SciTech Connect

    Yamakov, V.; Wolf, D.; Phillpot, S. R.; Mukherjee, A. K.; Gleiter, H.; Materials Science Division; Univ. of California; Forschungszentrum Karlsruhe

    2002-09-01

    The mechanical behaviour of nanocrystalline materials (that is, polycrystals with a grain size of less than 100 nm) remains controversial. Although it is commonly accepted that the intrinsic deformation behaviour of these materials arises from the interplay between dislocation and grain-boundary processes, little is known about the specific deformation mechanisms. Here we use large-scale molecular-dynamics simulations to elucidate this intricate interplay during room-temperature plastic deformation of model nanocrystalline Al microstructures. We demonstrate that, in contrast to coarse-grained Al, mechanical twinning may play an important role in the deformation behaviour of nanocrystalline Al. Our results illustrate that this type of simulation has now advanced to a level where it provides a powerful new tool for elucidating and quantifying-in a degree of detail not possible experimentally-the atomic-level mechanisms controlling the complex dislocation and grain-boundary processes in heavily deformed materials with a submicrometre grain size.

  14. Microstructure evolution process of Ferro-Aluminum based sandwich composite for electromagnetic shielding.

    PubMed

    Luo, Zhichao; Zhang, Qiang; Ma, Xiangyu; Wu, Gaohui

    2014-09-01

    In this paper, sandwich composite (SWC) with Fe-Al soft magnetic alloy sandwiched between pure iron substrates was proposed and fabricated by hot pressing and diffusion treatment. The microstructure evolution process of the composite was investigated. Fe/Fe2Al5/Fe diffusion couple was obtained at 700 °C and subsequently kept at 900 °C for further isothermal diffusion. During the diffusion reactive process, we confirmed that major FeAl2 and minor Fe4Al13 were produced when Fe2Al5 dissolved. After 10h of diffusion treatment, FeAl and α-Fe(Al) were the only two intermetallic phases left. Except FeAl2, the thickness of each intermetallic layer held good parabolic relationship with the diffusion annealing time. PMID:24981211

  15. Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

    DOE PAGESBeta

    Rabby, Reza; Tang, Wei; Reynolds, A. P.

    2015-05-13

    In this article, the effect of pin features and orientation/placement of the materials on advancing side were investigated for friction stir welding (FSW) of dissimilar aluminum alloys AA2050 and AA6061. Pins for FSW were produced with a 2.12 mm pitch thread having three flats/flutes. Three sets of rotational speed/welding speed were used to perform a series of welds in a butt joint arrangement. The results show that, joint quality, process response variables and welding temperature are highly affected by pin features and material orientation in FSW. Defect free joints with effective material transportation in the weld nugget zone were obtainedmore » when welding was performed with AA2050 on the advancing side. The tool also encounters less in-plane reaction force for welding with 2050 on the advancing side. Pin with thread+3 flats produces quality welds at low rotational and travel speed regardless of the location of alloys on advancing or retreating side.« less

  16. Semi-quantitative predictions of hot tearing and cold cracking in aluminum DC casting using numerical process simulator

    NASA Astrophysics Data System (ADS)

    Subroto, T.; Miroux, A.; Mortensen, D.; M'Hamdi, M.; Eskin, D. G.; Katgerman, L.

    2012-07-01

    Cracking is one of the most critical defects that may occur during aluminum direct-chill (DC) casting. There are two types of cracking typical of DC casting: hot tearing and cold cracking. To study and predict such defects, currently we are using a process simulator, ALSIM. ALSIM is able to provide semi-quantitative predictions of hot tearing and cold cracking susceptibility. In this work, we performed benchmark tests using predictions of both types of cracks and experimental results of DC casting trials. The trials series resulted in billets with hot tearing as well as cold cracking. The model was also used to study the influence of several casting variables such as casting speed and inlet geometry with respect to the cracking susceptibility in the ingots. In this work, we found that the sump geometry was changed by the feeding scheme, which played an important role in hot tear occurrence. Moreover, increasing the casting speed also increased the hot tear and cold crack susceptibility. In addition, from the result of simulation, we also observed a phenomenon that supported the hypotheses of connection between hot tearing and cold cracking.

  17. Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

    SciTech Connect

    Rabby, Reza; Tang, Wei; Reynolds, A. P.

    2015-05-13

    In this article, the effect of pin features and orientation/placement of the materials on advancing side were investigated for friction stir welding (FSW) of dissimilar aluminum alloys AA2050 and AA6061. Pins for FSW were produced with a 2.12 mm pitch thread having three flats/flutes. Three sets of rotational speed/welding speed were used to perform a series of welds in a butt joint arrangement. The results show that, joint quality, process response variables and welding temperature are highly affected by pin features and material orientation in FSW. Defect free joints with effective material transportation in the weld nugget zone were obtained when welding was performed with AA2050 on the advancing side. The tool also encounters less in-plane reaction force for welding with 2050 on the advancing side. Pin with thread+3 flats produces quality welds at low rotational and travel speed regardless of the location of alloys on advancing or retreating side.

  18. Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

    SciTech Connect

    Rabby, Reza; Tang, Wei; Reynolds, A. P.

    2015-07-01

    In this article, the effect of pin features and orientation/placement of the materials on advancing side were investigated for friction stir welding (FSW) of dissimilar aluminum alloys AA2050 and AA6061. Pins for FSW were produced with a 2.12 mm pitch thread having three flats/flutes. Three sets of rotational speed/welding speed were used to perform a series of welds in a butt joint arrangement. The results show that, joint quality, process response variables and welding temperature are highly affected by pin features and material orientation in FSW. Defect free joints with effective material transportation in the weld nugget zone were obtained when welding was performed with AA2050 on the advancing side. The tool also encounters less in-plane reaction force for welding with 2050 on the advancing side. Pin with thread+3 flats produces quality welds at low rotational and travel speed regardless of the location of alloys on advancing or retreating side.

  19. An experimental investigation of springback of AA6061 aluminum alloy strip via V- bending process

    NASA Astrophysics Data System (ADS)

    Abdullah, A. B.; Samad, Z.

    2013-12-01

    Springback is one of the common geometrical defects found in the sheet metal forming process. Aluminium alloy with high content of magnesium such as AA6061 is preferred for their high formability limit, but commonly springback becomes a drawback. In this study, springback behaviour of the AA6061 will be observed. The effect of length, thickness and bend angle to the springback pattern was investigated and the result depicted that springback is more significant to thickness and bend angle, while the length gives less effect.

  20. Influence of Process Parameters on Forming of Arched Aircraft Skin with Aluminum Alloy 2024

    NASA Astrophysics Data System (ADS)

    Yan, Huajun; Zhang, Shuangjie; Gao, Ying

    To solve these problems such as easily springback and hardly controlling the loading direction when arched aircraft skin is formed, stretch forming of steel plate with aluminium alloy 2024 was simulated by the finite element software Abaqus, and the shape of the stretch forming die was the arc with radius 350mm. The influence of process parameters, such as stretch forming track and dangling length on forming of arched aircraft skin was researched, and the reasonable range of stretch forming length track and dangling length was given. The results have significance for research the forming law of arched aircraft skin.

  1. On the processing, structure and properties of aluminum oxide-magnesium aluminate nanocomposites

    NASA Astrophysics Data System (ADS)

    McEnerney, Bryan William

    Improvement in the mechanical properties of ceramic materials is required to better integrate them into new technological applications, such as ballistic armor. While considerable attention has been given to advanced power preparation and powder processing techniques, there has been comparatively little investigation of the nanostructure of the materials. No systematic study has been performed to correlate very fine grain sizes with dynamic mechanical properties of ceramic materials. The purpose of this study is to investigate the high-strain-rate behavior of nanocomposite ceramic materials fabricated by a cost-effective, scalable processing. The starting powders chosen were Baikowski RC-SPT DBM Al 2O3 and Malakoff S30CR MgAl2O4, both being high-purity sub-1 mum powders. The test compositions studied were Al2O3---20 vol. % MgAl2O4, Al2O3---40 vol. % MgAl2O4, and Al2O3---60 vol. % MgAl2O4. The powders were consolidated by spray drying and then melting in a direct current (DC) arc plasma and, subsequently, quenched in water. The metastable powders were comminuted, cold pressed, and densified using hot isostatic pressing. The Vickers hardness of the materials was measured as a function of indentation load, and the strength was measured using a Split-Hopkinson Pressure Bar. The hardness of all three compositions was found to be unexpectedly high. This high hardness was attributed to the unique nanostructure of the materials. This nanostructure developed during decomposition of the metastable, plasma melted powder to the thermodynamically stable phases by solid state diffusion during hot isostatic pressing. With decreasing processing temperatures, the hardness of the samples improved significantly for the Al2O 3---40 vol. % MgAl2O4 and Al2O 3---60 vol. % MgAl2O4 compositions. It was further found that, within the standard deviation, there was minimal deviation between the hardness behaviors of these compositions, which was contrary to the behavior of the control samples

  2. Directionally Solidified Aluminum - 7 wt% Silicon Alloys: Comparison of Earth and International Space Station Processed Samples

    NASA Technical Reports Server (NTRS)

    Grugel, Richard N,; Tewari, Surendra; Rajamure, R. S.; Erdman, Robert; Poirier, David

    2012-01-01

    Primary dendrite arm spacings of Al-7 wt% Si alloy directionally solidified in low gravity environment of space (MICAST-6 and MICAST-7: Thermal gradient approx. 19 to 26 K/cm, Growth speeds varying from 5 to 50 microns/s show good agreement with the Hunt-Lu model. Primary dendrite trunk diameters of the ISS processed samples show a good fit with a simple analytical model based on Kirkwood s approach, proposed here. Natural convection, a) decreases primary dendrite arm spacing. b) appears to increase primary dendrite trunk diameter.

  3. Cathodic phenomena in aluminum electrowinning

    NASA Astrophysics Data System (ADS)

    Bouteillon, J.; Poignet, J. C.; Rameau, J. J.

    1993-02-01

    Although aluminum is one of the world's highest production-volume primary metals, it is particularly costly to produce for a variety of factors, not the least of which are the expenses associated with electrolytic reduction. Based on the scale of global aluminum processing, even minor improvements in the electrowinning technology can result in significant savings of resources. Thus, from this perspective, the following reviews recent studies of cathodic phenomena in aluminum electrowinning.

  4. Rapid and economical indicator for evaluating arsenic removal with minimum aluminum residual during coagulation process.

    PubMed

    Kang, Meea; Chen, Hong; Sato, Yuko; Kamei, Tasuku; Magara, Yasumoto

    2003-11-01

    Detection of various types of contaminants in water treatment plant by sophisticated analytical methods such as inductively coupled plasma/mass spectrometry and gas chromatography/mass spectrometry requires hours to days to provide the results. Because naturally occurring ultraviolet (UV) active compounds are commonly present in almost all source waters and can be rapidly monitored by UV absorbance at 260 nm (E260), the extent of correlation between the removal efficiency of E260 and the removal efficiency of As(V) with minimum soluble residual Al by coagulation process was investigated. Percentage removals for E260 were well correlated to those of As(V). When sufficient alum or polyaluminum chloride (PACl) was added for 60-65% removal of E260, 90-95% removal of As(V) was achieved with minimum soluble residual Al regardless of the initial level of turbidity, E260, and As(V). As E260 analysis is precisely available even by an unskilled plant operator in a few minutes, E260 removal efficiency appears to be the promising economical indicator for monitoring the effectiveness of the coagulation process for the removal of contaminants with minimum residual Al. PMID:14568045

  5. An evaluation of direct pressure sensors for monitoring the aluminum die casting process

    SciTech Connect

    Zhang, X.

    1997-12-31

    This study was conducted as part of the US Department of Energy (DOE) sponsored project Die Cavity Instrumentation. One objective of that project was to evaluate thermal, pressure, and gas flow process monitoring sensors in or near the die cavity as a means of securing improved process monitoring and control and better resultant part quality. The objectives of this thesis are to (1) evaluate a direct cavity pressure sensor in a controlled production campaign at the GM Casting Advanced Development Center (CADC) at Bedford, Indiana; and (2) develop correlations between sensor responses and product quality in terms of the casting weight, volume, and density. A direct quartz-based pressure sensor developed and marked by Kistler Instrument Corp. was acquired for evaluating as an in-cavity liquid metal pressure sensor. This pressure sensor is designed for use up to 700 C and 2,000 bars (29,000 psi). It has a pressure overload capacity up to 2,500 bars (36,250 psi).

  6. Properties of largest fragment produced by hypervelocity impact of aluminum spheres with thin aluminum sheets

    NASA Technical Reports Server (NTRS)

    Piekutowski, Andrew J.

    1992-01-01

    Results are presented from hypervelocity impact tests in which 1.275 g spheres of 2017-T4 Al alloy were fired at normal incidence at eight thicknesses of 6061-T6 Al alloy sheets, with impact velocity of about 6.7 km/sec; additional data are presented for smaller and larger spheres than these, in the cases of other Al alloy impact bumpers. A large fragment of the projectile is observable at the center of the debris clouds generated upon impact. The velocity of these large fragments decreased continuously with increasing bumper thickness/projectile diameter ratio, from 99 percent to less than 80 percent of impact velocity; there is a linear increase in the size of the central projectile fragment with decreasing shock-induced stress in the projectile.

  7. Experimental Investigations on Formability of Aluminum Tailor Friction Stir Welded Blanks in Deep Drawing Process

    NASA Astrophysics Data System (ADS)

    Kesharwani, R. K.; Panda, S. K.; Pal, S. K.

    2015-02-01

    In the present work, tailor friction stir welded blanks (TFSWBs) were fabricated successfully using 2.0-mm-thick AA5754-H22 and AA5052-H32 sheet metals with optimized tool design and process parameters. Taguchi L9 orthogonal array has been used to design the friction stir welding experiments, and the Grey relational analysis has been applied for the multi objective optimization in order to maximize the weld strength and total elongation reducing the surface roughness and energy consumption. The formability of the TFSWBs and parent materials was evaluated and compared in terms of limiting drawing ratio (LDR) using a conventional circular die. It was found that the formability of the TFSWBs was comparable with that of both the parent materials without failure in the weldment. A modified conical tractrix die (MCTD) was proposed to enhance the LDR of the TFSWBs. It was found that the formability was improved by 27% using the MCTD.

  8. Lift-Off Processing and Aluminum on Silicon Superconducting Circuit Coherence

    NASA Astrophysics Data System (ADS)

    Dunsworth, Andrew; Megrant, Anthony; Quintana, Chris; Chen, Zijun; Barends, Rami; Chen, Yu; Fowler, Austin; Jeffrey, Evan; Mutus, Josh; Roushan, Pedram; Sank, Daniel; Hoi, Iochun; Campbell, Brooks; Chiaro, Ben; Kelly, Julian; Neil, Charels; O'Malley, Peter; Vainsencher, Amit; Wenner, Jim; White, Ted; Cleland, Andrew; Martinis, John; Martinis Group Team

    2015-03-01

    Dielctric loss from two level states (TLS's) are a limiting decoherence method in planar superconducting qubits. Previously we have shown that liftoff deposited metal has more loss than etched devices. Current fabrication techniques of Xmon qubit devices limit this loss by using liftoff metal on only a small area of the transmon including the Josephson junctions. However this method leads to excess loss when used on a silicon substrate. I have used quality factor measurments of coplanar waveguide resonator circuits as a tool to measure isolated steps in the liftoff processes. I will report on the effects of these steps and their added loss. This research was funded by the Office of the Director of National Intelligence (ODNI), Intelligence Advanced Research Projects Activity (IARPA), through the Army Research Office Grant JMAR-05.

  9. Multiscale Modeling of Damage Processes in fcc Aluminum: From Atoms to Grains

    NASA Technical Reports Server (NTRS)

    Glaessgen, E. H.; Saether, E.; Yamakov, V.

    2008-01-01

    Molecular dynamics (MD) methods are opening new opportunities for simulating the fundamental processes of material behavior at the atomistic level. However, current analysis is limited to small domains and increasing the size of the MD domain quickly presents intractable computational demands. A preferred approach to surmount this computational limitation has been to combine continuum mechanics-based modeling procedures, such as the finite element method (FEM), with MD analyses thereby reducing the region of atomic scale refinement. Such multiscale modeling strategies can be divided into two broad classifications: concurrent multiscale methods that directly incorporate an atomistic domain within a continuum domain and sequential multiscale methods that extract an averaged response from the atomistic simulation for later use as a constitutive model in a continuum analysis.

  10. Evaluation of Various Depainting Processes on Mechanical Properties of 2024-T3 Aluminum Substrate

    NASA Technical Reports Server (NTRS)

    McGill, P.

    2001-01-01

    Alternate alkaline and neutral chemical paint strippers have been identified that, with respect to corrosion requirements, perform as well as or better than a methylene chloride baseline. These chemicals also, in general, meet corrosion acceptance criteria as specified in SAE MA 4872. Alternate acid chemical paint strippers have been identified that, with respect to corrosion requirements, perform as well as or better than a methylene chloride baseline. However, these chemicals do not generally meet corrosion acceptance criteria as specified in SAE MA 4872, especially in the areas of non-clad material performance and hydrogen embrittlement. Media blast methods reviewed in the study do not, in general, adversely affect fatigue performance or crack detectability of 2024-T3 substrate. Sodium bicarbonate stripping exhibited a tendency towards inhibiting crack detectability. These generalizations are based on a limited sample size and additional testing should be performed to characterize the response of specific substrates to specific processes.

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

    NASA Astrophysics Data System (ADS)

    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.

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

    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.

  13. Production of aluminum-silicon alloy and ferrosilicon and commercial-purity aluminum by the direct-reduction process. Third annual technical report, 1980 January 1-1980 December 31

    SciTech Connect

    Bruno, M.J.

    1981-01-01

    Progress on the program to demonstrate the technical feasibility of a pilot-sized Direct Reduction Process for producing aluminium and aluminium-silicon alloy is reported for Phase C. Progress is reported on reduction including the following tasks: supply burden material; burden beneficiation; effects of pilot operating parameters; pilot modifications; reactor scale-up design; calculating heat and mass balance; processing mathematical modeling; effects of process variables; information on supportive analytical, phase identification, and mechanical engineering data. Progress on alloy purification is reported in the following tasks: pilot unit installation; effects of pilot operating parameters; pilot unit modifications; and supportive mechanical engineering. Progress on purification to commercial grade aluminum is reported on: pilot unit installation; effects of pilot operating parameters; pilot unit modifications; support pilot operations; and supportive expended man-hours. Plans for Phase D are noted. (MCW)

  14. Microstructure and Mechanical Properties of AA1235 Aluminum Foil Stocks Produced Directly from Electrolytic Aluminum Melt

    NASA Astrophysics Data System (ADS)

    Xiong, Hanqing; Yu, Kun; Wen, Li; Yao, Sujuan; Dai, Yilong; Wang, Zhifeng

    2016-02-01

    A new process is developed to obtain high-quality AA1235 aluminum foil stocks and to replace the traditional manufacture process. During the new manufacture process, AA1235 aluminum sheets are twin-roll casted directly through electrolytic aluminum melt (EAM), and subsequently the sheets are processed into aluminum foil stocks by cold rolling and annealing. Microstructure and mechanical properties of the AA1235 aluminum sheets produced through such new process are investigated in each state by optimal microscope, scanning electron microscopy, X-ray diffraction, orientation imaging microscopy, transmission electron microscopy, etc. The results show that compared with the traditional AA1235 aluminum foil stocks produced through re-melted aluminum melt (RAM), the amount of impurities is decreased in the EAM aluminum foil stocks. The EAM aluminum foil stock obtains less β-FeSiAl5 phases, but more α-Fe2SiAl8 phases. The elongation of EAM aluminum foil stocks is improved significantly owing to more cubic orientation. Especially, the elongation value of the EAM aluminum foil stocks is approximately 25 pct higher than that of the RAM aluminum foil stocks. As a result, the EAM aluminum foil stocks are at an advantage in increasing the processing performance for the aluminum foils during subsequent processes.

  15. Aluminum Analysis.

    ERIC Educational Resources Information Center

    Sumrall, William J.

    1998-01-01

    Presents three problems based on the price of aluminum designed to encourage students to be cooperative and to use an investigative approach to learning. Students collect and synthesize information, analyze results, and draw conclusions. (AIM)

  16. Aluminum Hydroxide

    MedlinePlus

    ... penicillamine (Cuprimine, Depen), prednisone (Deltasone, Orasone), products containing iron, tetracycline (Sumycin, Tetracap, and others), ticlopidine (Ticlid), and vitamins.be aware that aluminum hydroxide may interfere with other medicines, making them less effective. Take your other medications 1 ...

  17. Temperature distribution study during the friction stir welding process of Al2024-T3 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Yau, Y. H.; Hussain, A.; Lalwani, R. K.; Chan, H. K.; Hakimi, N.

    2013-08-01

    Heat flux characteristics are critical to good quality welding obtained in the important engineering alloy Al2024-T3 by the friction stir welding (FSW) process. In the present study, thermocouples in three different configurations were affixed on the welding samples to measure the temperatures: in the first configuration, four thermocouples were placed at equivalent positions along one side of the welding direction; the second configuration involved two equivalent thermocouple locations on either side of the welding path; while the third configuration had all the thermocouples on one side of the layout but with unequal gaps from the welding line. A three-dimensional, non-linear ANSYS computational model, based on an approach applied to Al2024-T3 for the first time, was used to simulate the welding temperature profiles obtained experimentally. The experimental thermal profiles on the whole were found to be in agreement with those calculated by the ANSYS model. The broad agreement between the two kinds of profiles validates the basis for derivation of the simulation model and provides an approach for the FSW simulation in Al2024-T3 and is potentially more useful than models derived previously.

  18. Microstructure-strength relationship of a deformation processed aluminum-titanium composite

    SciTech Connect

    Lund, T.

    1998-02-23

    The mechanical properties, electrical properties and microstructures have been evaluated for an Al-20 wt % Ti deformation processed metal metal matrix composite (DMMC). The strength of the swaged, extruded and wire drawn composite increases several-fold with increasing deformation up to a true strain of 12.1, the maximum investigated. At this point the Ti was elongated and SEM and TEM analysis of the transverse direction of the wire showed the ribbon-like filaments that are common for this type of material. Texture development was also characterized to explain the deformation characteristics of the composite materials. The Ti filaments acquired a <10{bar 1}0> fiber texture during deformation, and the Al filaments acquired a dual texture of (111) and (100). Resistivity measurements of the composite showed that for the highest deformed sample ({eta} = 12.1), the resistivity increased linearly with temperature up to the temperature where Al{sub 3}Ti formed. At this point the slope increased. Beyond this point, the resistivity of the sample never returned to its original value. The temperature where Al{sub 3}Ti forms was investigated using DTA and XRD analysis. The reaction temperature decreases with increasing deformation true strain ({eta}) and filament spacing.

  19. Superplastic Forming of Multipass Friction Stir Processed Aluminum-Magnesium Alloy

    NASA Astrophysics Data System (ADS)

    Pradeep, S.; Pancholi, Vivek

    2014-09-01

    Multipass friction stir processing (FSP) of AA5086 Al-Mg alloy was carried out to obtain bulk fine grain material for superplastic forming. FSP produced inhomogeneous microstructure in the thickness direction. The aim of the present work was to understand superplastic forming behavior of distinct microstructural layers, i.e., nugget layer (NL) containing microstructure from nugget zone, thermo-mechanically affected/heat-affected layer (TL) containing microstructure from thermo-mechanically affected/heat-affected (TMAZ/HAZ) zone, and composite layer (CL) containing microstructure from both the above zones (nugget and TMAZ/HAZ). Superplastic forming of NL, TL, and CL blanks was carried out at constant gas pressure. Three different forming gas pressures of 0.75, 1.15, and 1.5 MPa corresponding to strain rates of 5 × 10-4 s-1, 1 × 10-3 s-1 , and 5 × 10-3 s-1, respectively, were used. Forming characteristics of CL were found to be comparable to that of NL and even better at higher forming pressures. Concomitant microstructural evolution during bulging of CL and NL plays an important role here.

  20. Superplastic Forming of Multipass Friction Stir Processed Aluminum-Magnesium Alloy

    NASA Astrophysics Data System (ADS)

    Pradeep, S.; Pancholi, Vivek

    2014-12-01

    Multipass friction stir processing (FSP) of AA5086 Al-Mg alloy was carried out to obtain bulk fine grain material for superplastic forming. FSP produced inhomogeneous microstructure in the thickness direction. The aim of the present work was to understand superplastic forming behavior of distinct microstructural layers, i.e., nugget layer (NL) containing microstructure from nugget zone, thermo-mechanically affected/heat-affected layer (TL) containing microstructure from thermo-mechanically affected/heat-affected (TMAZ/HAZ) zone, and composite layer (CL) containing microstructure from both the above zones (nugget and TMAZ/HAZ). Superplastic forming of NL, TL, and CL blanks was carried out at constant gas pressure. Three different forming gas pressures of 0.75, 1.15, and 1.5 MPa corresponding to strain rates of 5 × 10-4 s-1, 1 × 10-3 s-1 , and 5 × 10-3 s-1, respectively, were used. Forming characteristics of CL were found to be comparable to that of NL and even better at higher forming pressures. Concomitant microstructural evolution during bulging of CL and NL plays an important role here.

  1. Thermohydrogen processing (THP) of titanium alloy and titanium-aluminum alloys

    NASA Astrophysics Data System (ADS)

    Qazi, Javaid Iqbal

    The microstructures, phases and phase transformations occurring in cast and Hot Isostatic Pressed (HIP'd) Ti-6Al-4V-H and the blended elemental (BE) TiAl-H systems were investigated. In this work, the existing Ti-6Al-4V-H phase diagram was revised and the time-temperature-transformation (TTT) diagrams for beta-phase (isothermal) and martensite (quench plus aging) decomposition were determined at different hydrogen concentrations. Alloying with hydrogen decreases the nose temperatures for the start of both the beta/martensite decompositions in a linear fashion and increases the nose times for both of these in a non-linear fashion. During aging at temperatures below the beta transus temperature, the martensite decomposes into alpha+betaM (metastable beta) and on quenching, from the aging temperature, the betaM transforms to martensite + beta R (residual beta) with the amount of latter increasing with increasing hydrogen content. Microstructures varying from alpha-lamellar laths to fine equiaxed alpha-grains were produced in the Ti-6Al-4V alloy, by using different thermohydrogen processing (THP) treatments. A microstructure consisting of mixed equiaxed and elongated alpha-grains were only produced in samples containing 30at.%H after the complete decomposition of the beta/martensite below a critical temperature (Tc), followed by dehydrogenation. A mixture consisting of partially equiaxed alpha-grains thus produced by THP, increased the tensile strength from 841MPa (starting Ti-6Al-4V) to 965MPa after THP and also increased the % elongation from 7.5% to 10.5%. In addition to other THP parameters, the final microstructure also depends on the starting microstructure and recommendations are made for future work in this regard. Initial results of temperature cycling treatments, which involved heat treating of Ti-6Al-4V samples containing 30at.%H at 680°C for 5 minutes followed by water quenching and repetition of the same treatment for 10 cycles, did not show a decrease in

  2. Experimental and analytical investigation of the seizure process in aluminum-silicon alloy/steel tribocontacts

    NASA Astrophysics Data System (ADS)

    He, Xiaozhou

    1998-12-01

    This research is an experimental and analytical investigation of the scuffing/seizure mechanism in Al-Si alloy/steel tribocontacts. An analytical model is developed based on analyses and experiments to predict scuffing/seizure failure in Al-Si alloy/steel tribocontacts, which can be applied to tribo-components in engines, refrigerators and air conditioners. The wear and scuffing/seizure experiments have been conducted through a block-on-ring tester for 339 and ESE-M2A137 Al-Si alloys under the dry and boundary lubrication conditions. The experimental research consists of: (a) wear debris generation and EDX analysis, (b) wear surface morphological analysis, (c) scuffing/seizure mechanism and process analysis, (d) scuffing/seizure PV curves under the dry contact and boundary lubrication, and (e) effects of several main factors on scuffing/seizure. The analytical research includes the following: (a) the investigation of the scuffing/seizure mechanisms in the Al-Si alloy/steel tribocontacts, (b) 3-D asperity contact pressures for longitudinal, transverse and isotropic surface roughness profiles, (c) 3-D surface asperity contact temperature rise due to the friction, (d) failure analyses of the various lubricating films, (e) analyses of the temperature dependence of surface tangential traction and shear strength in a surface layer of Al-Si alloy, (f) the scuffing/seizure failure analytical model under dry contact and boundary lubrication. The analytical model is based on the new hypothesis of three defense lines against scuffing/seizure failure: the adsorbed oil film, oxide film and the ratio of surface tangential traction with the shear strength in a surface layer. These two films together with a surface layer itself form three defense lines against scuffing/seizure. The surface tangential traction exceeds the bulk shear strength in a surface layer of Al-Si alloy is the necessary and sufficient condition for the scuffing/seizure occurrence. The analytical model has a

  3. Processing, characterization and mechanical behavior of novel aluminum/silicon carbide metal-ceramic nanolaminates

    NASA Astrophysics Data System (ADS)

    Singh, Danny Rao Pratap

    Nanoscale laminated composites are a novel class of materials with excellent mechanical properties like strength, flexibility, and toughness. Properties in these materials can be tailored by varying layer thicknesses, microstructure, and controlling internal stresses. Most of research to-date has focused on metal-metal and ceramic-ceramic laminates. The field of metal-ceramic laminates has remained relatively unexplored. From a mechanical structure point of view, metal-ceramic systems present a good combination of strength and hardness. Hence, there is a need for understanding and evaluating these composites in nanolaminate form. In this work, the deformation behavior of Al-SiC nanolaminates as a model system has been studied. The work has been categorized into 3 major areas of research. The first involves processing and microstructural characterization of these novel materials. Nanoscale Al/SiC layered composites were fabricated using magnetron sputtering. Samples with varying volume fractions of Al and SiC were synthesized. The second area involves quantifying the residual stresses in these materials. These are quantified by x-ray synchrotron and beam-curvature techniques. The third area focuses on understanding the fundamental mechanisms for deformation damage, and fracture under indentation and micro-compression loading. Fracture/Damage analysis is carried out using focused ion beam (FIB) and scanning electron microscopy (SEM). The systematic study has revealed the enhanced mechanical properties of metal-ceramic nanolaminates and the fundamental mechanisms governing the strength and failure of these materials. It has been found that Al/SiC metal-ceramic systems can exhibit high strength together with high toughness and flexibility. High compressive residual stresses are generated during the sputter deposition of these nanolaminates which are associated with the large number of interfaces present in the nanolaminate architecture. The mechanical properties

  4. Controlled Directional Solidification of Aluminum - 7 wt Percent Silicon Alloys: Comparison Between Samples Processed on Earth and in the Microgravity Environment Aboard the International Space Station

    NASA Technical Reports Server (NTRS)

    Grugel, Richard N.; Tewari, Surendra N.; Erdman, Robert G.; Poirier, David R.

    2012-01-01

    An overview of the international "MIcrostructure Formation in CASTing of Technical Alloys" (MICAST) program is given. Directional solidification processing of metals and alloys is described, and why experiments conducted in the microgravity environment aboard the International Space Station (ISS) are expected to promote our understanding of this commercially relevant practice. Microstructural differences observed when comparing the aluminum - 7 wt% silicon alloys directionally solidified on Earth to those aboard the ISS are presented and discussed.

  5. Production of aluminum metal by electrolysis of aluminum sulfide

    DOEpatents

    Minh, N.Q.; Loutfy, R.O.; Yao, N.P.

    1982-04-01

    Metallic aluminum may be produced by the electrolysis of Al/sub 2/S/sub 3/ at 700 to 800/sup 0/C in a chloride melt composed of one or more alkali metal chlorides, and one or more alkaline earth metal chlorides and/or aluminum chloride to provide improved operating characteristics of the process.

  6. Production of aluminum metal by electrolysis of aluminum sulfide

    DOEpatents

    Minh, Nguyen Q.; Loutfy, Raouf O.; Yao, Neng-Ping

    1984-01-01

    Production of metallic aluminum by the electrolysis of Al.sub.2 S.sub.3 at 700.degree.-800.degree. C. in a chloride melt composed of one or more alkali metal chlorides, and one or more alkaline earth metal chlorides and/or aluminum chloride to provide improved operating characteristics of the process.

  7. Weld Repair of Thin Aluminum Sheet

    NASA Technical Reports Server (NTRS)

    Beuyukian, C. S.; Mitchell, M. J.

    1986-01-01

    Weld repairing of thin aluminum sheets now possible, using niobium shield and copper heat sinks. Refractory niobium shield protects aluminum adjacent to hole, while copper heat sinks help conduct heat away from repair site. Technique limits tungsten/inert-gas (TIG) welding bombardment zone to melt area, leaving surrounding areas around weld unaffected. Used successfully to repair aluminum cold plates on Space Shuttle, Commercial applications, especially in sealing fractures, dents, and holes in thin aluminum face sheets or clad brazing sheet in cold plates, heat exchangers, coolers, and Solar panels. While particularly suited to thin aluminum sheet, this process also used in thicker aluminum material to prevent surface damage near weld area.

  8. Aluminum: Aluminum Scrap Decoater

    SciTech Connect

    Blazek, S.

    1999-01-29

    NICE3 and the Philip Services Corporation are cost-sharing a demonstration project to decoat metal using indirect-fired controlled-atmosphere (IDEX) kilns, which can both process solid organics such as rubber and plastics, and minimize dust formation and emission of volatile organic compounds. The publication explains how this cost-effective, two-step system operates.

  9. Influence of NH4Cl Powder Addition for Fabrication of Aluminum Nitride Coating in Reactive Atmospheric Plasma Spray Process

    NASA Astrophysics Data System (ADS)

    Shahien, Mohammed; Yamada, Motohiro; Yasui, Toshiaki; Fukumoto, Masahiro

    2011-01-01

    Reactive plasma spray is the key to fabricating aluminum nitride (AlN) thermally sprayed coatings. It was possible to fabricate AlN/Al composite coatings using atmospheric plasma spray process through plasma nitriding of Al powders (Al 30 μm). The nitriding reaction and the AlN content could be improved by controlling the spray distance and the feedstock powder particle size. Increasing the spray distance and/or using smaller particle size of Al powders improved the in-flight nitriding reaction. However, it was difficult to fabricate thick and dense AlN coatings with an increase in the spray distance and/or when using fine particles. Thus, the coatings thickness was suppressed because of the complete nitriding of some particles (formation of AlN particles) during flight, which prevents the particle deposition. Furthermore, the excessive vaporization of Al fine particles (due to increased particle temperature) decreased the deposition efficiency. To fabricate thick AlN coatings in the reactive plasma spray process, improving the nitriding reaction of the large Al particles at short spray distance is required to decrease the vaporization of Al particles during flight. This study investigated the influence of adding ammonium chloride (NH4Cl) powders on the nitriding process of large Al powders and on the microstructure of the fabricated coatings. It was possible to fabricate thick AlN coatings at 100 mm spray distance with small addition of NH4Cl powders to the Al feedstock powders (30 μm). Addition of NH4Cl to the starting Al powders promoted the formation of AlN through changing the reaction path to vapor-phase nitridation chlorination-nitridation sequences as confirmed by the thermodynamic analysis of possible intermediate reactions. This changes the nitriding reaction to a mild way, so it is more controlled with no explosive mode and with relatively low heating rates. Thus, NH4Cl acts as a catalyst, nitrogen source, and diluent agent. Furthermore, the evolved

  10. Nondestructive detection of an undesirable metallic phase, T.sub.1, during processing of aluminum-lithium alloys

    DOEpatents

    Buck, Otto; Bracci, David J.; Jiles, David C.; Brasche, Lisa J. H.; Shield, Jeffrey E.; Chumbley, Leonard S.

    1990-08-07

    A method is disclosed for detecting the T.sub.1 phase in aluminum-lithium alloys through simultaneous measurement of conductivity and hardness. In employing eddy current to measure conductivity, when the eddy current decreases with aging of the alloy, while the hardness of the material continues to increase, the presence of the T.sub.1 phase may be detected.

  11. Behavior of dissolved aluminum in the Huanghe (Yellow River) and its estuary: Impact of human activities and sorption processes

    NASA Astrophysics Data System (ADS)

    Wang, Zhao-Wei; Ren, Jing-Ling; Zhang, Gui-Ling; Liu, Su-Mei; Zhang, Xiang-Zhao; Liu, Zhe; Zhang, Jing

    2015-02-01

    Dissolved aluminum (Al) is a sensitive tracer for biogeochemical cycles in the ocean. There has been a dramatic decline in water and sediment fluxes into the sea from the Huanghe because of climate change and human activities. Water-Sediment Regulation Schemes (WSRSs) have been implemented annually to flush trapped sediments from the upstream watercourse and reservoirs of the river. Monthly observations to investigate the behavior of dissolved Al in the lower reach of the Huanghe were carried out from November 2008 to December 2010. During 2009, daily observations were made to assess the impact of the ninth WSRS on the lower reach of the Huanghe and three cruises were carried out in the Huanghe Estuary in 2009 (prior to, during and following the WSRS). The monthly concentrations of dissolved Al ranged from 25 nM to 362 nM (average 90 nM) in the lower reach of the Huanghe. Assessment of the seasonal variation of dissolved Al showed that the highest concentrations occurred in summer and the lowest in winter: these corresponded to the variations in water discharge and sediment loads, which were controlled by WSRS events. During the ninth WSRS events in 2009 the daily runoff and sediment load increased from 200 m3/s to 3600 m3/s and from 0.1 g/L to 5 g/L, respectively. The concentration of dissolved Al increased from 180 nM to 600 nM (average 380 nM) in less than 20 days, which were equivalent to 43% of the annual Al flux into the Bohai. Exchange between dissolved and particulate Al, investigated using a simple sorption model based on the distribution coefficient (Kd), was approximately 106 mL/g in the Huanghe. The average concentrations of dissolved Al in the Huanghe Estuary prior to, during and following the WSRS were 243 nM, 238 nM and 186 nM, respectively. The comparable concentrations of dissolved Al in the Huanghe Estuary prior to and during the WSRS indicate that removal processes occurred in the initial stages of mixing in the estuary. The Al

  12. Influence of composition and processing parameters on the properties of solution-processed aluminum phosphate oxide (AlPO) thin films

    NASA Astrophysics Data System (ADS)

    Norelli, Kevin M.; Plassmeyer, Paul N.; Woods, Keenan N.; Glassy, Benjamin A.; Knutson, Christopher C.; Beekman, Matt; Page, Catherine J.

    2016-05-01

    The effects of precursor solution concentration, composition, and spin-processing parameters on the thickness and electrical properties of ultra-smooth aluminum oxide phosphate (Al2O3-3x(PO4)2x or "AlPO") thin films prepared using aqueous solutions are reported. Compositions were verified by electron probe micro-analysis and range from Al2O1.5(PO4) to AlPO4 (x = P:Al from 0.5 to 1.0). Film thicknesses were determined using X-ray reflectivity measurements and were found to depend systematically on solution concentration, P:Al ratio, and spin-speed. Metal-insulator-semiconductor devices were fabricated to determine electrical properties as a function of composition. As the P:Al ratio increased from 0.5 to 1.0, the dielectric constant decreased from 6.0 to 4.6, leakage currents increased from 0.45 to 65 nA cm-2 at 1 MV cm-1 and dielectric breakdown (defined as leakage currents >10 μA cm-2) decreased from 9.74 to 2.84 MV cm-1. These results establish composition, concentration, and spin-speed for the production of AlPO films with targeted thicknesses and electrical properties.

  13. Aluminum alloy

    NASA Technical Reports Server (NTRS)

    Blackburn, Linda B. (Inventor); Starke, Edgar A., Jr. (Inventor)

    1989-01-01

    This invention relates to aluminum alloys, particularly to aluminum-copper-lithium alloys containing at least about 0.1 percent by weight of indium as an essential component, which are suitable for applications in aircraft and aerospace vehicles. At least about 0.1 percent by weight of indium is added as an essential component to an alloy which precipitates a T1 phase (Al2CuLi). This addition enhances the nucleation of the precipitate T1 phase, producing a microstructure which provides excellent strength as indicated by Rockwell hardness values and confirmed by standard tensile tests.

  14. Detachment of Tertiary Dendrite Arms during Controlled Directional Solidification in Aluminum - 7 wt Percent Silicon Alloys: Observations from Ground-based and Microgravity Processed Samples

    NASA Technical Reports Server (NTRS)

    Grugel, Richard N.; Erdman, Robert; Van Hoose, James R.; Tewari, Surendra; Poirier, David

    2012-01-01

    Electron Back Scattered Diffraction results from cross-sections of directionally solidified aluminum 7wt% silicon alloys unexpectedly revealed tertiary dendrite arms that were detached and mis-oriented from their parent arm. More surprisingly, the same phenomenon was observed in a sample similarly processed in the quiescent microgravity environment aboard the International Space Station (ISS) in support of the joint US-European MICAST investigation. The work presented here includes a brief introduction to MICAST and the directional solidification facilities, and their capabilities, available aboard the ISS. Results from the ground-based and microgravity processed samples are compared and possible mechanisms for the observed tertiary arm detachment are suggested.

  15. Effects of Al-5Ti-1B master alloy on the microstructural evaluation of a highly alloyed aluminum alloy produced by SIMA process

    SciTech Connect

    Alipour, M.; Emamy, M.; Azarbarmas, M.; Karamouz, M.

    2010-06-15

    This study was undertaken to investigate the influence of Al-5Ti-1B master alloy on the structural characteristics of Al-12Zn-3 Mg-2.5Cu aluminum alloy. The optimum amount of Ti containing master alloy for proper grain refining was selected as 6 wt.%. A modified strain-induced, melt-activated (SIMA) process for semi-solid processing of alloys was proposed. In order to examine the effectiveness of the modified SIMA process, the recrystallized microstructures of the Al alloy (Al-12Zn-3 Mg-2.5Cu) prepared by the modified SIMA processes were macroscopically. The modified SIMA process employed casting, warm multi-forging, recrystallization and partial melting instead of the conventional process. Reheating condition to obtain a fine globular microstructure was optimized. The microstructure evolution of reheated Al-12Zn-3 Mg-2.5Cu aluminum alloy was characterized by SEM (Scanning electron microscopy) and optical microscopy. In this study the relation between the induced strain with size and shape of grain size has been studied. Results indicated that with the increase of strain sphericity of particles, their size decreases and sphericity takes place in less reahiting time.

  16. REMOVAL OF ALUMINUM COATINGS

    DOEpatents

    Peterson, J.H.

    1959-08-25

    A process is presented for dissolving aluminum jackets from uranium fuel elements without attack of the uranium in a boiling nitric acid-mercuric nitrate solution containing up to 50% by weight of nitrtc acid and mercuric nitrate in a concentration of between 0.05 and 1% by weight.

  17. Aluminum for plasmonics.

    PubMed

    Knight, Mark W; King, Nicholas S; Liu, Lifei; Everitt, Henry O; Nordlander, Peter; Halas, Naomi J

    2014-01-28

    Unlike silver and gold, aluminum has material properties that enable strong plasmon resonances spanning much of the visible region of the spectrum and into the ultraviolet. This extended response, combined with its natural abundance, low cost, and amenability to manufacturing processes, makes aluminum a highly promising material for commercial applications. Fabricating Al-based nanostructures whose optical properties correspond with theoretical predictions, however, can be a challenge. In this work, the Al plasmon resonance is observed to be remarkably sensitive to the presence of oxide within the metal. For Al nanodisks, we observe that the energy of the plasmon resonance is determined by, and serves as an optical reporter of, the percentage of oxide present within the Al. This understanding paves the way toward the use of aluminum as a low-cost plasmonic material with properties and potential applications similar to those of the coinage metals. PMID:24274662

  18. Orbital fabrication of aluminum foam and apparatus therefore

    NASA Technical Reports Server (NTRS)

    Tucker, Dennis S. (Inventor)

    2010-01-01

    A process for producing foamed aluminum in space comprising the steps of: heating aluminum until it is molten; applying the force of gravity to the molten aluminum; injecting gas into the molten aluminum to produce molten foamed aluminum; and allowing the molten foamed aluminum to cool to below melting temperature. The apparatus for carrying out this invention comprises: a furnace which rotates to simulate the force of gravity and heats the aluminum until it is molten; a door on the furnace, which is opened for charging the aluminum into the furnace, closed for processing and opened again for removal of the foamed aluminum; a gas injection apparatus for injecting gas into the molten aluminum within the furnace; and an extraction apparatus adjacent the door for removing the foamed aluminum from the furnace.

  19. Effect of aluminum speciation on fouling mechanisms by pre-coagulation/ultrafiltration process with different NOM fractions.

    PubMed

    Sun, Weiguang; Nan, Jun; Yao, Meng; Xing, Jia; Tian, Jiayu

    2016-09-01

    Ultrafiltration is an emerging technology for drinking water production, but the membrane fouling is still a challenge. This study was carried out to investigate the effect of aluminum speciation on UF membrane fouling behavior by different NOM fractions-humic substances and proteins, as represented by humic acid (HA) and bovine serum albumin (BSA), respectively. The interesting results showed that the total fouling resistance of the mixture of HA-BSA-kaolinite solution without coagulant demonstrated a slight decrease in comparison with those of the individually filtered substances, indicating a mitigatory fouling effect. The hydrolysis of aluminum products was various as pH and membrane fouling was related to aluminum speciation. The average size of flocs dramatically increased and fractal dimension of flocs decreased with the increasing of pH value independent on water quality, which indicated that aluminum speciation had a significant impact on floc properties. For the mixture of HA-BSA-kaolinte, the slightly larger of flocs average size in comparison with the individual organic fraction after coagulation was probably attributing that BSA was encapsulated by HA to enlarge the molecular length and floc size further increased. The membrane performance also showed that coagulation effluent of HA-BSA-kaolinite mitigated membrane fouling. The strong linear relationship was observed between flocs fractal dimension and final membrane flux in this research. From the results, the control of flocs fractal dimension should be considered as a new technique for traditional hybrid coagulation/ultrafiltration system, which resulted in minimized total and irreversible fouling and has a meaningful engineering application value. PMID:27230150

  20. Cracking associated with micrometeoroid impact craters in anodized aluminum alloy clamps on LDEF

    NASA Technical Reports Server (NTRS)

    Murr, Lawrence E.; Niou, Chorng S.; Quinones, Stella; Murr, Kyle S.

    1992-01-01

    The Long Duration Exposure Facility (LDEF) is a reusable hollow-cylindrical satellite sustaining a total of 57 different experiments. The 130 sq m of spacecraft surface area included anodized 6061-T6 Al alloy bay frames and clamps for holding experiment trays in the bay areas. Attention is presently given to the micrometeoroid impact crater features observed on two tray clamps recovered from the LDEF leading-edge locations. It is found that even very subtle surface modifications in structural alloy anodizing can influence micrometeoroid impact crater cracking, notable radial cracking due to the ejecta-rim of the impact craters.

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

    SciTech Connect

    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.

  2. Reactively Deposited Aluminum Oxide and Fluoropolymer Filled Aluminum Oxide Protective Coatings for Polymers

    NASA Technical Reports Server (NTRS)

    Rutledge, Sharon K.; Banks, Bruce A.; Hunt, Jason

    1995-01-01

    Reactive ion beam sputter deposition of aluminum simultaneous with low energy arrival of oxygen ions at the deposition surface enables the formation of highly transparent aluminum oxide films. Thick (12 200 A), adherent, low stress, reactively deposited aluminum oxide films were found to provide some abrasion resistance to polycarbonate substrates. The reactively deposited aluminum oxide films are also slightly more hydrophobic and more transmitting in the UV than aluminum oxide deposited from an aluminum oxide target. Simultaneous reactive sputter deposition of aluminum along with polytetrafluoroethylene (PTFE Teflon) produces fluoropolymer-filled aluminum oxide films which are lower in stress, about the same in transmittance, but more wetting than reactively deposited aluminum oxide films. Deposition properties, processes and potential applications for these coatings will be discussed.

  3. Aluminum Nanoholes for Optical Biosensing.

    PubMed

    Barrios, Carlos Angulo; Canalejas-Tejero, Víctor; Herranz, Sonia; Urraca, Javier; Moreno-Bondi, María Cruz; Avella-Oliver, Miquel; Maquieira, Ángel; Puchades, Rosa

    2015-01-01

    Sub-wavelength diameter holes in thin metal layers can exhibit remarkable optical features that make them highly suitable for (bio)sensing applications. Either as efficient light scattering centers for surface plasmon excitation or metal-clad optical waveguides, they are able to form strongly localized optical fields that can effectively interact with biomolecules and/or nanoparticles on the nanoscale. As the metal of choice, aluminum exhibits good optical and electrical properties, is easy to manufacture and process and, unlike gold and silver, its low cost makes it very promising for commercial applications. However, aluminum has been scarcely used for biosensing purposes due to corrosion and pitting issues. In this short review, we show our recent achievements on aluminum nanohole platforms for (bio)sensing. These include a method to circumvent aluminum degradation--which has been successfully applied to the demonstration of aluminum nanohole array (NHA) immunosensors based on both, glass and polycarbonate compact discs supports--the use of aluminum nanoholes operating as optical waveguides for synthesizing submicron-sized molecularly imprinted polymers by local photopolymerization, and a technique for fabricating transferable aluminum NHAs onto flexible pressure-sensitive adhesive tapes, which could facilitate the development of a wearable technology based on aluminum NHAs. PMID:26184330

  4. Aluminum Nanoholes for Optical Biosensing

    PubMed Central

    Barrios, Carlos Angulo; Canalejas-Tejero, Víctor; Herranz, Sonia; Urraca, Javier; Moreno-Bondi, María Cruz; Avella-Oliver, Miquel; Maquieira, Ángel; Puchades, Rosa

    2015-01-01

    Sub-wavelength diameter holes in thin metal layers can exhibit remarkable optical features that make them highly suitable for (bio)sensing applications. Either as efficient light scattering centers for surface plasmon excitation or metal-clad optical waveguides, they are able to form strongly localized optical fields that can effectively interact with biomolecules and/or nanoparticles on the nanoscale. As the metal of choice, aluminum exhibits good optical and electrical properties, is easy to manufacture and process and, unlike gold and silver, its low cost makes it very promising for commercial applications. However, aluminum has been scarcely used for biosensing purposes due to corrosion and pitting issues. In this short review, we show our recent achievements on aluminum nanohole platforms for (bio)sensing. These include a method to circumvent aluminum degradation—which has been successfully applied to the demonstration of aluminum nanohole array (NHA) immunosensors based on both, glass and polycarbonate compact discs supports—the use of aluminum nanoholes operating as optical waveguides for synthesizing submicron-sized molecularly imprinted polymers by local photopolymerization, and a technique for fabricating transferable aluminum NHAs onto flexible pressure-sensitive adhesive tapes, which could facilitate the development of a wearable technology based on aluminum NHAs. PMID:26184330

  5. Flow simulation and solidification phenomena of AC4CH aluminum alloy in semi-solid forging process by explicit MPS method

    NASA Astrophysics Data System (ADS)

    Regmi, Amit; Shintaku, Hiroki; Sasaki, Tsutomu; Koshizuka, Seiichi

    2015-09-01

    Semi-solid forging (SSF) is a powerful manufacturing technology to fabricate near-net shaped products in automotive industries. During SSF process, the filling behavior and solidification process of AC4CH aluminum alloy is presented in this paper. The explicit MPS method program solving Navier-Stokes equation is coupled with heat transfer and solidification has been used to predict the filling pattern and temperature distribution of semi-solid material (SSM). The non-Newtonian rheological model was used as the constitutive equation of SSM. In this study, numerical analysis of SSF was carried out in box cavity with various flange thickness (4, 8, 12 and 16 mm) and corresponding experiments were undertaken for AC4CH aluminum alloy with solid fraction less than 0.5. The numerical results of SSM filling pattern and solidification phenomena in flange were validated with the experimental results. During solidification process, flow calculation was stopped and only thermal calculation was carried out. The shrinkage defect was well predicted near the lower mid area of the box cavity with flange thickness 16 mm.

  6. Evaluating of NASA-Langley Research Center explosion seam welding

    NASA Technical Reports Server (NTRS)

    Otto, H. E.; Wittman, R.

    1977-01-01

    An explosion bonding technique to meet current fabrication requirements was demonstrated. A test program was conducted on explosion bonded joints, compared to fusion joints in 6061-T6 aluminum. The comparison was made in required fixtures, non-destructive testing, static strength and fatigue strength.

  7. Galvanic Corrosion In (Graphite/Epoxy)/Alloy Couples

    NASA Technical Reports Server (NTRS)

    Danford, Merlin D.; Higgins, Ralph H.

    1988-01-01

    Effects of galvanic coupling between graphite/epoxy composite material, G/E, and D6AC steel, 6061-T6 aluminum, and Inconel(R) 718 nickel alloy in salt water described in report. Introductory section summarizes previous corrosion studies of G/E with other alloys. Details of sample preparation presented along with photographs of samples before and after immersion.

  8. Aluminum reclamation from dross. (Latest citations from the Aluminum Industry Abstracts database). Published Search

    SciTech Connect

    1996-06-01

    The bibliography contains citations concerning aluminum reclamation from dross. Topics include dross treatment technology, the environmental benefits of aluminum recovery from dross, and the economics of aluminum reclamation in dross processing systems. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

  9. Development of an Explosive Bonding Process for Producing High Strength Bonds between Niobium and 6061-T651 Aluminum

    SciTech Connect

    Palmer, T A; Elmer, J W; Brasher, D; Butler, D; Riddle, R

    2005-09-23

    An explosive bonding procedure for joining 9.5 mm thick niobium plate to 203 mm thick 6061-T651 Al plate has been developed in order to maximize the bond tensile and impact strengths and the amount of bonded material across the surface of the plate. This procedure improves upon previous efforts, in which the 9.5 mm thick niobium plate is bonded directly to 6061-T4 Al plate. In this improved procedure, thin Nb and Al interlayers are explosively clad between the thicker niobium and aluminum plates. Bonds produced using these optimized parameters display a tensile strength of approximately 255 MPa and an impact strength per unit area of approximately 0.148 J/mm{sup 2}. Specialized mechanical testing geometries and procedures are required to measure these bond properties because of the unique bond geometry. In order to ensure that differences in the thermal expansion coefficients of aluminum and niobium do not adversely affect the bond strength, the effects of thermal cycling at temperatures between -22 C and 45 C on the mechanical properties of these bonds have also been investigated by testing samples in both the as-received and thermal cycled conditions. Based on the results obtained from this series of mechanical tests, thermal cycling is shown to have no adverse effect on the resulting tensile and impact strengths of the bonds produced using the optimized bonding parameters.

  10. Development of digital image processing based methodology to study, quantify and correlate the microstructure and three dimensional fracture surface morphology of aluminum alloy 7050

    NASA Astrophysics Data System (ADS)

    Dighe, Manish Deepak

    2000-10-01

    7XXX series wrought aluminum alloys are extensively used for structural aerospace applications due to their high strength to weight ratio, excellent corrosion resistance, and high fracture resistance. 7050 is an important alloy of this group, which is widely used for the applications such as aircraft wing skin structures, aircraft landing gear parts, and fuselage frame structure. Therefore, it is of interest to investigate the fracture behavior of 7050 aluminum alloy, which is a typical alloy of 7XXX series. The aim of this research is to quantitatively characterize and model the relationships among processing, microstructure, fracture surface morphology, and fracture toughness of hot-rolled partially recrystallized precipitation hardened 7050 alloy. A new technique is developed which permits simultaneous viewing of the fracture surface and the microstructure just below and above the fracture surface. This technique is then applied to identify, validate and quantify various fracture micro-mechanisms observed on the fracture surface. To get a better insight in to the shape and anisotropy of the recrystallized grains, the three-dimensional structure of the microstructure is reconstructed using serial sectioning. The gathered information is utilized to develop a mathematical model relating the various processing parameters and microstructural attributes to the fracture toughness.

  11. Synthesis and processing of Al{sub 2}O{sub 3}/Al composites by in situ reaction of aluminum and mullite

    SciTech Connect

    Fahrenholtz, W.G.; Ewsuk, K.G.; Loehman, R.E.; Tomsia, A.P.

    1995-02-01

    Al{sub 2}O{sub 3}/Al composites, were formed by reacting molten aluminum metal with dense mullite ceramic preforms. The composites produced by this reactive metal penetration process (RMP) have a two phase, interpenetrating microstructure in which both the ceramic and the metal are continuous in three dimensions. Scanning electron microscopy (SEM) micrographs of composites produced by RMP show a fine microstructure comprised of interlocked metal and ceramic phases, with a feature size of approximately 2 {mu}m. RMP is a relatively rapid process with metal penetration rates of nearly 5 mm/hour at 1100{degrees}C after a short incubation period. An activation energy of 92 kJ/mole was calculated from reaction rate data. Transmission electron microscopy (TEM) micrographs reveal that aluminum metal penetrates along the mullite grain boundaries before reaction with the mullite grains, indicating that diffusion along grain boundaries may be the rate limiting step for the reaction. Thermodynamic information, results of microstructure analyses, and kinetic data indicate that RMP proceeds in 4 stages: (1) Al melting and the formation of a thermodynamically stable metal/ceramic interface; (2) depletion of oxygen from the grain boundaries intersecting the ceramic/metal interface; (3) Al metal penetration into the ceramic preform along grain boundaries; and (4) Al reaction with and conversion of individual mullite grains.

  12. Production of anhydrous aluminum chloride composition

    DOEpatents

    Vandergrift, G.F. III; Krumpelt, M.; Horwitz, E.P.

    1981-10-08

    A process is described for producing an anhydrous aluminum chloride composition from a water-based aluminous material such as a slurry of aluminum hydroxide in a multistage extraction process in which the aluminum ion is first extracted into an organic liquid containing an acidic extractant and then extracted from the organic phase into an alkali metal chloride or chlorides to form a melt containing a mixture of chlorides of alkali metal and aluminum. In the process, the organic liquid may be recycled. In addition, the process advantageously includes an electrolysis cell for producing metallic aluminum and the alkali metal chloride or chlorides may be recycled for extraction of the aluminum from the organic phase.

  13. Aluminum: Industry of the future

    SciTech Connect

    1998-11-01

    For over a century, the US aluminum industry has led the global market with advances in technology, product development, and marketing. Industry leaders recognize both the opportunities and challenges they face as they head into the 21st century, and that cooperative R and D is key to their success. In a unique partnership, aluminum industry leaders have teamed with the US Department of Energy`s Office of Industrial Technologies (OIT) to focus on innovative technologies that will help to strengthen the competitive position of the US aluminum industry and, at the same time, further important national goals. This industry-led partnership, the Aluminum Industry of the Future, promotes technologies that optimize the use of energy and materials in operations and reduce wastes and energy-related emissions. Led by The Aluminum Association, industry leaders began by developing a unified vision of future market, business, energy, and environmental goals. Their vision document, Partnerships for the Future, articulates a compelling vision for the next 20 years: to maintain and grow the aluminum industry through the manufacture and sale of competitively priced, socially desirable, and ecologically sustainable products. Continued global leadership in materials markets will require the combined resources of industry, universities, and government laboratories. By developing a unified vision, the aluminum industry has provided a framework for the next step in the Industries of the Future process, the development of a technology roadmap designed to facilitate cooperative R and D.

  14. Aluminum permanganate battery

    SciTech Connect

    Marsh, C.; Licht, S.L.

    1993-11-30

    A battery is provided comprising an aluminum anode, an aqueous solution of permanganate as the cathodic species and a second electrode capable of reducing permanganate. Such a battery system is characterized by its high energy density and low polarization losses when operating at high temperatures in a strong caustic electrolyte, i.e., high concentration of hydroxyl ions. A variety of anode and electrocatalyst materials are suitable for the efficient oxidation-reduction process and are elucidated.

  15. Effects of casting conditions and deformation processing on A356 aluminum and A356-20 vol. pct SiC composites

    NASA Technical Reports Server (NTRS)

    Rozak, G. A.; Lewandowski, J. J.; Wallace, J. F.; Altmisoglu, A.

    1992-01-01

    The effects of casting conditions and deformation processing on the mechanical properties of unreinforced A356 aluminum and A356-20 vol pct SiC composite were investigated by tensile properties in these compounds fabricated by either sand casting or squeeze casting techniques followed by hot working to 33, 50, 90, and 95 percent reductions. The evolution of the microstructure and values of tensile properties were evaluated for the cast materials in each of the hot worked conditions. It was found that, while the deformation processing of the sand-cast composite resulted in banding of the Al and SiC particles within the microstructure, such features were not observed in the squeeze-cast microstructure. The tensile strengths of the squeeze cast materials was found to be higher than those of the sand cast materials, for both the unreinforced and composite samples, while increased amounts of deformation were found to improve the ductility of the composite.

  16. Micro-dent arrays fabricated by a novel net mask laser shock processing on the surface of LY2 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Dai, Feng-Ze; Lu, Jin-Zhong; Zhang, Yong-Kang; Luo, Kai-Yu; Zhang, Lei; Wang, Qing-Wei; Ren, Xu-Dong; Li, Pin

    2012-07-01

    A novel technology called net-mask laser shock processing (NMLSP) was introduced to fabricate micro-dent arrays on the surface of LY2 aluminum alloy. Experimental results showed that the as-fabricated micro-dents whose diameter and depth were about 230-250 μm and 9.3 μm, respectively, was closed to be circular although the original shape of the net mask was square. The height of upwarped area around micro-dent was about 4 μm. Moreover, the interference of neighboring surface shock waves would affect the topography of micro-dents. A dynamic analysis performed by ABAQUS/Explicit code exhibited that the dynamic formation process of micro-dents fabricated by NMLSP, and the simulation results were mostly consistent with experiment results.

  17. Transfer and transport of aluminum in filtration unit.

    PubMed

    Wen-dong, Wang; Hong-wei, Yang; Hua-zhang, Zhao; Zhan-peng, Jiang

    2007-01-01

    Aluminum salt coagulants were used prevalently in various water works. In this article, the effects of filtration on residual aluminum concentration and species distribution were researched by determining the concentration of different aluminum species before and after single layer filter, double layer filter, and membrane filtration units. In the research, size exclusion chromatography (SEC) was used to separate colloidal and soluble aluminum, ion exchange chromatography (IEC) was used to separate organic and inorganic aluminum, and inductivity coupled plasma-atomic emission spectrometry (ICP-AES) was used to determine the aluminum concentration. The results showed that the rapid filtration process had the ability of removing residual aluminum from coagulant effluent water, and that double layer filtration was more effective in residual aluminum removal than single layer filtration, while nano filtration was more effective than micro filtration. It was found that when the residual aluminum concentration was below 1 mg/L in sediment effluent, the residual aluminum concentration in treated water was above 0.2 mg/L. The direct rapid filtration process mainly removed the suspended aluminum. The removal of soluble and colloidal aluminum was always less than 10% and the natural small particles that adsorbed the amount of soluble or small particles aluminum on their surface were difficult to be removed in this process. Micro filtration and nano filtration were good technologies for removing aluminum; the residual aluminum concentration in the effluent was less than 0.05 mg/L. PMID:17966844

  18. UPDATE ON FRICTION BONDING OF MONOLITHIC U-MO FUEL PLATES

    SciTech Connect

    D. E. Burkes; N. P. Hallinan; J. M. Wight; M. D. Chapple

    2007-09-01

    Friction Bonding (FB), formerly referred to as Friction Stir Welding, is an alternative plate fabrication technique to encapsulate monolithic U-Mo fuel foils inside 6061-T6 aluminum alloy cladding. Over the past year, significant progress has been made in the area of FB, including improvements in tool material, tool design, process parameters, cooling capability and capacity and modeling, all of which improve and enhance the quality of fabricated fuel plates, reproducibility of the fabrication process and bond quality of the fuel plates. Details of this progress and how it relates to the observed improvements and enhancements are discussed. In addition, details on how these improvements have been implemented into the last two RERTR mini-plate irradiation campaigns are also discussed.

  19. Update on friction bonding of monolithic U-Mo fuel plates

    SciTech Connect

    Burkes, D.E.; Hallinan, N.P.; Wight, J.M.; Chapple, M.D.

    2008-07-15

    Friction Bonding (FB), formerly referred to as Friction Stir Welding, is an alternative plate fabrication technique to encapsulate monolithic U-Mo fuel foils inside 6061-T6 aluminum alloy cladding. Over the past year, significant progress has been made in the area of FB, including improvements in tool material, tool design, process parameters, cooling capability and capacity and modeling, all of which improve and enhance the quality of fabricated fuel plates, reproducibility of the fabrication process and bond quality of the fuel plates. Details of this progress and how it relates to the observed improvements and enhancements are discussed. In addition, details on how these improvements have been implemented into the last two RERTR mini-plate irradiation campaigns are also discussed. (author)

  20. Advances in aluminum casting technology

    SciTech Connect

    Tiryakioglu, M.; Campbell, J.

    1998-01-01

    This symposium focuses on the improvements of aluminum casting quality and reliability through a better understanding of processes and process variables, and explores the latest innovations in casting-process design that allow increasing use of the castings to replace complex assemblies and heavy steel and cast-iron components in aerospace and automotive applications. Presented are 35 papers by international experts in the various aspects of the subject. The contents include: Semisolid casting; Computer-aided designing of molds and castings; Casting-process modeling; Aluminum-matrix composite castings; HIPing of castings; Progress in the US car project; Die casting and die design; and Solidification and properties.

  1. Optimization of wet shaking table process using response surface methodology applied to the separation of copper and aluminum from the fine fraction of shredder ELVs.

    PubMed

    Jordão, Helga; Sousa, António Jorge; Carvalho, M Teresa

    2016-02-01

    With the purpose of reducing the waste generated by end-of-life vehicles (ELVs) by enhancing the recovery and recycling of nonferrous metals, an experimental study was conducted with the finest size fraction of nonferrous stream produced at an ELV shredder plant. The aim of this work was to characterize the nonferrous stream and to evaluate the efficiency of a gravity concentration process in separating light and heavy nonferrous metal particles that could be easily integrated in a ELV shredder plant (in this case study the separation explicitly addressed copper and aluminum separation). The characterization of a sample of the 0-10mm particle size fraction showed a mixture of nonferrous metals with a certain degree of impurity due to the present of contaminants such as plastics. The majority of the particles exhibited a wire shape, preventing an efficient separation of materials without prior fragmentation. The gravity concentration process selected for this study was the wet shaking table and three operating parameters of the equipment were manipulated. A full factorial design in combination with a central composite design was employed to model metals recovery. Two second order polynomial equations were successfully fitted to describe the process and predict the recovery of copper and aluminum in Cu concentrate under the conditions of the present study. The optimum conditions were determined to be 11.1° of inclination, 2.8L/min of feed water flow and 4.9L/min of wash water flow. All three final products of the wet shaking table had a content higher than 90% in relation to one of the metals, wherein a Cu concentrate product was obtained with a Cu content of 96%, and 78% of Cu recovery and 2% of Al recovery. PMID:26470828

  2. Aluminum Carbothermic Technology

    SciTech Connect

    Bruno, Marshall J.

    2005-03-31

    This report documents the non-proprietary research and development conducted on the Aluminum Carbothermic Technology (ACT) project from contract inception on July 01, 2000 to termination on December 31, 2004. The objectives of the program were to demonstrate the technical and economic feasibility of a new carbothermic process for producing commercial grade aluminum, designated as the ''Advanced Reactor Process'' (ARP). The scope of the program ranged from fundamental research through small scale laboratory experiments (65 kW power input) to larger scale test modules at up to 1600 kW power input. The tasks included work on four components of the process, Stages 1 and 2 of the reactor, vapor recovery and metal alloy decarbonization; development of computer models; and economic analyses of capital and operating costs. Justification for developing a new, carbothermic route to aluminum production is defined by the potential benefits in reduced energy, lower costs and more favorable environmental characteristics than the conventional Hall-Heroult process presently used by the industry. The estimated metrics for these advantages include energy rates at approximately 10 kWh/kg Al (versus over 13 kWh/kg Al for Hall-Heroult), capital costs as low as $1250 per MTY (versus 4,000 per MTY for Hall-Heroult), operating cost reductions of over 10%, and up to 37% reduction in CO2 emissions for fossil-fuel power plants. Realization of these benefits would be critical to sustaining the US aluminum industries position as a global leader in primary aluminum production. One very attractive incentive for ARP is its perceived ability to cost effectively produce metal over a range of smelter sizes, not feasible for Hall-Heroult plants which must be large, 240,000 TPY or more, to be economical. Lower capacity stand alone carbothermic smelters could be utilized to supply molten metal at fabrication facilities similar to the mini-mill concept employed by the steel industry. Major

  3. Processing and properties of TiNi shape memory fiber-reinforced 6061 aluminum matrix composite made by spark plasma sintering

    NASA Astrophysics Data System (ADS)

    Mizuuchi, Kiyoshi; Inoue, Kanryu; Hamada, K.; Sugioka, M.; Itami, M.; Okanda, Y.; Kawahara, M.

    2000-08-01

    Aluminum alloy matrix composite reinforced by continuous TiNi shape memory allow (SMA) fiber was fabricated by Spark Plasma Sintering (SPS) process of A1 alloy powder with 20 vol. % of the TiNi SMA fiber, and its microstructure and mechanical properties were examined. The A1 alloy powder with the TiNi fiber was readily consolidated into composite at temperatures between 633K and 873K. The relative packing density of the composite fabricated increased with increasing sintering temperature. Reaction occurred at the boundary between A1 alloy matrix and TiNi fiber and the interfacial reaction is considered to consist of three intermetallic phases, Ni3Ti (next to TiNI), Ni2Ti and Al3Ni (next to A1 matrix). The tensile yield stress of the composite deformed in tension at 373K was higher by about 40MPa than at 293K.

  4. A Processing Map for Hot Deformation of an Ultrafine-Grained Aluminum-Magnesium-Silicon Alloy Prepared by Mechanical Milling and Hot Extrusion

    NASA Astrophysics Data System (ADS)

    Asgharzadeh, Hamed; Rahbar Niazi, Masoud; Simchi, Abdolreza

    2015-12-01

    Uniaxial compression test at different temperatures [573 K to 723 K (300 °C to 450 °C)] and strain rates (0.01 to 1 s-1) was employed to study the hot deformation behavior of an ultrafine-grained (UFG) Al6063 alloy prepared by the powder metallurgy route. The UFG alloy with an average grain size of ~0.3 µm was prepared by mechanical milling of a gas-atomized aluminum alloy powder for 20 hours followed by hot powder extrusion at 723 K (450 °C). To elaborate the effect of grain size, the aluminum alloy powder was extruded without mechanical milling to attain a coarse-grained (CG) structure with an average grain size of about 2.2 µm. By employing the dynamic materials model, processing maps for the hot deformation of the UFG and CG Al alloy were constructed. For investigation of microstructural evolutions and deformation instability occurring upon hot working, optical microscopy, scanning electron microscopy coupled with electron backscattered diffraction and transmission electron microscopy were utilized. It is shown that the grain refinement increases the deformation flow stress while reducing the strain hardening and power dissipation efficiency during the deformation process at the elevated temperatures. Restoration mechanisms, including dynamic recovery and recrystallization are demonstrated to control microstructural evolutions and thus the deformation behavior. Coarsening of the grain structure in the UFG alloy is illustrated, particularly when the deformation is performed at high temperatures and low strain rates. The manifestations of instability are observed in the form of cracking and void formation.

  5. Measurement of tool forces in diamond turning

    SciTech Connect

    Drescher, J.; Dow, T.A.

    1988-12-01

    A dynamometer has been designed and built to measure forces in diamond turning. The design includes a 3-component, piezoelectric transducer. Initial experiments with this dynamometer system included verification of its predicted dynamic characteristics as well as a detailed study of cutting parameters. Many cutting experiments have been conducted on OFHC Copper and 6061-T6 Aluminum. Tests have involved investigation of velocity effects, and the effects of depth and feedrate on tool forces. Velocity has been determined to have negligible effects between 4 and 21 m/s. Forces generally increase with increasing depth of cut. Increasing feedrate does not necessarily lead to higher forces. Results suggest that a simple model may not be sufficient to describe the forces produced in the diamond turning process.

  6. PREPARATION OF ACTINIDE-ALUMINUM ALLOYS

    DOEpatents

    Moore, R.H.

    1962-09-01

    BS>A process is given for preparing alloys of aluminum with plutonium, uranium, and/or thorium by chlorinating actinide oxide dissolved in molten alkali metal chloride with hydrochloric acid, chlorine, and/or phosgene, adding aluminum metal, and passing air and/or water vapor through the mass. Actinide metal is formed and alloyed with the aluminum. After cooling to solidification, the alloy is separated from the salt. (AEC)

  7. Design for aluminum recycling

    SciTech Connect

    Not Available

    1993-10-01

    This article describes the increasing use of aluminum in automobiles and the need to recycle to benefit further growth of aluminum applications by assuring an economical, high-quality source of metal. The article emphasizes that coordination of material specifications among designers can raise aluminum scrap value and facilitate recycling. Applications of aluminum in automobile construction are discussed.

  8. Plasma Source Ion Implantation of Aluminum and Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Walter, Kevin Carl

    Three plasma source ion implantation (PSII) schemes applied to three aluminum systems have been studied. Pure aluminum, and aluminum alloys 7075 (Al-Cu-Mg-Zn) and A390 (Al-17Si-Cu-Fe) were (1) argon ion sputter-cleaned and nitrogen-implanted, (2) nitrogen-implanted without sputter -cleaning, and (3) argon-implanted. Nitrogen implantation was performed with the goal of modifying the surface properties by transformation of the surface to aluminum-nitride. Argon implantation was performed with the goal of modifying the surface properties by inducing radiation damage. All implantation schemes were accomplished using a glow discharge mode of the PSII process. Implanted surfaces were investigated using Auger depth profiling and Transmission Electron Microscopy. The profiles indicated a stoichiometric layer, ~ 0.15 μm thick, of AlN on the nitrogen-implanted samples. Electron microscopy confirmed the complete conversion of the aluminum surface to AlN. Knoop microhardness tests showed an increase in surface hardness, especially at low loads. The improvements were independent of prior sputter-cleaning and were approximately equal for the studied aluminum systems. Pin-on-disk wear tests were conducted using a ruby stylus and isopropanol lubrication. Argon implantation decreased the wear resistance of pure aluminum and 7075. Nitrogen implantation improved the wear rates by a factor of ~10 for pure aluminum and 7075. These improvements were independent of prior sputter-cleaning. The coefficient of friction was not significantly influenced by the implantation schemes. Due to a coarse microstructure, tribological tests of ion-implanted A390 were inconclusive. Corrosion studies performed in a 3.5 wt% NaCl solution (seawater) indicated nitrogen implantation gave pure aluminum improved corrosion resistance. The improvement is due to the complete conversion of the aluminum surface to AlN. Because of pre-existing precipitates, the corrosion properties of 7075 and A390 were not

  9. Subsurface Aluminum Nitride Formation in Iron-Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Bott, June H.

    Transformation-induced plasticity (TRIP) steels containing higher amounts of aluminum than conventional steels are ideal for structural automotive parts due to their mechanical properties. However, the aluminum tends to react with any processing environment at high temperatures and therefore presents significant challenges during manufacturing. One such challenge occurs during secondary cooling, reheating, and hot-rolling and is caused by a reaction with nitrogen-rich atmospheres wherein subsurface aluminum nitride forms in addition to internal and external oxides. The nitrides are detrimental to mechanical properties and cause surface cracks. It is important to understand how these nitrides and oxides form and their consequences for the quality of steel products. This study looks at model iron-aluminum (up to 8 wt.% aluminum) alloys and uses confocal laser scanning microscopy, x-ray diffraction, scanning electron microscopy with energy dispersive x-ray spectrometry, and transmission electron microscopy to study the effect of various conditions on the growth and development of these precipitates in a subsurface oxygen-depleted region. By using model alloys and controlling the experimental atmosphere, this study is able to understand some of the more fundamental materials science behind aluminum nitride formation in aluminum-rich iron alloys and the relationship between internal nitride and oxide precipitation and external oxide scale morphology and composition. The iron-aluminum alloys were heated in N2 atmospheres containing oxygen impurities. It was found that nitrides formed when bulk aluminum content was below 8 wt.% when oxygen was sufficiently depleted due to the internal oxidation. In the samples containing 1 wt.% aluminum, the depth of the internal oxide and nitride zones were in agreement with a diffusion-based model. Increasing aluminum content to 3 and 5 wt% had the effects of modifying the surface-oxide scale composition and increasing its continuity

  10. Automobile bodies: Can aluminum be an economical alternative to steel?

    NASA Astrophysics Data System (ADS)

    Roth, Richard; Clark, Joel; Kelkar, Ashish

    2001-08-01

    Although the use of aluminum in cars has been increasing for the past two decades, progress has been limited in developing aluminum auto bodies. In fact, most aluminum substitution has come in the form of castings and forgings in the transmission, wheels, etc. Car manufacturers have developed all-aluminum cars with two competing designs: conventional unibody and the spaceframe. However, aluminum is far from being a material of choice for auto bodies. The substitution of aluminum for steel is partly influenced by regulatory pressures to meet fuel efficiency standards by reducing vehicle weight, and to meet recycling standards. The key obstacles are the high cost of primary aluminum as compared to steel and added fabrication costs of aluminum panels. Both the aluminum and the automotive industries have attempted to make aluminum a cost-effective alternative to steel. This paper analyzes the cost of fabrication and assembly of four different aluminum car body designs, making comparisons with conventional steel designs at current aluminum prices and using current aluminum fabrication technology. It then attempts to determine if aluminum can be an alternative to steel at lower primary aluminum prices, and improved fabrication processes.

  11. Solution Processing of Cadmium Sulfide Buffer Layer and Aluminum-Doped Zinc Oxide Window Layer for Thin Films Solar Cells

    NASA Astrophysics Data System (ADS)

    Alam, Mahboob; Islam, Mohammad; Achour, Amine; Hayat, Ansar; Ahsan, Bilal; Rasheed, Haroon; Salam, Shahzad; Mujahid, Mohammad

    2014-07-01

    Cadmium sulfide (CdS) and aluminum-doped zinc oxide (Al:ZnO) thin films are used as buffer layer and front window layer, respectively, in thin film solar cells. CdS and Al:ZnO thin films were produced using chemical bath deposition (CBD) and sol-gel technique, respectively. For CBD CdS, the effect of bath composition and temperature, dipping time and annealing temperature on film properties was investigated. The CdS films are found to be polycrystalline with metastable cubic crystal structure, dense, crack-free surface morphology and the crystallite size of either few nanometers or 12-17 nm depending on bath composition. In case of CdS films produced with 1:2 ratio of Cd and S precursors, spectrophotometer studies indicate quantum confinement effect, owing to extremely small crystallite size, with an increase in Eg value from 2.42 eV (for bulk CdS) to 3.76 eV along with a shift in the absorption edge toward 330 nm wavelength. The optimum annealing temperature is 400°C beyond which film properties deteriorate through S evaporation and CdO formation. On the other hand, Al:ZnO films prepared via spin coating of precursor sols containing 0.90-1.10 at.% Al show that, with an increase in Al concentration, the average grain size increases from 28 nm to 131 nm with an associated decrease in root-mean-square roughness. The minimum value of electrical resistivity, measured for the films prepared using 0.95 at.% Al in the precursor sol, is 2.7 × 10-4 Ω ṡ cm. The electrical resistivity value rises upon further increase in Al doping level due to introduction of lattice defects and Al segregation to the grain boundary area, thus limiting electron transport through it.

  12. Aluminum-stabilized NB3SN superconductor

    DOEpatents

    Scanlan, Ronald M.

    1988-01-01

    An aluminum-stabilized Nb.sub.3 Sn superconductor and process for producing same, utilizing ultrapure aluminum. Ductile components are co-drawn with aluminum to produce a conductor suitable for winding magnets. After winding, the conductor is heated to convert it to the brittle Nb.sub.3 Sn superconductor phase, using a temperature high enough to perform the transformation but still below the melting point of the aluminum. This results in reaction of substantially all of the niobium, while providing stabilization and react-in-place features which are beneficial in the fabrication of magnets utilizing superconducting materials.

  13. Low-aluminum content iron-aluminum alloys

    SciTech Connect

    Sikka, V.K.; Goodwin, G.M.; Alexander, D.J.

    1995-06-01

    The low-aluminum-content iron-aluminum program deals with the development of a Fe-Al alloy with aluminum content such as a produce the minimum environmental effect at room temperature. The FAPY is an Fe-16 at. % Al-based alloy developed at the Oak Ridge National Laboratory as the highest aluminum-containing alloy with essentially no environmental effect. The chemical composition for FAPY in weight percent is: aluminum = 8.46, chromium = 5.50, zirconium = 0.20, carbon = 0.03, molybdenum = 2.00, yttrium = 0.10 and iron = 83.71. The ignots of the alloy can be hot worked by extrusion, forging, and rolling processes. The hot-worked cast structure can be cold worked with intermediate anneals at 800{degrees}C. Typical room-temperature ductility of the fine-grained wrought structure is 20 to 25% for this alloy. In contrast to the wrought structure, the cast ductility at room temperature is approximately 1% with a transition temperature of approximately 100 to 150{degrees}C, above which ductility values exceed 20%. The alloy has been melted and processed into bar, sheet, and foil. The alloy has also been cast into slabs, step-blocks of varying thicknesses, and shapes. The purpose of this section is to describe the welding response of cast slabs of three different thicknesses of FAPY alloy. Tensile, creep, and Charpy-impact data of the welded plates are also presented.

  14. Correlating shaped charge performance with processing conditions and microstructure of an aluminum alloy 1100 liner enabled by a new method to arrest nascent jet formation

    NASA Astrophysics Data System (ADS)

    Scheid, James Eric

    Aluminum-lined shaped charges are used in special applications where jet and / or slug residue in the target is undesired. The three different microstructures of the aluminum liners studied herein resulted from three different manufacturing interpretations of the same design. One interpretation was completely machining the liners from best available annealed round stock. The second was to cold-forge the liners from annealed round-stock in an open-die forge to near-final dimensions, and then machine the liners to the final dimensions. The third variant in this study was to use the above forged liner, but with annealing after the machining. These three manufacturing choices resulted in significant variations in shaped charge performance. The goal of this research was to clarify the relationships between the liner metal microstructure and properties, and the corresponding shaped charge dynamic flow behavior. What began as an investigation into user-reported performance problems associated inherently with liner manufacturing processes and resultant microstructure, resolved into new understandings of the relationships between aluminum liner microstructure and shaped charge collapse kinetics. This understanding was achieved through an extensive literature review and the comprehensive characterization of the material properties of three variants of an 1100 aluminum shaped charge liner with a focus on collapse and nascent jet formation. The machined liner had a microstructure with large millimeter-sized grains and fine particles aligned in bands parallel to the charge axis. The forged liner microstructure consisted of very small one micrometer-sized (1 mum) subgrains and fine particles aligned largely in bands elongated parallel to the liner contour. The annealed liner was characterized by ten micrometer (10 mum) sized equiaxed grains with residual fine particles in the forged alignment. This characterization was enabled by the development, execution and validation of a

  15. Electromagnetic bonding of plastics to aluminum

    NASA Technical Reports Server (NTRS)

    Sheppard, A. T.; Silbert, L.

    1980-01-01

    Electromagnetic curing is used to bond strain gage to aluminum tensile bar. Electromagnetic energy heats only plastic/metal interface by means of skin effect, preventing degradation of heat-treated aluminum. Process can be easily applied to other metals joined by high-temperature-curing plastic adhesives.

  16. Laboratory Powder Metallurgy Makes Tough Aluminum Sheet

    NASA Technical Reports Server (NTRS)

    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.

  17. Crystal Plasticity Analysis of Texture Evolution of Pure Aluminum During Processing by a New Severe Plastic Deformation Technique

    NASA Astrophysics Data System (ADS)

    Khajezade, Ali; Parsa, Mohammad Habibi; Mirzadeh, Hamed

    2016-02-01

    Texture evolution in a newly developed severe plastic deformation technique, named multi-axial incremental forging and shearing (MAIFS), was studied applying the visco-plastic self-consistent crystal plasticity formulation by consideration of macroscopic deformation history. The simulated texture evolutions revealed that although shear-like texture had developed by the MAIFS process, texture components rotated around normal to mid-plane section. This could be ascribed to the complex deformation history that naturally develops during processing by the MAIFS process. The increased complexity of the deformation history in the MAIFS process, compared to the techniques that are solely based on the simple shear deformation, causes more activated slip planes, which in turn can result in an enhanced grain refinement ability of this processing technique.

  18. Recycling of aluminum salt cake

    SciTech Connect

    Jody, B.J.; Daniels, E.J.; Bonsignore, P.V.; Karvelas, D.E.

    1991-12-01

    The secondary aluminum industry generates more than 110 {times} 10{sup 3} tons of salt-cake waste every year. This waste stream contains about 3--5% aluminum, 15--30% aluminum oxide, 30--40% sodium chloride, and 20--30% potassium chloride. As much as 50% of the content of this waste is combined salt (sodium and potassium chlorides). Salt-cake waste is currently disposed of in conventional landfills. In addition, over 50 {times} 10{sup 3} tons of black dross that is not economical to reprocess a rotary furnace for aluminum recovery ends up in landfills. The composition of the dross is similar to that of salt cake, except that it contains higher concentrations of aluminum (up to 20%) and correspondingly lower amounts of salts. Because of the high solubility of the salts in water, these residues, when put in landfills, represent a potential source of pollution to surface-water and groundwater supplies. The increasing number of environmental regulations on the generation and disposal of industrial wastes are likely to restrict the disposal of these salt-containing wastes in conventional landfills. Processes exist that employ the dissolution and recovery of the salts from the waste stream. These wet-processing methods are economical only when the aluminum concentration in that waste exceeds about 10%. Argonne National Laboratory (ANL) conducted a study in which existing technologies were reviewed and new concepts that are potentially more cost-effective than existing processes were developed and evaluated. These include freeze crystallization, solvent/antisolvent extraction, common-ion effect, high-pressure/high-temperature process, and capillary-effect systems. This paper presents some of the technical and economic results of the aforementioned ANL study.

  19. Process for the production of metal nitride sintered bodies and resultant silicon nitride and aluminum nitride sintered bodies

    NASA Technical Reports Server (NTRS)

    Yajima, S.; Omori, M.; Hayashi, J.; Kayano, H.; Hamano, M.

    1983-01-01

    A process for the manufacture of metal nitride sintered bodies, in particular, a process in which a mixture of metal nitrite powders is shaped and heated together with a binding agent is described. Of the metal nitrides Si3N4 and AIN were used especially frequently because of their excellent properties at high temperatures. The goal is to produce a process for metal nitride sintered bodies with high strength, high corrosion resistance, thermal shock resistance, thermal shock resistance, and avoidance of previously known faults.

  20. Hydrometallurgical process for the recovery of high value metals from spent lithium nickel cobalt aluminum oxide based lithium-ion batteries

    NASA Astrophysics Data System (ADS)

    Joulié, M.; Laucournet, R.; Billy, E.

    2014-02-01

    A hydrometallurgical process is developed to recover valuable metals of the lithium nickel cobalt aluminum oxide (NCA) cathodes from spent lithium-ion batteries (LIBs). Effect of parameters such as type of acid (H2SO4, HNO3 and HCl), acid concentration (1-4 mol L-1), leaching time (3-18 h) and leaching temperature (25-90 °C) with a solid to liquid ratio fixed at 5% (w/v) are investigated to determine the most efficient conditions of dissolution. The preliminary results indicate that HCl provides higher leaching efficiency. In optimum conditions, a complete dissolution is performed for Li, Ni, Co and Al. In the nickel and cobalt recovery process, at first the Co(II) in the leaching liquor is selectively oxidized in Co(III) with NaClO reagent to recover Co2O3, 3H2O by a selective precipitation at pH = 3. Then, the nickel hydroxide is precipitated by a base addition at pH = 11. The recovery efficiency of cobalt and nickel are respectively 100% and 99.99%.

  1. X-ray photoelectron spectroscopy study of catalyzed aluminum carbide formation at aluminum-carbon interfaces

    NASA Technical Reports Server (NTRS)

    Rabenberg, L.; Maruyama, Benji

    1990-01-01

    Aluminum carbide may form at aluminum-graphite interfaces during the high-temperature processing of graphite fiber-reinforced aluminum metal matrix composites. The chemical interactions leading to the formation of the aluminum carbide in the solid state involve the breaking of the carbon-carbon bonds within the graphite, the transport of the carbon atoms across the interface, and the reaction with the aluminum to form Al4C3. The aluminum carbide formation process has been followed using X-ray photoelectron spectroscopy of model, thin-film, reaction couples. The overall reaction is shown to be catalyzed by the presence of water vapor. Water at the interface increases reaction kinetics by apparently weakening the bonds between the surface carbon atoms and their substrate. This result is in general agreement with what is known to occur during the oxidation of graphite in air.

  2. Occupational exposure to aluminum and its biomonitoring in perspective.

    PubMed

    Riihimäki, Vesa; Aitio, Antero

    2012-11-01

    Exposure to aluminum at work is widespread, and people are exposed to several species of aluminum, which differ markedly as to the kinetics and toxicity. Especially welding of aluminum is widely applied and continuously expanding. Inhalation of fine particles of sparsely soluble aluminum results in the retention of deposited particles in the lungs. From the lungs, aluminum is released to the blood and distributed to bones and the brain, and excreted to urine. Soluble aluminum compounds are not accumulated in the lungs. Neurotoxicity is the critical effect of exposure to sparsely soluble aluminum compounds. Studies on workers exposed to aluminum welding fumes have revealed disturbances of cognitive processes, memory and concentration, and changes in mood and EEG. Early pulmonary effects have been observed among aluminum powder-production workers using high-resolution computed tomography. The primary objective of aluminum biomonitoring (BM) is to help prevent the formation of aluminum burden in the lungs and thereby to prevent harmful accumulation of aluminum in target organs. BM of aluminum can be effectively used for this purpose in the production/use of aluminum powders, aluminum welding, as well as plasma cutting, grinding, polishing and thermal spraying of aluminum. BM of aluminum may also be similarly useful in the smelting of aluminum and probably in the production of corundum. BM can help identify exposed individuals and roughly quantitate transient exposure but cannot predict health effects in the production/use of soluble aluminum salts. For urinary aluminum (U-Al) we propose an action limit of 3 µmol/L, corrected to a relative density of 1.021, in a sample collected preshift after two days without occupational exposure, and without use of aluminum-containing drugs. This value corresponds roughly to 2.3 µmol/g creatinine. Compliance with this limit is expected to protect the worker against the critical effect of aluminum in exposure to sparsely soluble

  3. Mechanical properties and microstructure of 6061 aluminum alloy severely deformed by ARB process and subsequently aged at low temperatures

    NASA Astrophysics Data System (ADS)

    Terada, Daisuke; Kaneda, Yoma; Horita, Zenji; Matsuda, Kenji; Hirosawa, Shoichi; Tsuji, Nobuhiro

    2014-08-01

    In order to clarify the aging behavior in ultrafine grained (UFG) Al alloys, a commercial Al-Mg-Si alloy was severely deformed by accumulative roll-bonding (ARB) process and subsequently aged at 100°C or 170°C. The age-hardening behavior and microstructure change during aging were investigated. At 170 °C, age-hardening was observed in solution treated (ST) specimens, but solution-treated and ARB-processed specimens were not hardened by aging. On the other hand, the hardness of the both ST specimen and ARB-processed specimen increased by aging at 100°C. From TEM observation, it was found that the ARB- processed specimen had an ultrafine lamellar boundary structure and the structure was kept during aging at 170°C and 100°C. In the ST specimen aged at 170°C, fine precipitates were observed within coarse grains. In the specimen ARB-processed and subsequently aged at 170°C, coarser precipitates were observed within ultrafine grains and on grain boundaries. It was considered that the reason why the hardness of the specimens ARB-processed and subsequently aged did not increase was coarsening of precipitates. In the specimens aged at 100°C, obvious precipitates were not observed, but clusters Mg and Si seemed to form during the aging, leading to the increase in the hardness of the specimen. From the results, it was suggested that aging at low temperatures could improve mechanical properties of Al alloys through combining grain refinement and precipitation hardening.

  4. Specific features of aluminum nanoparticle water and wet air oxidation

    SciTech Connect

    Lozhkomoev, Aleksandr S. Glazkova, Elena A. Svarovskaya, Natalia V. Bakina, Olga V. Kazantsev, Sergey O. Lerner, Marat I.

    2015-10-27

    The oxidation processes of the electrically exploded aluminum nanopowders in water and in wet air are examined in the paper. The morphology of the intermediate reaction products of aluminum oxidation has been studied using the transmission electron microscopy. It was shown that the aluminum nanopowder water oxidation causes the formation of the hollow spheres with mesoporous boehmite nanosheets coating. The wedge-like bayerite particles are formed during aluminum nanopowder wet air oxidation.

  5. Specific features of aluminum nanoparticle water and wet air oxidation

    NASA Astrophysics Data System (ADS)

    Lozhkomoev, Aleksandr S.; Glazkova, Elena A.; Svarovskaya, Natalia V.; Bakina, Olga V.; Kazantsev, Sergey O.; Lerner, Marat I.

    2015-10-01

    The oxidation processes of the electrically exploded aluminum nanopowders in water and in wet air are examined in the paper. The morphology of the intermediate reaction products of aluminum oxidation has been studied using the transmission electron microscopy. It was shown that the aluminum nanopowder water oxidation causes the formation of the hollow spheres with mesoporous boehmite nanosheets coating. The wedge-like bayerite particles are formed during aluminum nanopowder wet air oxidation.

  6. Spray Rolling Aluminum Strip

    SciTech Connect

    Lavernia, E.J.; Delplanque, J-P; McHugh, K.M.

    2006-05-10

    Spray forming is a competitive low-cost alternative to ingot metallurgy for manufacturing ferrous and non-ferrous alloy shapes. It produces materials with a reduced number of processing steps, while maintaining materials properties, with the possibility of near-net-shape manufacturing. However, there are several hurdles to large-scale commercial adoption of spray forming: 1) ensuring strip is consistently flat, 2) eliminating porosity, particularly at the deposit/substrate interface, and 3) improving material yield. Through this program, a new strip/sheet casting process, termed spray rolling, has been developed, which is an innovative manufacturing technique to produce aluminum net-shape products. Spray rolling combines the benefits of twin-roll casting and conventional spray forming, showing a promising potential to overcome the above hurdles associated with spray forming. Spray rolling requires less energy and generates less scrap than conventional processes and, consequently, enables the development of materials with lower environmental impacts in both processing and final products. Spray Rolling was developed as a collaborative project between the University of California-Davis, the Colorado School of Mines, the Idaho National Engineering and Environmental Laboratory, and an industry team. The following objectives of this project were achieved: (1) Demonstration of the feasibility of the spray rolling process at the bench-scale level and evaluation of the materials properties of spray rolled aluminum strip alloys; and (2) Demonstration of 2X scalability of the process and documentation of technical hurdles to further scale up and initiate technology transfer to industry for eventual commercialization of the process.

  7. Scaleable Clean Aluminum Melting Systems

    SciTech Connect

    Han, Q.; Das, S.K.

    2008-02-15

    The project entitled 'Scaleable Clean Aluminum Melting Systems' was a Cooperative Research and Development Agreements (CRADAs) between Oak Ridge National Laboratory (ORNL) and Secat Inc. The three-year project was initially funded for the first year and was then canceled due to funding cuts at the DOE headquarters. The limited funds allowed the research team to visit industrial sites and investigate the status of using immersion heaters for aluminum melting applications. Primary concepts were proposed on the design of furnaces using immersion heaters for melting. The proposed project can continue if the funding agency resumes the funds to this research. The objective of this project was to develop and demonstrate integrated, retrofitable technologies for clean melting systems for aluminum in both the Metal Casting and integrated aluminum processing industries. The scope focused on immersion heating coupled with metal circulation systems that provide significant opportunity for energy savings as well as reduction of melt loss in the form of dross. The project aimed at the development and integration of technologies that would enable significant reduction in the energy consumption and environmental impacts of melting aluminum through substitution of immersion heating for the conventional radiant burner methods used in reverberatory furnaces. Specifically, the program would couple heater improvements with furnace modeling that would enable cost-effective retrofits to a range of existing furnace sizes, reducing the economic barrier to application.

  8. Control of interfacial reactions during liquid phase processing of aluminum matrix composites reinforced with INCONEL 601 fibers

    NASA Astrophysics Data System (ADS)

    Boland, F.; Colin, C.; Delannay, F.

    1998-06-01

    A comprehensive investigation is made of the parameters affecting the extent of interface reactions during squeeze casting of composites consisting of a matrix of either pure Al or alloy AS13 reinforced with fibers of INCONEL 601. The process parameters are the preform thickness and temperature, the fiber volume fraction, the temperature and mass of the liquid metal, and the temperature of the die. Adjustment of these process parameters made possible the full control of reactions. It is found that reactions proceed mainly in the solid state after decomposition of the oxide barrier layer covering the fibers. A simple kinetic model is developed that enlightens the role of this barrier layer. No trace of reaction could be detected in composites processed using preoxidized preforms. Alloying Al with Si also induces a drastic reduction of reactivity. The high ductility of the composites attests to the processing quality. An original procedure is proposed for measuring the activation energy for initiation of reactions by differential thermal analysis.

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

    SciTech Connect

    Weiss, David C.; 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.

  10. Aluminum plasmonic photocatalysis

    PubMed Central

    Hao, Qi; Wang, Chenxi; Huang, Hao; Li, Wan; Du, Deyang; Han, Di; Qiu, Teng; Chu, Paul K.

    2015-01-01

    The effectiveness of photocatalytic processes is dictated largely by plasmonic materials with the capability to enhance light absorption as well as the energy conversion efficiency. Herein, we demonstrate how to improve the plasmonic photocatalytic properties of TiO2/Al nano-void arrays by overlapping the localized surface plasmon resonance (LSPR) modes with the TiO2 band gap. The plasmonic TiO2/Al arrays exhibit superior photocatalytic activity boasting an enhancement of 7.2 folds. The underlying mechanisms concerning the radiative energy transfer and interface energy transfer processes are discussed. Both processes occur at the TiO2/Al interface and their contributions to photocatalysis are evaluated. The results are important to the optimization of aluminum plasmonic materials in photocatalytic applications. PMID:26497411

  11. Aluminum and Young Artists.

    ERIC Educational Resources Information Center

    Anderson, Thomas

    1980-01-01

    The author suggests a variety of ways in which aluminum and aluminum foil can be used in elementary and junior high art classes: relief drawing and rubbing; printing; repousse; sculpture; mobiles; foil sculpture; and three dimensional design. Sources of aluminum supplies are suggested. (SJL)

  12. Aluminum recovery as a product with high added value using aluminum hazardous waste.

    PubMed

    David, E; Kopac, J

    2013-10-15

    The samples of hazardous aluminum solid waste such as dross were physically and chemically characterized. A relationship between density, porosity and metal content of dross was established. The paper also examines the chemical reactions involving aluminum dross in landfill and the negative consequences. To avoid environmental problems and to recovery the aluminum, a processing method was developed and aluminum was recovered as an added value product such as alumina. This method refers to a process at low temperature, in more stages: acid leaching, purification, precipitation and calcination. At the end of this process aluminum was extracted, first as Al(3+) soluble ions and final as alumina product. The composition of the aluminum dross and alumina powder obtained were measured by applying the leaching tests, using atomic absorption spectrometry (AAS) and chemical analysis. The mineralogical composition of aluminum dross samples and alumina product were determined by X-ray diffraction (XRD) and the morphological characterization was performed by scanning electron microscopy (SEM). The method presented in this work allows the use of hazardous aluminum solid waste as raw material to recover an important fraction from soluble aluminum content as an added value product, alumina, with high grade purity (99.28%). PMID:23959251

  13. Examination of the physical processes associated with the keyhole region of variable polarity plasma arc welds in aluminum alloy 2219

    NASA Technical Reports Server (NTRS)

    Walsh, Daniel W.

    1987-01-01

    The morphology and properties of the Variable Polarity Plasma Arc (VPPA) weld composite zone are intimately related to the physical processes associated with the keyhole. This study examined the effects of oxide, halide, and sulfate additions to the weld plate on the keyhole and the weld pool. Changes in both the arc plasma character and the bead morphology were correlated to the chemical environment of the weld. Pool behavior was observed by adding flow markers to actual VPPA welds. A low temperature analog to the welding process was developed. The results of the study indicate that oxygen, even at low partial pressures, can disrupt the stable keyhole and weld pool. The results also indicate that the Marangoni surface tension driven flows dominate the weld pool over the range of welding currents studied.

  14. Novel applications of microwaves in the metallurgical processing of a nickel-ferrous laterite ore and an aluminum industry waste

    NASA Astrophysics Data System (ADS)

    Samouhos, M.; Taxiarchou, M.; Kouvelos, E.

    2016-04-01

    Microwave radiation is a relatively new source of energy in the pyrometallurgical process. In this study, the application of microwaves in the carbothermic reductive roasting of a nickeliferous hematitic laterite ore and a red mud are investigated. The effective microwave heating (at temperatures above 900°C) of the aforementioned materials is attainable due to the relatively high values of their imaginary permittivity (ε")- In both two cases, the reduction of the included hematite was attempted, and the reduction degree was calculated as a function of: (a) the heating time and (b) the supplied microwave power. The mechanism of Fe+3 to Fe0 conversion was investigated using Mössbaurer spectroscopy revealing the formation of magnetite, fayalite and nano-structured metallic iron. Finally, it should be noted that that the gaseous products of the microwave pyrometallurgical process were analyzed using a mass spectroscopic technique, which is an important novelty.

  15. EBSD Study on Grain Boundary and Microtexture Evolutions During Friction Stir Processing of A413 Cast Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Shamanian, Morteza; Mostaan, Hossein; Safari, Mehdi; Szpunar, Jerzy A.

    2016-07-01

    The as-cast Al alloys contain heterogeneous distributions of non-deforming particles due to non-equilibrium solidification effects. Therefore, these alloys have poor tribological and mechanical behaviors. It is well known that using friction stir processing (FSP), very fine microstructure is created in the as-cast Al alloys, while their wear resistance can be improved. In this research work, FSP is used to locally refine a surface layer of the coarse as-cast microstructure of cast A413 Al alloy. The main objective of this study is to investigate the effect of FSP on microstructure and microtexture evolutions in A413 cast Al alloy. The grain boundary character distribution, grain structure, and microtexture evolutions in as-cast and friction stir processed A413 Al alloy are analyzed by electron back scatter diffraction technique. It is found that with the FSP, the fraction of low ∑boundary such as ∑3, 7, and 9 are increased. The obtained results show that there are no deformation texture components in the structure of friction stir processed samples. However, some of the main recrystallization texture components such as BR and cubeND are formed during FSP which indicate the occurrence of dynamic recrystallization phenomenon due to the severe plastic deformation induced by the rotation of tool.

  16. EBSD Study on Grain Boundary and Microtexture Evolutions During Friction Stir Processing of A413 Cast Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Shamanian, Morteza; Mostaan, Hossein; Safari, Mehdi; Szpunar, Jerzy A.

    2016-05-01

    The as-cast Al alloys contain heterogeneous distributions of non-deforming particles due to non-equilibrium solidification effects. Therefore, these alloys have poor tribological and mechanical behaviors. It is well known that using friction stir processing (FSP), very fine microstructure is created in the as-cast Al alloys, while their wear resistance can be improved. In this research work, FSP is used to locally refine a surface layer of the coarse as-cast microstructure of cast A413 Al alloy. The main objective of this study is to investigate the effect of FSP on microstructure and microtexture evolutions in A413 cast Al alloy. The grain boundary character distribution, grain structure, and microtexture evolutions in as-cast and friction stir processed A413 Al alloy are analyzed by electron back scatter diffraction technique. It is found that with the FSP, the fraction of low ∑boundary such as ∑3, 7, and 9 are increased. The obtained results show that there are no deformation texture components in the structure of friction stir processed samples. However, some of the main recrystallization texture components such as BR and cubeND are formed during FSP which indicate the occurrence of dynamic recrystallization phenomenon due to the severe plastic deformation induced by the rotation of tool.

  17. X-ray Microtomography Analysis of the Aluminum Alloy Composite Reinforced by SiC After Friction Stir Processing

    NASA Astrophysics Data System (ADS)

    Wójcicka, Anna; Mroczka, Krzysztof; Kurtyka, Paweł; Binkowski, Marcin; Wróbel, Zygmunt

    2014-09-01

    Despite many years of using friction stir processing (FSP), there are many unexplained aspects concerning the processes which appear during FSP: determining the direction of flow and mixing of the materials and the degree of mixing and microstructure fragmentation in specific areas. This paper presents the impact of FSP on the micro- and macrostructure of the composite with hypo-eutectic Si matrix reinforced by SiC particles. The analysis of the structure of the processed area in FSP in the relation to the microstructure of the base material has been made using x-ray microtomography. The results of these studies have been juxtaposed with studies using microscopic methods (light microscopy and SEM). The microtomography images revealed an additional separation on the advancing side and the weld nugget, where on the basis of a 3D reconstruction a layer microstructure on the direction of linear movement of the tool has been demonstrated. The analyses have revealed a limited flow of the material above the weld nugget. The main advantages of the research method applied were the possibility to show the invisible or barely visible elements of the microstructure using standard test methods and the ability to analyze the microstructure changes uninterruptedly in different directions in the volume of the material.

  18. CATALYST ACTIVITY MAINTENANCE FOR THE LIQUID PHASE SYNTHESIS GAS-TO-DIMETHYL ETHER PROCESS PART II: DEVELOPMENT OF ALUMINUM PHOSPHATE AS THE DEHYDRATION CATALYST FOR THE SINGLE-STEP LIQUID PHASE SYNGAS-TO-DME PROCESS

    SciTech Connect

    Xiang-Dong Peng

    2002-05-01

    At the heart of the single-step liquid phase syngas-to-DME process (LPDME{trademark}) is a catalyst system that can be active as well as stable. In the Alternative Fuels I program, a dual-catalyst system containing a Cu-based commercial methanol synthesis catalyst (BASF S3-86) and a commercial dehydration material ({gamma}-alumina) was demonstrated. It provided the productivity and selectivity expected from the LPDME process. However, the catalyst system deactivated too rapidly to warrant a viable commercial process [1]. The mechanistic investigation in the early part of the DOE's Alternative Fuels II program revealed that the accelerated catalyst deactivation under LPDME conditions is due to detrimental interaction between the methanol synthesis catalyst and methanol dehydration catalyst [2,3]. The interaction was attributed to migration of Cu- and/or Zn-containing species from the synthesis catalyst to the dehydration catalyst. Identification of a dehydration catalyst that did not lead to this detrimental interaction while retaining adequate dehydration activity was elusive. Twenty-nine different dehydration materials were tested, but none showed the desired performance [2]. The search came to a turning point when aluminum phosphate was tested. This amorphous material is prepared by precipitating a solution containing Al(NO{sub 3}){sub 3} and H{sub 3}PO{sub 4} with NH{sub 4}OH, followed by washing, drying and calcination. The aluminum phosphate catalyst has adequate dehydration activity and good stability. It can co-exist with the Cu-based methanol synthesis catalyst without negatively affecting the latter catalyst's stability. This report documents the details of the development of this catalyst. These include initial leads, efforts in improving activity and stability, investigation and development of the best preparation parameters and procedures, mechanistic understanding and resulting preparation guidelines, and the accomplishments of this work.

  19. Rheological behavior and microstructural evolution of semi-solid hypereutectic aluminum-silicon-magnesium-copper alloys using rheoforming process

    NASA Astrophysics Data System (ADS)

    Tebib, Mehand

    The aim of the current study was to investigate the rheological behavior and microstructural evolution of hypereutectic Al-Si-Cu and Al-Si-Mg-Cu alloys using conventional and modified SEED process (Swirled Enthalpy Equilibration Device). In the first part; the feasibility of semi-solid processing of hypereutectic Al-Si-Cu A390 alloys using a novel rheoforming process was investigated. A combination of the SEED process, isothermal holding using insulation and addition of solid alloy during swirling was introduced as a novel method to improve the processability of semi-solid A390 slurries. The effects of isothermal holding and the addition of solid alloy on the temperature gradient between the centre and the wall and on the formation of alpha-Al particles were examined. In addition, phosphorus and strontium were added to the molten metal to refine the primary and eutectic silicon structure to facilitate semi-solid processing. It was found that the combination of the SEED process with two additional processing steps can produce semisolid 390 alloys that can be rheoformed. In the second part, the effects of Mg additions ranging from 6 to 15% on the solidification behaviour of hypereutectic Al-155i-xMg-4Cu alloys was investigated using thermodynamic calculations, thermal analysis and extensive microstructural examination. The Mg level strongly influenced the microstructural evolution of the primary Mg2Si phase as well as the solidification behaviour. Thermodynamic predictions using ThermoCalc software reported the occurrence of six reactions, comprising the formation of primary Mg2 Si, two pre-eutectic binary reactions, forming either Mg2Si + Si or Mg2Si + alpha-Al phases, the main ternary eutectic reaction forming Mg2Si + Si + alpha-Al, and two post-eutectic reactions resulting in the precipitation of the Q-Al5Mg8Cu 2Si6 and theta-Al2Cu phases, respectively. Microstructures of the four alloys studied confirmed the presence of these phases, in addition to that of the pi

  20. Diffuse Parenchymal Diseases Associated With Aluminum Use and Primary Aluminum Production

    PubMed Central

    2014-01-01

    Aluminum use and primary aluminum production results in the generation of various particles, fumes, gases, and airborne materials with the potential for inducing a wide range of lung pathology. Nevertheless, the presence of diffuse parenchymal or interstitial lung disease related to these processes remains controversial. The relatively uncommon occurrence of interstitial lung diseases in aluminum-exposed workers—despite the extensive industrial use of aluminum—the potential for concurrent exposure to other fibrogenic fibers, and the previous use of inhaled aluminum powder for the prevention of silicosis without apparent adverse respiratory effects are some of the reasons for this continuing controversy. Specific aluminum-induced parenchymal diseases described in the literature, including existing evidence of interstitial lung diseases, associated with primary aluminum production are reviewed. PMID:24806728

  1. Double-sided fiber laser beam welding process of T-joints for aluminum aircraft fuselage panels: Filler wire melting behavior, process stability, and their effects on porosity defects

    NASA Astrophysics Data System (ADS)

    Tao, Wang; Yang, Zhibin; Chen, Yanbin; Li, Liqun; Jiang, Zhenguo; Zhang, Yunlong

    2013-11-01

    Aluminum alloy T-joints for aircraft fuselage panels were fabricated by double-sided fiber laser beam welding with filler wire, and the influence of the wire feeding posture on the welding process stability was investigated. A CMOS high speed video system was used to observe the wire melting behavior and the weld pool dynamics in real time during the welding process by using a bandpass red laser with an emission wavelength of 808 nm as backlight source to illuminate the welding zone. The weld porosity defects were analyzed by X-ray radiography. The effects of wire feeding posture on the wire melting behavior, process stability, and porosity defects were investigated. The experimental results indicated that three distinct filler material transfer modes were identified under different wire feeding positions: liquid bridge transfer mode, droplet transfer mode, and spreading transfer mode. The liquid bridge transfer mode could guarantee a stable welding process, and result in the lowest porosity. Compared with wire feeding in the leading direction, the process was not stable and porosity increased when wire feeding in the trailing direction. Increased in the wire feeding angle was disadvantage for pores to escape from the weld molten pool, meanwhile, it made the welding process window smaller due to increasing the centering precision requirement for adjusting the filler wire.

  2. Thermal analysis of friction welding process in relation to the welding of YSZ-alumina composite and 6061 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Uday, M. B.; Fauzi, M. N. Ahmad; Zuhailawati, H.; Ismail, A. B.

    2012-08-01

    The objective of this work is to establish an analytical data for heat generation by friction welding, based on different parameters of the contact condition between two dissimilar materials. The ceramic composite of Al2O3-YSZ and 6061 Al alloy, which is the example of joining materials by friction welding was used in the experiments. Alumina rods containing 0, 25 and 50 wt% yttria stabilized zirconia were produced by slip casting in Plaster of Paris molds and subsequently sintered at 1600 °C. The diameter of both the ceramic and metal rods was 16 mm. Rotational speeds for friction welding were between 630 and 2500 rpm. As a result, different data was evaluated for obtaining joint properties and operating conditions, and obtained results are useful in modeling the welding process and reliability joint under various conditions.

  3. Gravitational influences on the liquid-state homogenization and solidification of aluminum antimonide. [space processing of solar cell material

    NASA Technical Reports Server (NTRS)

    Ang, C.-Y.; Lacy, L. L.

    1979-01-01

    Typical commercial or laboratory-prepared samples of polycrystalline AlSb contain microstructural inhomogeneities of Al- or Sb-rich phases in addition to the primary AlSb grains. The paper reports on gravitational influences, such as density-driven convection or sedimentation, that cause microscopic phase separation and nonequilibrium conditions to exist in earth-based melts of AlSb. A triple-cavity electric furnace is used to homogenize the multiphase AlSb samples in space and on earth. A comparative characterization of identically processed low- and one-gravity samples of commercial AlSb reveals major improvements in the homogeneity of the low-gravity homogenized material.

  4. Improvement of Mechanical Properties in the Functionally Graded Aluminum Matrix Nanocomposites Fabricated via a Novel Multistep Friction Stir Processing

    NASA Astrophysics Data System (ADS)

    Salehi, Mojtaba; Farnoush, Hamidreza; Heydarian, Arash; Aghazadeh Mohandesi, Jamshid

    2015-02-01

    In the present study, the functionally graded bulk Al-SiC nanocomposites were successfully fabricated by applying a novel multistep friction stir processing. Microstructural observations by scanning electron microscope indicated a proper distribution of SiC nanoparticles in the Al 6061 matrix. Microhardness profiles descended to 50 from 160 Hv due to the formation of compositionally gradient of SiC nanoparticles along the thickness. The tensile behavior of graded samples revealed a simultaneous enhancement of ultimate tensile strength (44 pct), strain at maximum stress (244 pct), and work of fracture (492 pct) with respect to the homogeneous sample. Furthermore, the graded samples sustained up to 4 pct strain after initiation of primary cracking, while the catastrophic fracture occurred instantly after cracking in the homogenous sample. A dimple-like ductile fracture surface was observed for the graded layers in which an increase in the SiC particle content will result in smaller dimple size.

  5. Improvement of Mechanical Properties in the Functionally Graded Aluminum Matrix Nanocomposites Fabricated via a Novel Multistep Friction Stir Processing

    NASA Astrophysics Data System (ADS)

    Salehi, Mojtaba; Farnoush, Hamidreza; Heydarian, Arash; Aghazadeh Mohandesi, Jamshid

    2014-09-01

    In the present study, the functionally graded bulk Al-SiC nanocomposites were successfully fabricated by applying a novel multistep friction stir processing. Microstructural observations by scanning electron microscope indicated a proper distribution of SiC nanoparticles in the Al 6061 matrix. Microhardness profiles descended to 50 from 160 Hv due to the formation of compositionally gradient of SiC nanoparticles along the thickness. The tensile behavior of graded samples revealed a simultaneous enhancement of ultimate tensile strength (44 pct), strain at maximum stress (244 pct), and work of fracture (492 pct) with respect to the homogeneous sample. Furthermore, the graded samples sustained up to 4 pct strain after initiation of primary cracking, while the catastrophic fracture occurred instantly after cracking in the homogenous sample. A dimple-like ductile fracture surface was observed for the graded layers in which an increase in the SiC particle content will result in smaller dimple size.

  6. Spray Rolling Aluminum Strip for Transportation Applications

    SciTech Connect

    Kevin M. McHugh; Y. Lin; Y. Zhou; E. J. Lavernia; J.-P. Delplanque; S. B. Johnson

    2005-02-01

    Spray rolling is a novel strip casting technology in which molten aluminum alloy is atomized and deposited into the roll gap of mill rolls to produce aluminum strip. A combined experimental/modeling approach has been followed in developing this technology with active participation from industry. The feasibility of this technology has been demonstrated at the laboratory scale and it is currently being scaled-up. This paper provides an overview of the process and compares the microstructure and properties of spray-rolled 2124 aluminum alloy with commercial ingot-processed material

  7. Virus inactivation in aluminum and polyaluminum coagulation.

    PubMed

    Matsui, Yoshihiko; Matsushita, Taku; Sakuma, Satoru; Gojo, Takahito; Mamiya, Teppei; Suzuoki, Hiroshi; Inoue, Takanobu

    2003-11-15

    Inorganic aluminum salts, such as aluminum sulfate, are coagulants that cause small particles, such as bacteria and viruses as well as inorganic particles, to destabilize and combine into larger aggregates. In this investigation, batch coagulation treatments of water samples spiked with Qbeta, MS2, T4, and P1 viruses were conducted with four different aluminum coagulants. The total infectious virus concentration in the suspension of floc particles that eventually formed by dosing with coagulant was measured after the floc particles were dissolved by raising the pH with an alkaline beef extract solution. The virus concentrations were extremely reduced after the water samples were dosed with aluminum coagulants. Viruses mixed with and adsorbed onto preformed aluminum hydroxide floc were, however, completely recovered after the floc dissolution. These results indicated that the aluminum coagulation process inactivates viruses. Virucidal activity was most prominent with the prehydrolyzed aluminum salt coagulant, polyaluminum chloride (PACl). Virucidal activity was lower in river water than in ultrapure water--natural organic matter in the river water depressed the virucidal activity. Mechanisms and kinetics of the virus inactivation were discussed. Our results suggest that intermediate polymers formed during hydrolysis of the aluminum coagulants sorbed strongly to viruses, either rendering them inactive or preventing infectivity. PMID:14655704

  8. A Doping Lattice of Aluminum and Copper with Accelerated Electron Transfer Process and Enhanced Reductive Degradation Performance

    PubMed Central

    Zhang, Lin; Gao, Xue; Zhang, Zhixuan; Zhang, Mingbo; Cheng, Yiqian; Su, Jixin

    2016-01-01

    Treatment of azo dye effluents has received increasing concerns over the years due to their potential harms to natural environment and human health. The present study described the degrading ability of the as-synthesized crystalline Al-Cu alloys for removal of high-concentration Acid Scarlet 3R in alkaline aqueous solutions and its degradation mechanism. Al-Cu alloy particles with Al/Cu ratios 19:1 were successfully synthesized by high-energy mechanical milling. Characterization results showed that 10 h mechanical alloying process could lead to the formation of crystalline Al(Cu) solid solution. Batch experiment results confirmed the excellent ability of Al-Cu alloy particles for the degradation of 3R in aqueous solution. Under a certain condition ([Al-Cu]0 = 2 g/L, [3R]0 = 200 mg/L, [NaCl]0 = 25 g/L, initial pH = 10.9), the 3R could be completely degraded within only 3 min. It was also found that the degradation reaction followed zero-order kinetics model with respect to the initial dye concentration. The intermediate compounds were identified by UV-vis, FT-IR and HPLC-MS, and a pathway was proposed. Additionally, post-treatment Al-Cu alloy particles were characterized by SEM and TEM, and the results showed that the degradation might be attributed to the corrosion effect of Al-Cu alloys. PMID:27535800

  9. A Doping Lattice of Aluminum and Copper with Accelerated Electron Transfer Process and Enhanced Reductive Degradation Performance.

    PubMed

    Zhang, Lin; Gao, Xue; Zhang, Zhixuan; Zhang, Mingbo; Cheng, Yiqian; Su, Jixin

    2016-01-01

    Treatment of azo dye effluents has received increasing concerns over the years due to their potential harms to natural environment and human health. The present study described the degrading ability of the as-synthesized crystalline Al-Cu alloys for removal of high-concentration Acid Scarlet 3R in alkaline aqueous solutions and its degradation mechanism. Al-Cu alloy particles with Al/Cu ratios 19:1 were successfully synthesized by high-energy mechanical milling. Characterization results showed that 10 h mechanical alloying process could lead to the formation of crystalline Al(Cu) solid solution. Batch experiment results confirmed the excellent ability of Al-Cu alloy particles for the degradation of 3R in aqueous solution. Under a certain condition ([Al-Cu]0 = 2 g/L, [3R]0 = 200 mg/L, [NaCl]0 = 25 g/L, initial pH = 10.9), the 3R could be completely degraded within only 3 min. It was also found that the degradation reaction followed zero-order kinetics model with respect to the initial dye concentration. The intermediate compounds were identified by UV-vis, FT-IR and HPLC-MS, and a pathway was proposed. Additionally, post-treatment Al-Cu alloy particles were characterized by SEM and TEM, and the results showed that the degradation might be attributed to the corrosion effect of Al-Cu alloys. PMID:27535800

  10. 40 CFR 421.20 - Applicability: description of the primary aluminum smelting subcategory.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... primary aluminum smelting subcategory. 421.20 Section 421.20 Protection of Environment ENVIRONMENTAL... CATEGORY Primary Aluminum Smelting Subcategory § 421.20 Applicability: description of the primary aluminum... production of aluminum from alumina in the Hall-Heroult process....

  11. 40 CFR 421.20 - Applicability: description of the primary aluminum smelting subcategory.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... primary aluminum smelting subcategory. 421.20 Section 421.20 Protection of Environment ENVIRONMENTAL... CATEGORY Primary Aluminum Smelting Subcategory § 421.20 Applicability: description of the primary aluminum... production of aluminum from alumina in the Hall-Heroult process....

  12. 40 CFR 421.20 - Applicability: description of the primary aluminum smelting subcategory.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... primary aluminum smelting subcategory. 421.20 Section 421.20 Protection of Environment ENVIRONMENTAL... CATEGORY Primary Aluminum Smelting Subcategory § 421.20 Applicability: description of the primary aluminum... production of aluminum from alumina in the Hall-Heroult process....

  13. Cast B2-phase iron-aluminum alloys with improved fluidity

    DOEpatents

    Maziasz, Philip J.; Paris, Alan M.; Vought, Joseph D.

    2002-01-01

    Systems and methods are described for iron aluminum alloys. A composition includes iron, aluminum and manganese. A method includes providing an alloy including iron, aluminum and manganese; and processing the alloy. The systems and methods provide advantages because additions of manganese to iron aluminum alloys dramatically increase the fluidity of the alloys prior to solidification during casting.

  14. Preliminary Investigation of Zircaloy-4 as a Research Reactor Cladding Material

    SciTech Connect

    Brian K Castle

    2012-05-01

    As part of a scoping study for the ATR fuel conversion project, an initial comparison of the material properties of Zircaloy-4 and Aluminum-6061 (T6 and O-temper) is performed to provide a preliminary evaluation of Zircaloy-4 for possible inclusion as a candidate cladding material for ATR fuel elements. The current fuel design for the ATR uses Aluminum 6061 (T6 and O temper) as a cladding and structural material in the fuel element and to date, no fuel failures have been reported. Based on this successful and longstanding operating history, Zircaloy-4 properties will be evaluated against the material properties for aluminum-6061. The preliminary investigation will focus on a comparison of density, oxidation rates, water chemistry requirements, mechanical properties, thermal properties, and neutronic properties.

  15. Interactions of satellite-speed helium atoms with satellite surfaces. 2: Energy distributions of reflected helium atoms

    NASA Technical Reports Server (NTRS)

    Liu, S. M.; Knuth, E. L.

    1976-01-01

    Energy transfer in collisions of satellite-speed (7,000 m/sec) helium atoms with a cleaned 6061-T6 satellite-type aluminum surface was investigated using the molecular-beam technique. The amount of energy transferred was determined from the measured energy of the molecular-beam and the measured spatial and energy distributions of the reflected atoms. Spatial distributions of helium atoms scattered from a 6061-T6 aluminum surface were measured. The scattering pattern exhibits a prominent backscattering, probably due to the gross surface roughness and/or the relative lattice softness of the aluminum surface. Energy distributions of reflected helium atoms from the same surface were measured for six different incidence angles. For each incidence angle, distributions were measured at approximately sixty scattering positions. At a given scattering position, the energy spectra of the reflected helium atoms and the background gas were obtained using the retarding-field energy analyzer.

  16. A novel mechanism of aluminum-induced cell death involving vacuolar processing enzyme and vacuolar collapse in tobacco cell line BY-2.

    PubMed

    Kariya, Koki; Demiral, Tijen; Sasaki, Takayuki; Tsuchiya, Yoshiyuki; Turkan, Ismail; Sano, Toshio; Hasezawa, Seiichiro; Yamamoto, Yoko

    2013-11-01

    The role of vacuole in the cell death mechanism induced by aluminum (Al) was investigated in tobacco (Nicotiana tabacum L.) cell line BY-2. Cells at logarithmic phase of growth were treated without (control) or with Al (up to 150 μM) in a treatment medium containing CaCl2, sucrose and 2-(N-morpholino) ethanesulfonic acid (MES) buffer (pH 5.0). After 18 h treatment, both the integrity of the plasma membrane (estimated by Evans blue uptake) and growth capacity (estimated by post-Al treatment growth in nutrient medium) were decreased, while the activity of vacuolar processing enzyme (VPE) was increased, in the Al dose-dependent manner. The activity of the vacuole (estimated by neutral red uptake) was slightly increased at 50 μM then decreased with an increase in Al concentration. Direct observation of morphological changes of vacuole in a transgenic BY-2 expressing GFP-AtVam3p fusion protein localized on tonoplast indicated Al-induced collapse of vacuole. Time-course experiments indicated that both an increase in VPE activity and a loss of growth capacity were clearly observed at 6 h of the treatment time, prior to the loss of plasma membrane integrity. The presence of Ac-YVAD-CHO (an inhibitor effective to VPE) during Al treatment suppressed a loss of plasma membrane integrity. The expression of VPE genes (VPE-1a, VPE-1b) were significantly enhanced by Al treatment. Taken together, we conclude that an enhancement of VPE activity by Al is controlled at transcriptional level, and is a key factor leading to a loss of integrity of the plasma membrane and a loss of growth capacity. PMID:23891542

  17. Automated and aluminum welding technology

    NASA Astrophysics Data System (ADS)

    Jones, Clyde S.

    1994-10-01

    Automated welding technology and techniques for welding advanced aluminum alloys with potential for industrial and commercial applications have been developed by the National Aeronautics and Space Administration at the Marshall Space Flight Center. These technologies are being offered to private companies for commercial development, and include: Variable polarity plasma arc welding, a welding process that produces high-quality aluminum welds for fabrication of the space shuttle external tank and space station common module structures. This process uses reverse polarity pulses to produce welds virtually free of internal defects. Advanced weld sensor technology, comprised of machine vision-based weld seam tracking that uses both structured and global laser illumination for finding weld joints, even those difficult to discern by the human eye. Weld pool feedback is accomplished with a vision system to measure arc symmetry and molten weld pool geometry. A weld bead profiler trails the welding torch. It provides feedback to the process control system, which records quality control data.

  18. Aspects of aluminum toxicity

    SciTech Connect

    Hewitt, C.D.; Savory, J.; Wills, M.R. )

    1990-06-01

    Aluminum is the most abundant metal in the earth's crust. The widespread occurrence of aluminum, both in the environment and in foodstuffs, makes it virtually impossible for man to avoid exposure to this metal ion. Attention was first drawn to the potential role of aluminum as a toxic metal over 50 years ago, but was dismissed as a toxic agent as recently as 15 years ago. The accumulation of aluminum, in some patients with chronic renal failure, is associated with the development of toxic phenomena; dialysis encephalopathy, osteomalacic dialysis osteodystrophy, and an anemia. Aluminum accumulation also occurs in patients who are not on dialysis, predominantly infants and children with immature or impaired renal function. Aluminum has also been implicated as a toxic agent in the etiology of Alzheimer's disease, Guamiam amyotrophic lateral sclerosis, and parkinsonism-dementia. 119 references.

  19. Domestic aluminum resources: dilemmas of development

    SciTech Connect

    Staats, E.B.

    1980-07-17

    Concerns about supply disruptions and price gouging that could endanger aluminum production in the United States have spurred research in this country on processes to manufacture aluminum from ores other than bauxite. The United States has no large bauxite deposits but it has plentiful resources of other aluminum ores if the technology can be developed to use them economically. Sources of aluminium include alunite, anorthosite, dawsonite, and clay/acid. Miniplants for clay/nitric acid and clay/hydrochloric acid, gas-induced crystallization have been constructed.

  20. FLOWSHEET FOR ALUMINUM REMOVAL FROM SLUDGE BATCH 6

    SciTech Connect

    Pike, J; Jeffrey Gillam, J

    2008-12-17

    Samples of Tank 12 sludge slurry show a substantially larger fraction of aluminum than originally identified in sludge batch planning. The Liquid Waste Organization (LWO) plans to formulate Sludge Batch 6 (SB6) with about one half of the sludge slurry in Tank 12 and one half of the sludge slurry in Tank 4. LWO identified aluminum dissolution as a method to mitigate the effect of having about 50% more solids in High Level Waste (HLW) sludge than previously planned. Previous aluminum dissolution performed in a HLW tank in 1982 was performed at approximately 85 C for 5 days and dissolved nearly 80% of the aluminum in the sludge slurry. In 2008, LWO successfully dissolved 64% of the aluminum at approximately 60 C in 46 days with minimal tank modifications and using only slurry pumps as a heat source. This report establishes the technical basis and flowsheet for performing an aluminum removal process in Tank 51 for SB6 that incorporates the lessons learned from previous aluminum dissolution evolutions. For SB6, aluminum dissolution process temperature will be held at a minimum of 65 C for at least 24 days, but as long as practical or until as much as 80% of the aluminum is dissolved. As planned, an aluminum removal process can reduce the aluminum in SB6 from about 84,500 kg to as little as 17,900 kg with a corresponding reduction of total insoluble solids in the batch from 246,000 kg to 131,000 kg. The extent of the reduction may be limited by the time available to maintain Tank 51 at dissolution temperature. The range of dissolution in four weeks based on the known variability in dissolution kinetics can range from 44 to more than 80%. At 44% of the aluminum dissolved, the mass reduction is approximately 1/2 of the mass noted above, i.e., 33,300 kg of aluminum instead of 66,600 kg. Planning to reach 80% of the aluminum dissolved should allow a maximum of 81 days for dissolution and reduce the allowance if test data shows faster kinetics. 47,800 kg of the dissolved

  1. Low-aluminum-content iron-aluminum alloys

    SciTech Connect

    Sikka, V.K.; Baldwin, R.H.; Howell, C.R.

    1993-07-01

    The low room-temperature ductility Fe{sub 3}Al-based alloys is associated with their environmental embrittlement. Reducing the aluminum level from 29 to 16 at % has been found to be an effective method in essentially eliminating the environmental-embrittlement effect and increasing the room-temperature ductility value to over 25%. This paper will present data on alloy compositions, melting, casting and processing methods, and mechanical properties. Plans for future work on these alloys will also be described.

  2. Aqueous recovery of actinides from aluminum alloys

    SciTech Connect

    Gray, J.H.; Chostner, D.F.; Gray, L.W.

    1989-01-01

    Early in the 1980's, a joint Rocky Flats/Savannah River program was established to recover actinides from scraps and residues generated during Rocky Flats purification operations. The initial program involved pyrochemical treatment of Molten Salt Extraction (MSE) chloride salts and Electrorefining (ER) anode heel metal to form aluminum alloys suitable for aqueous processing at Savannah River. Recently Rocky Flats has expressed interest in expanding the aluminum alloy program to include treatment of chloride salt residues from a modified Molten Salt Extraction process and from the Electrorefining purification operations. Samples of the current aluminum alloy buttons were prepared at Rocky Flats and sent to Savannah River Laboratory for flowsheet development and characterization of the alloys. A summary of the scrub alloy-anode heel alloy program will be presented along with recent results from aqueous dissolution studies of the new aluminum alloys. 2 figs., 4 tabs.

  3. Production of sodium-22 from proton irradiated aluminum

    DOEpatents

    Taylor, Wayne A.; Heaton, Richard C.; Jamriska, David J.

    1996-01-01

    A process for selective separation of sodium-22 from a proton irradiated minum target including dissolving a proton irradiated aluminum target in hydrochloric acid to form a first solution including aluminum ions and sodium ions, separating a portion of the aluminum ions from the first solution by crystallization of an aluminum salt, contacting the remaining first solution with an anion exchange resin whereby ions selected from the group consisting of iron and copper are selectively absorbed by the anion exchange resin while aluminum ions and sodium ions remain in solution, contacting the solution with an cation exchange resin whereby aluminum ions and sodium ions are adsorbed by the cation exchange resin, and, contacting the cation exchange resin with an acid solution capable of selectively separating the adsorbed sodium ions from the cation exchange resin while aluminum ions remain adsorbed on the cation exchange resin is disclosed.

  4. Aluminum Target Dissolution in Support of the Pu-238 Program

    SciTech Connect

    McFarlane, Joanna; Benker, Dennis; DePaoli, David W; Felker, Leslie Kevin; Mattus, Catherine H

    2014-09-01

    Selection of an aluminum alloy for target cladding affects post-irradiation target dissolution and separations. Recent tests with aluminum alloy 6061 yielded greater than expected precipitation in the caustic dissolution step, forming up to 10 wt.% solids of aluminum hydroxides and aluminosilicates. We present a study to maximize dissolution of aluminum metal alloy, along with silicon, magnesium, and copper impurities, through control of temperature, the rate of reagent addition, and incubation time. Aluminum phase transformations have been identified as a function of time and temperature, using X-ray diffraction. Solutions have been analyzed using wet chemical methods and X-ray fluorescence. These data have been compared with published calculations of aluminum phase diagrams. Temperature logging during the transients has been investigated as a means to generate kinetic and mass transport data on the dissolution process. Approaches are given to enhance the dissolution of aluminum and aluminosilicate phases in caustic solution.

  5. MTBE OXIDATION BY BIFUNCTIONAL ALUMINUM

    EPA Science Inventory

    Bifunctional aluminum, prepared by sulfating zero-valent aluminum with sulfuric acid, has a dual functionality of simultaneously decomposing both reductively- and oxidatively-degradable contaminants. In this work, the use of bifunctional aluminum for the degradation of methyl te...

  6. Studies on aluminum neurotoxicity

    SciTech Connect

    Cho, S.

    1988-01-01

    This work reports the inhibitory effects of aluminum on glucose-6-phosphate dehydrogenase (G6PD) from yeast and brains. The aluminum contents and several enzyme activities in aluminum-fed rat brain homogenates were compared with those in age-matched control groups. The concentration of aluminum in the homogenates of the aluminum-fed groups were twice of that of the controls. Acetylcholinesterase activities were the same as in both groups but hexokinase and G6PD activities in the aluminum-fed group were about 73% and 70% of the control, respectively. Further studies on the inhibitory effects of aluminum on G6PD were performed with the enzymes purified from human and pig brains. Two forms of G6PD isozymes were purified from human and pig brain by ammonium sulfate fractionation, hydroxylapatite chromatography, affinity chromatography with NADP-agarose and Blue-Sepharose CL-6B, and gel filtration with Sephadex S-300. The two forms of isozymes (isozyme I and II), purified to be homogeneous, had a molecular weight of 220,000, and composed of 4 subunits of molecular weight of 57,000. HPLC peptide maps of tryptic digests and amino acid analyses of the isozymes showed extensive homologies between the isozymes. Interestingly, only the isozyme II in human and pig brain were active with 6-phosphogluconate as a substrate. No such an activity was found in isozyme I. Aluminum inactivated G6PD activity of the human and pig brain isozyme I and isozyme II without affecting the 6-phosphogluconate dehydrogenase activity of the isozyme II. Circular dichroism studies showed that the binding of aluminum to G6PD induced a decrease in {alpha}-helix and {beta}-sheet and a increase in random coil. Therefore it is suggested that inactivation of G6PD by aluminum is due to the conformational change induced by aluminum binding.

  7. Aluminum laser welding optimization

    NASA Astrophysics Data System (ADS)

    Chmelíčková, Hana; Halenka, Viktor; Lapšanská, Hana; Havelková, Martina

    2007-04-01

    Pulsed Nd:YAG laser with maximal power 150 W is used in our laboratory to cut, drill and weld metal and non-metal thin materials to thickness 2 mm. Welding is realized by fixed processing head or movable fiber one with beam diameter 0,6 mm in focus plane. Welding of stainless and low-carbon steel was tested before and results are publicized and used in practice. Now the goal of our experiment was optimization of process parameters for aluminum that has other physical properties than steels, lower density, higher heat conductivity and surface reflexivity. Pure alumina specimen 0,8 mm and Al-Mg-Si alloy 0,5 mm prepared for butt welds. Problem with surface layer of Al IIO 3 was overcome by sanding and chemical cleaning with grinding paste. Critical parameters for good weld shape are specimen position from beam focus plane, pulse length and energy, pulse frequency and the motion velocity that determines percentage of pulse overlap. Argon as protective gas was used with speed 6 liters per second. Thermal distribution in material can be modeled by numerical simulation. Software tool SYSWELD makes possible to fit laser as surface heat source, define weld geometry, and make meshing of specimen to finite elements and compute heat conduction during process. Color isotherms, vectors, mechanical deformations and others results can be study in post-processing.

  8. Superhydrophobic coating deposited directly on aluminum

    NASA Astrophysics Data System (ADS)

    Escobar, Ana M.; Llorca-Isern, Nuria

    2014-06-01

    This study develops an alternative method for enhancing superhydrophobicity on aluminum surfaces with an amphiphilic reagent such as the dodecanoic acid. The goal is to induce superhydrophobicity directly through a simple process on pure (99.9 wt%) commercial aluminum. The initial surface activation leading to the formation of the superhydrophobic coating is studied using confocal microscopy. Superhydrophobic behavior is analyzed by contact angle measurements, scanning electron microscopy (SEM) and atomic force microscopy (AFM). The highest contact angle (approaching 153°) was obtained after forming hierarchical structures with a particular roughness obtained by grinding and polishing microgrooves on the aluminum surface together with the simultaneous action of HCl and dodecanoic acid. The results also showed that after immersion in the ethanol-acidic-fatty acid solutions, they reacted chemically through the action of the fatty acid, on the aluminum surface. The mechanism is analyzed by TOF-SIMS and XPS in order to determine the molecules involved in the reaction. The TOF-SIMS analysis revealed that the metal and its oxides seem to be necessary, and that free-aluminum is anchored to the fatty acid molecules and to the alumina molecules present in the medium. Consequently, both metallic aluminum and aluminum oxides are necessary in order to form the compound responsible for superhydrophobicity.

  9. Pulmonary fibrosis and occupational exposure to aluminum.

    PubMed

    al-Masalkhi, A; Walton, S P

    1994-02-01

    Many reports of respiratory disease attributable to aluminum exposure have appeared in the European medical literature during the last 50 years. Great Britain and Germany are two major industrialized nations that acknowledge a causal relationship between occupational exposure to aluminum and respiratory impairment. For factory workers in these countries, pulmonary disease attributed to respirable aluminum particulates is compensated as a workplace disability. In North America, however, there is a lack of consensus regarding the pathogenicity of aluminum fumes and dust to the worker. This view may be based on a difference in the types of industrial usage, the updated methods of aluminum processing in this country, or the benefits of a modern workplace. It has also been proposed that the development of aluminum-induced pulmonary disease may depend on a particular host factor that has not yet been identified. We describe a patient whom we believe developed severe respiratory compromise and irreversible pulmonary fibrosis from a lifetime of industrial aluminum exposure. PMID:8163901

  10. FABRICATION OF URANIUM-ALUMINUM ALLOYS

    DOEpatents

    Saller, H.A.

    1959-12-15

    A process is presented for producing a workable article of a uranium- aluminum alloy in which the uranium content is between 14 and 70% by weight; aluminum powder and powdered UAl/sub 2/, UAl/sub 3/, UAl/sub 5/, or UBe/sub 9/ are mixed, and the mixture is compressed into the shape desired and sintered at between 450 and 600 deg C.

  11. Advanced powder metallurgy aluminum alloys and composites

    NASA Technical Reports Server (NTRS)

    Lisagor, W. B.; Stein, B. A.

    1982-01-01

    The differences between powder and ingot metallurgy processing of aluminum alloys are outlined. The potential payoff in the use of advanced powder metallurgy (PM) aluminum alloys in future transport aircraft is indicated. The national program to bring this technology to commercial fruition and the NASA Langley Research Center role in this program are briefly outlined. Some initial results of research in 2000-series PM alloys and composites that highlight the property improvements possible are given.

  12. Effect of Na2WO4 on Growth Process and Corrosion Resistance of Micro-arc Oxidation Coatings on 2A12 Aluminum Alloys in CH3COONa Electrolyte

    NASA Astrophysics Data System (ADS)

    Lin, Zhaoqing; Yu, Huijun; He, Siyu; Wang, Diangang; Chen, Chuanzhong

    2016-01-01

    Ceramic coatings were deposited on 2A12 aluminum alloys using micro-arc oxidation (MAO) technology in CH3COONa-Na2WO4 electrolyte. The MAO process was studied by recording the current-time curve. The influences of Na2WO4 concentrations on the coatings in CH3COONa electrolyte were investigated. The results show that the Na2WO4 concentrations affect the MAO process and performances of the coatings directly. Na2WO4 in excess is harmful for the formation of Al2O3 in this electrolyte. The corrosion resistance was enhanced with the decrease of Na2WO4 concentration.

  13. Spark plasma sintering of aluminum matrix composites

    NASA Astrophysics Data System (ADS)

    Yadav, Vineet

    2011-12-01

    Aluminum matrix composites make a distinct category of advanced engineering materials having superior properties over conventional aluminum alloys. Aluminum matrix composites exhibit high hardness, yield strength, and excellent wear and corrosion resistance. Due to these attractive properties, aluminum matrix composites materials have many structural applications in the automotive and the aerospace industries. In this thesis, efforts are made to process high strength aluminum matrix composites which can be useful in the applications of light weight and strong materials. Spark Plasma Sintering (SPS) is a relatively novel process where powder mixture is consolidated under the simultaneous influence of uniaxial pressure and pulsed direct current. In this work, SPS was used to process aluminum matrix composites having three different reinforcements: multi-wall carbon nanotubes (MWCNTs), silicon carbide (SiC), and iron-based metallic glass (MG). In Al-CNT composites, significant improvement in micro-hardness, nano-hardness, and compressive yield strength was observed. The Al-CNT composites further exhibited improved wear resistance and lower friction coefficient due to strengthening and self-lubricating effects of CNTs. In Al-SiC and Al-MG composites, microstructure, densification, and tribological behaviors were also studied. Reinforcing MG and SiC also resulted in increase in micro-hardness and wear resistance.

  14. Aluminum space frame technology

    SciTech Connect

    Birch, S.

    1994-01-01

    This article examines the increased application of aluminum to the construction of automobile frames. The topics of the article include a joint venture between Audi and Alcoa, forms in which aluminum is used, new alloys and construction methods, meeting rigidity and safety levels, manufacturing techniques, the use of extrusions, die casting, joining techniques, and pollution control during manufacturing.

  15. Anodizing Aluminum with Frills.

    ERIC Educational Resources Information Center

    Doeltz, Anne E.; And Others

    1983-01-01

    "Anodizing Aluminum" (previously reported in this journal) describes a vivid/relevant laboratory experience for general chemistry students explaining the anodizing of aluminum in sulfuric acid and constrasting it to electroplating. Additions to this procedure and the experiment in which they are used are discussed. Reactions involved are also…

  16. Cast aluminum denture base.

    PubMed

    Barco, M T; Dembert, M L

    1987-08-01

    The laboratory procedures for a cast aluminum base denture have been presented. If an induction casting machine is not available, the "two-oven technique" works well, provided the casting arm is kept spinning manually for 4 minutes after casting. If laboratory procedures are executed precisely and with care, the aluminum base denture can be cast with good results. PMID:3305884

  17. Is the Aluminum Hypothesis Dead?

    PubMed Central

    2014-01-01

    The Aluminum Hypothesis, the idea that aluminum exposure is involved in the etiology of Alzheimer disease, dates back to a 1965 demonstration that aluminum causes neurofibrillary tangles in the brains of rabbits. Initially the focus of intensive research, the Aluminum Hypothesis has gradually been abandoned by most researchers. Yet, despite this current indifference, the Aluminum Hypothesis continues to attract the attention of a small group of scientists and aluminum continues to be viewed with concern by some of the public. This review article discusses reasons that mainstream science has largely abandoned the Aluminum Hypothesis and explores a possible reason for some in the general public continuing to view aluminum with mistrust. PMID:24806729

  18. Aluminum structural applications

    SciTech Connect

    Lucas, G.

    1996-05-01

    Extensive research by aluminum producers and automakers in the 1980s resulted in the development of technologies that enable building of aluminum cars that meet and exceed all the expectations of today`s drivers and passengers, yet weigh several hundred pounds less than their steel counterparts. The Acura NSX sports car, the Audi A8, and the Jaguar XJ220 have all been introduced. Ford has built 40 aluminum-intensive automobiles based on the Taurus/Sable for test purposes, and General Motors recently announced an aluminum-structured electric vehicle. The design flexibility that aluminum allows is shown by these examples. Each uses a somewhat different technology that is particularly suited to the vehicle and its market.

  19. The Surface Tension of Pure Aluminum and Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Bainbridge, Ian Frank; Taylor, John Andrew

    2013-08-01

    The surface tension of high purity and commercial purity aluminum in vacuo was determined using the sessile drop method and the results were found to compare favorably with published data. The effects of holding atmosphere, substrate, and "surface fracture" of the sessile drop on the measured surface tension values were investigated together with the effects of different solute elements commonly present in commercial aluminum alloys. The results obtained suggest that the nature of the surface oxide film formed on the droplets (affected by alloy composition and atmosphere) and the rupture of this film are the dominant factors influencing the surface tension values obtained. Changes in surface tension values of up to 60 pct were observed. The possible effect of this variable surface tension on practical casting processes, such as direct chill casting, is suggested.

  20. Explosive Welding of Aluminum to Aluminum: Analysis, Computations and Experiments

    NASA Astrophysics Data System (ADS)

    Grignon, F.; Benson, D.; Vecchio, K. S.; Meyers, M. A.

    2004-07-01

    6061 T0 aluminum alloy was joined to 6061 T0 aluminum alloy by explosive welding. This is a process in which the controlled energy of a detonating explosive is used to create a metallic bond between two similar or dissimilar materials. The welding conditions were tailored to produce both wavy and straight interfaces. A three-pronged study was used to establish the conditions for straight weld formation: (a) analytical calculation of the domain of weldability; (b) characterization of the explosive welding experiments carried out under different conditions, and (c) 2D finite differences simulation of these tests using the explicit Eulerian hydrocode Raven with a Johnson-Cook constitutive equation for the Al alloy. The numerical simulation and the analytical calculations confirm the experimental results and explain the difficulties met for obtaining a continuous straight interface along the entire weld.

  1. Underwater vapor phase burning of aluminum particles and on aluminum ignition during steam explosions

    SciTech Connect

    Epstein, M. )

    1991-09-01

    Recently reported experimental studies on aluminum-water steam explosions indicate that there may be a critical metal temperature at which the process changes over from a physical explosion to one which is very violent and involves the rapid liberation of chemical energy. In this report we examine the hypothesis that vapor-phase burning of aluminum is a necessary condition for the occurrence of such ignition-type'' steam explosions. An available two-phase stagnation flow film-boiling model is used to calculate the steam flux to the vaporizing aluminum surface. Combining this calculation with the notion that there is an upper limit to the magnitude of the metal vaporization rate at which the reaction regime must change from vapor phase to surface burning, leads to prediction of the critical metal surface temperature below which vapor phase burning is impossible. The critical temperature is predicted for both the aluminum-water pre-mixture configuration in which coarse drops of aluminum are falling freely through water and for the finely-fragmented aluminum drops in the wake of the pressure shock that triggers'' the explosion. Vapor phase burning is predicted to be possible during the pre-mixture phase but not very likely during the trigger phase of a steam explosion. The implications of these findings in terms of the validity of the hypothesis that ignition may begin with the vapor phase burning of aluminum is discussed. Recently postulated, alternative mechanisms of underwater aluminum ignition are also discussed.

  2. Underwater vapor phase burning of aluminum particles and on aluminum ignition during steam explosions

    SciTech Connect

    Epstein, M.

    1991-09-01

    Recently reported experimental studies on aluminum-water steam explosions indicate that there may be a critical metal temperature at which the process changes over from a physical explosion to one which is very violent and involves the rapid liberation of chemical energy. In this report we examine the hypothesis that vapor-phase burning of aluminum is a necessary condition for the occurrence of such ``ignition-type`` steam explosions. An available two-phase stagnation flow film-boiling model is used to calculate the steam flux to the vaporizing aluminum surface. Combining this calculation with the notion that there is an upper limit to the magnitude of the metal vaporization rate at which the reaction regime must change from vapor phase to surface burning, leads to prediction of the critical metal surface temperature below which vapor phase burning is impossible. The critical temperature is predicted for both the aluminum-water pre-mixture configuration in which coarse drops of aluminum are falling freely through water and for the finely-fragmented aluminum drops in the wake of the pressure shock that ``triggers`` the explosion. Vapor phase burning is predicted to be possible during the pre-mixture phase but not very likely during the trigger phase of a steam explosion. The implications of these findings in terms of the validity of the hypothesis that ignition may begin with the vapor phase burning of aluminum is discussed. Recently postulated, alternative mechanisms of underwater aluminum ignition are also discussed.

  3. Aluminum recycling in the automotive industry. (Latest citations from the Aluminum Industry Abstracts database). Published Search

    SciTech Connect

    Not Available

    1994-06-01

    The bibliography contains citations concerning design and development of processes to recycle aluminum from automobiles. Scrap separation, shredding, and processing are covered including new equipment. Aluminum market information is included with respect to material selection for automobiles and new products developed from recycled material. References also discuss changes in automobile design to increase recycling oppertunities. (Contains a minimum of 107 citations and includes a subject term index and title list.)

  4. Dry lubricant films for aluminum forming.

    SciTech Connect

    Wei, J.; Erdemir, A.; Fenske, G. R.

    1999-03-30

    During metal forming process, lubricants are crucial to prevent direct contact, adhesion, transfer and scuffing of workpiece materials and tools. Boric acid films can be firmly adhered to the clean aluminum surfaces by spraying their methanol solutions and provide extremely low friction coefficient (about 0.04). The cohesion strengths of the bonded films vary with the types of aluminum alloys (6061, 6111 and 5754). The sheet metal forming tests indicate that boric acid films and the combined films of boric acid and mineral oil can create larger strains than the commercial liquid and solid lubricants, showing that they possess excellent lubricities for aluminum forming. SEM analyses indicate that boric acid dry films separate the workpiece and die materials, and prevent their direct contact and preserve their surface qualities. Since boric acid is non-toxic and easily removed by water, it can be expected that boric acid films are environmentally friendly, cost effective and very efficient lubricants for sheet aluminum cold forming.

  5. Macrodeformation Twins in Single-Crystal Aluminum.

    PubMed

    Zhao, F; Wang, L; Fan, D; Bie, B X; Zhou, X M; Suo, T; Li, Y L; Chen, M W; Liu, C L; Qi, M L; Zhu, M H; Luo, S N

    2016-02-19

    Deformation twinning in pure aluminum has been considered to be a unique property of nanostructured aluminum. A lingering mystery is whether deformation twinning occurs in coarse-grained or single-crystal aluminum at scales beyond nanotwins. Here, we present the first experimental demonstration of macrodeformation twins in single-crystal aluminum formed under an ultrahigh strain rate (∼10^{6}  s^{-1}) and large shear strain (200%) via dynamic equal channel angular pressing. Large-scale molecular dynamics simulations suggest that the frustration of subsonic dislocation motion leads to transonic deformation twinning. Deformation twinning is rooted in the rate dependences of dislocation motion and twinning, which are coupled, complementary processes during severe plastic deformation under ultrahigh strain rates. PMID:26943543

  6. The Cleaning of Aluminum Frame Assembly Units

    SciTech Connect

    Shen, T H

    2001-05-16

    The Brulin immersion and the precision cleaning experiments have shown that neither the Brulin solution nor the precision cleaning in AstroPak causes the smut formation on aluminum surfaces. The acid-bath cleaning in GTC is the primary source of the smut formation. The current GTC acid formulation etches the aluminum matrix quite aggressively, but does not appear to appreciably attack the Si particles. Therefore, this acid-bath cleaning will leave the cast-aluminum part surfaces with many protruded Si particles, which could potentially cause smut problems in the cleaning process down-stream. To ensure the removal of all loose Si particles from the cast-aluminum parts, it is necessary to physically hand-wipe and vigorously wash the acid-bath cleaned surfaces. Furthermore, the casting porosity in alloy A356 could be another source in causing high swipe readings in the FAU parts.

  7. Hydrolysis of aluminum dross material to achieve zero hazardous waste.

    PubMed

    David, E; Kopac, J

    2012-03-30

    A simple method with high efficiency for generating high pure hydrogen by hydrolysis in tap water of highly activated aluminum dross is established. Aluminum dross is activated by mechanically milling to particles of about 45 μm. This leads to removal of surface layer of the aluminum particles and creation of a fresh chemically active metal surface. In contact with water the hydrolysis reaction takes place and hydrogen is released. In this process a Zero Waste concept is achieved because the other product of reaction is aluminum oxide hydroxide (AlOOH), which is nature-friendly and can be used to make high quality refractory or calcium aluminate cement. For comparison we also used pure aluminum powder and alkaline tap water solution (NaOH, KOH) at a ratio similar to that of aluminum dross content. The rates of hydrogen generated in hydrolysis reaction of pure aluminum and aluminum dross have been found to be similar. As a result of the experimental setup, a hydrogen generator was designed and assembled. Hydrogen volume generated by hydrolysis reaction was measured. The experimental results obtained reveal that aluminum dross could be economically recycled by hydrolysis process with achieving zero hazardous aluminum dross waste and hydrogen generation. PMID:22326245

  8. Electrodeposition of magnesium and magnesium/aluminum alloys

    DOEpatents

    Mayer, A.

    1988-01-21

    Electrolytes and plating solutions for use in processes for electroplating and electroforming pure magnesium and alloys of aluminum and magnesium and also electrodeposition processes. An electrolyte of this invention is comprised of an alkali metal fluoride or a quaternary ammonium halide, dimethyl magnesium and/or diethyl magnesium, and triethyl aluminum and/or triisobutyl aluminum. An electrolyte may be dissolved in an aromatic hydrocarbon solvent to form a plating solution. The proportions of the component compounds in the electrolyte are varied to produce essentially pure magnesium or magnesium/aluminum alloys having varying selected compositions.

  9. Electrodeposition of magnesium and magnesium/aluminum alloys

    DOEpatents

    Mayer, Anton

    1988-01-01

    Electrolytes and plating solutions for use in processes for electroplating and electroforming pure magnesium and alloys of aluminum and magnesium and also electrodeposition processes. An electrolyte of this invention is comprised of an alkali metal fluoride or a quaternary ammonium halide, dimethyl magnesium and/or diethyl magnesium, and triethyl aluminum and/or triisobutyl aluminum. An electrolyte may be dissolved in an aromatic hydrocarbon solvent to form a plating solution. The proportions of the component compounds in the electrolyte are varied to produce essentially pure magnesium or magnesium/aluminum alloys having varying selected compositions.

  10. Aluminum nitrate recrystallization and recovery from liquid extraction raffinates

    SciTech Connect

    Griffith, W.L.; Compere, A.L.; Googin, J.M.; Huxtable, W.P.

    1991-09-01

    The solid sludges resulting form biodenitrification of discarded aluminum nitrate are the largest Y-12 Plant process solid waste. Aluminum nitrate feedstocks also represent a major plant materials cost. The chemical constraints on aluminum nitrate recycle were investigated to determine the feasibility of increasing recycle while maintaining acceptable aluminum nitrate purity. Reported phase behavior of analogous systems, together with bench research, indicated that it would be possible to raise the recycle rate from 35% to between 70 and 90% by successive concentration and recrystallization of the mother liquor. A full scale pilot test successfully confirmed the ability to obtain 70% recycle in existing process equipment.

  11. Energy Assessment Helps Kaiser Aluminum Save Energy and Improve Productivity

    SciTech Connect

    2008-07-01

    The Kaiser Aluminum plant in Sherman, Texas, adjusted controls and made repairs to a furnace for a simple payback of 1 month. Kaiser adopted DOE's Process Heating Assessment and Survey Tool (PHAST) software as the corporate diagnostic tool and has used it to evaluate process heating systems at five other aluminum plants.

  12. Low Temperature Aluminum Dissolution Of Sludge Waste

    SciTech Connect

    Keefer, M.T.; Hamm, B.A.; Pike, J.A.

    2008-07-01

    High Level Waste (HLW) at the Savannah River Site (SRS) is currently stored in aging underground storage tanks. This waste is a complex mixture of insoluble solids, referred to as sludge, and soluble salts. Continued long-term storage of these radioactive wastes poses an environmental risk. The sludge is currently being stabilized in the Defense Waste Processing Facility (DWPF) through a vitrification process immobilizing the waste in a borosilicate glass matrix for long-term storage in a federal repository. Without additional treatment, the existing volume of sludge would produce nearly 8000 canisters of vitrified waste. Aluminum compounds, along with other non-radioactive components, represent a significant portion of the sludge mass currently planned for vitrification processing in DWPF. Removing the aluminum from the waste stream reduces the volume of sludge requiring vitrification and improves production rates. Treating the sludge with a concentrated sodium hydroxide (caustic) solution at elevated temperatures (>90 deg. C) to remove aluminum is part of an overall sludge mass reduction effort to reduce the number of vitrified canisters, shorten the life cycle for the HLW system, and reduce the risk associated with the long term storage of radioactive wastes at SRS. A projected reduction of nearly 900 canisters will be achieved by performing aluminum dissolution on six targeted sludge batches; however, a project to develop and install equipment will not be ready for operation until 2013. The associated upgrades necessary to implement a high temperature process in existing facilities are costly and present many technical challenges. Efforts to better understand the characteristics of the sludge mass and dissolution kinetics are warranted to overcome these challenges. Opportunities to further reduce the amount of vitrified waste and increase production rates should also be pursued. Sludge staged in Tank 51 as the next sludge batch for feed to DWPF consisted

  13. Drawn arc stud welding: Crossing over from steel to aluminum

    SciTech Connect

    Ramasamy, S.

    2000-01-01

    In their quest to reduce vehicle weights, car manufacturers are exploring further use of aluminum, including more aluminum components in body construction. To acquire a better understanding of aluminum stud welding, auto manufacturers worldwide have formed a task force to conduct research on aluminum joining methods. Currently, Emhart Fastening Teknologies is working with this group in development programs such as Earthing studs, WELDFAST and Self-Pierce Rivet (SPR). The global automotive industry is clearly committed to the increased use of aluminum in cars and trucks. This presents enormous challenges and responsibilities for assembly systems suppliers, particularly those specializing in welding processes. Continuing strides in the technological sophistication of DASW is bringing this process to the forefront in advancing the use of aluminum in vehicles throughout the world.

  14. Clinical biochemistry of aluminum

    SciTech Connect

    King, S.W.; Savory, J.; Wills, M.R.

    1981-05-01

    Aluminum toxicity has been implicated in the pathogenesis of a number of clinical disorders in patients with chronic renal failure on long-term intermittent hemodialysis treatment. The predominant disorders have been those involving either bone (osteomalacic dialysis osteodystrophy) or brain (dialysis encephalopathy). In nonuremic patients, an increased brain aluminum concentration has been implicated as a neurotoxic agent in the pathogenesis of Alzheimer's disease and was associated with experimental neurofibrillary degeneration in animals. The brain aluminum concentrations of patients dying with the syndrome of dialysis encephalopathy (dialysis dementia) are significantly higher than in dialyzed patients without the syndrome and in nondialyzed patients. Two potential sources for the increased tissue content of aluminum in patients on hemodialysis have been proposed: (1) intestinal absorption from aluminum containing phosphate-binding gels, and (2) transfer across the dialysis membrane from aluminum in the water used to prepare the dialysate. These findings, coupled with our everyday exposure to the ubiquitous occurrence of aluminum in nature, have created concerns over the potential toxicity of this metal.

  15. Electrically Conductive Anodized Aluminum Surfaces

    NASA Technical Reports Server (NTRS)

    Nguyen, Trung Hung

    2006-01-01

    Anodized aluminum components can be treated to make them sufficiently electrically conductive to suppress discharges of static electricity. The treatment was conceived as a means of preventing static electric discharges on exterior satin-anodized aluminum (SAA) surfaces of spacecraft without adversely affecting the thermal-control/optical properties of the SAA and without need to apply electrically conductive paints, which eventually peel off in the harsh environment of outer space. The treatment can also be used to impart electrical conductivity to anodized housings of computers, medical electronic instruments, telephoneexchange equipment, and other terrestrial electronic equipment vulnerable to electrostatic discharge. The electrical resistivity of a typical anodized aluminum surface layer lies between 10(exp 11) and 10(exp 13) Omega-cm. To suppress electrostatic discharge, it is necessary to reduce the electrical resistivity significantly - preferably to < or = 10(exp 9) Omega-cm. The present treatment does this. The treatment is a direct electrodeposition process in which the outer anodized surface becomes covered and the pores in the surface filled with a transparent, electrically conductive metal oxide nanocomposite. Filling the pores with the nanocomposite reduces the transverse electrical resistivity and, in the original intended outer-space application, the exterior covering portion of the nanocomposite would afford the requisite electrical contact with the outer-space plasma. The electrical resistivity of the nanocomposite can be tailored to a value between 10(exp 7) and 10(exp 12) Omega-cm. Unlike electrically conductive paint, the nanocomposite becomes an integral part of the anodized aluminum substrate, without need for adhesive bonding material and without risk of subsequent peeling. The electrodeposition process is compatible with commercial anodizing production lines. At present, the electronics industry uses expensive, exotic

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

    PubMed

    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. PMID:27090705

  17. Electron Positron Proton Spectrometer for use at Laboratory for Laser Energetics

    SciTech Connect

    Ayers, S L

    2010-04-07

    The Electron Positron Proton Spectrometer (EPPS) is mounted in a TIM (Ten-Inch Manipulator) system on the Omega-60 or Omega-EP laser facilities at the University of Rochester, Laboratory for Laser Energetics (LLE), when in use, see Fig. 1. The Spectrometer assembly, shown in Fig. 2, is constructed of a steel box containing magnets, surrounded by Lead 6% Antimony shielding with SS threaded insert, sitting on an Aluminum 6061-T6 plate.

  18. A chronoamperometric study of anodic processes at various types of carbon anode in Al[sub 2]O[sub 3]-Na[sub 3]AlF[sub 6] melts used in the electrolytic production of aluminum

    SciTech Connect

    Djokic, S.S.; Conway, B.E. . Dept. of Chemistry); Belliveau, T.F. . Arvida Research and Development Centre)

    1994-08-01

    The performance of four graphites and glassy carbon as sensor anode materials in chronoamperometry experiments for possible determination of Al[sub 2]O[sub 3] were comparatively examined in alumina-cryolite melts at 1,010 C. With graphite anode materials, the anode process(es) is (are) not fully diffusion controlled nor are the results adequately reproducible. Only at glassy carbon is (are) the anodic process(es) diffusion controlled. Consequently, at glassy-carbon sensor anodes, the dependence of the response current function on Al[sub 2]O[sub 3] concentration is found to be approximately linear. The presence or absence of Al metal, dissolved in the melt, as arises in the practical technology of electrolytic aluminum smelting, has a significant effect on the results due mainly to background current contributions from oxidation of dissolved Al.

  19. CHARACTERIZATION AND ALUMINUM DISSOLUTION DEMONSTRATION WITH A 3 LITER TANK 51H SAMPLE

    SciTech Connect

    Hay, M; John Pareizs, J; Cj Bannochie, C; Michael Stone, M; Damon Click, D; Daniel McCabe, D

    2008-02-29

    A 3-liter sludge slurry sample was sent to SRNL for demonstration of a low temperature aluminum dissolution process. The sludge was characterized before and after the aluminum dissolution. Post aluminum dissolution sludge settling and the stability of the decanted supernate were also observed. The characterization of the as-received 3-liter sample of Tank 51H sludge slurry shows a typical high aluminum HM sludge. The XRD analysis of the dried solids indicates Boehmite is the predominant crystalline form of aluminum in the sludge solids. However, amorphous phases of aluminum present in the sludge would not be identified using this analytical technique. The low temperature (55 C) aluminum dissolution process was effective at dissolving aluminum from the sludge. Over the three week test, {approx}42% of the aluminum was dissolved out of the sludge solids. The process appears to be selective for aluminum with no other metals dissolving to any appreciable extent. At the termination of the three week test, the aluminum concentration in the supernate had not leveled off indicating more aluminum could be dissolved from the sludge with longer contact times or higher temperatures. The slow aluminum dissolution rate in the test may indicate the dissolution of the Boehmite form of aluminum however; insufficient kinetic data exists to confirm this hypothesis. The aluminum dissolution process appears to have minimal impact on the settling rate of the post aluminum dissolution sludge. However, limited settling data were generated during the test to quantify the effects. The sludge settling was complete after approximately twelve days. The supernate decanted from the settled sludge after aluminum dissolution appears stable and did not precipitate aluminum over the course of several months. A mixture of the decanted supernate with Tank 11 simulated supernate was also stable with respect to precipitation.

  20. Lightweight Aluminum/Nano composites for Automotive Drive Train Applications

    SciTech Connect

    Chelluri, Bhanumathi; Knoth, Edward A.; Schumaker, Edward J.

    2012-12-14

    During Phase I, we successfully processed air atomized aluminum powders via Dynamic Magnetic Compaction (DMC) pressing and subsequent sintering to produce parts with properties similar to wrought aluminum. We have also showed for the first time that aluminum powders can be processed without lubes via press and sintering to 100 % density. This will preclude a delube cycle in sintering and promote environmentally friendly P/M processing. Processing aluminum powders via press and sintering with minimum shrinkage will enable net shape fabrication. Aluminum powders processed via a conventional powder metallurgy process produce too large a shrinkage. Because of this, sinter parts have to be machined into specific net shape. This results in increased scrap and cost. Fully sintered aluminum alloy under this Phase I project has shown good particle-to-particle bonding and mechanical properties. We have also shown the feasibility of preparing nano composite powders and processing via pressing and sintering. This was accomplished by dispersing nano silicon carbide (SiC) powders into aluminum matrix comprising micron-sized powders (<100 microns) using a proprietary process. These composite powders of Al with nano SiC were processed using DMC press and sinter process to sinter density of 85-90%. The process optimization along with sintering needs to be carried out to produce full density composites.