Materials data handbook: Aluminum alloy 6061

NASA Technical Reports Server (NTRS)

Muraca, R. F.; Whittick, J. S.

1972-01-01

A summary of the materials property information for aluminum alloy 6061 is presented. The scope of the information includes physical and mechanical properties of the alloy at cryogenic, ambient, and elevated temperatures. Information on material procurement, metallurgy, corrosion, environmental effects, fabrication, and joining techniques is developed.

Corrosion Properties of Dissimilar Friction Stir Welded 6061 Aluminum and HT590 Steel

NASA Astrophysics Data System (ADS)

Seo, Bosung; Song, Kuk Hyun; Park, Kwangsuk

2018-05-01

Corrosion properties of dissimilar friction stir welded 6061 aluminum and HT590 steel were investigated to understand effects of galvanic corrosion. As cathode when coupled, HT590 was cathodically protected. However, the passivation of AA6061 made the aluminum alloy cathode temporarily, which leaded to corrosion of HT590. From the EIS analysis showing Warburg diffusion plot in Nyquist plots, it can be inferred that the stable passivation layer was formed on AA6061. However, the weld as well as HT590 did not show Warburg diffusion plot in Nyquist plots, suggesting that there was no barrier for corrosion or even if it exists, the barrier had no function for preventing and/or retarding charge transport through the passivation layer. The open circuit potential measurements showed that the potential of the weld was similar to that of HT590, which lied in the pitting region for AA6061, making the aluminum alloy part of the weld keep corrosion state. That resulted in the cracked oxide film on AA6061 of the weld, which could not play a role of corrosion barrier.

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.

Ultrasonic semi-solid coating soldering 6061 aluminum alloys with Sn-Pb-Zn alloys.

PubMed

Yu, Xin-ye; Xing, Wen-qing; Ding, Min

2016-07-01

In this paper, 6061 aluminum alloys were soldered without a flux by the ultrasonic semi-solid coating soldering at a low temperature. According to the analyses, it could be obtained that the following results. The effect of ultrasound on the coating which promoted processes of metallurgical reaction between the components of the solder and 6061 aluminum alloys due to the thermal effect. Al2Zn3 was obtained near the interface. When the solder was in semi-solid state, the connection was completed. Ultimately, the interlayer mainly composed of three kinds of microstructure zones: α-Pb solid solution phases, β-Sn phases and Sn-Pb eutectic phases. The strength of the joints was improved significantly with the minimum shear strength approaching 101MPa. Copyright © 2016. Published by Elsevier B.V.

Direct-soldering 6061 aluminum alloys with ultrasonic coating.

PubMed

Ding, Min; Zhang, Pei-lei; Zhang, Zhen-yu; Yao, Shun

2010-02-01

In this study, the authors applied furnace soldering with ultrasonic coating method to solder 6061 aluminum alloy and investigated the effects of both coating time and soldering temperature on its properties. The following results were obtained: firstly, the solder region mainly composed of four kinds of microstructure zones: rich Sn zone, rich-Pb zone, Sn-Pb eutectic phase and rich Al zone. Meanwhile, the microanalysis identified a continuous reaction product at the alumina-solder interface as a rich-Pb zone. Therefore, the joint strength changed with soldering time and soldering temperature. Secondly, the tensile data had significantly greater variability, with values ranging from 13.99MPa to 24.74MPa. The highest value was obtained for the samples coated with Sn-Pb-Zn alloy for 45s. Fractures occurred along the solder-alumina interface for the 6061 aluminum alloy with its surface including hybrid tough fracture of dimple and tear ridge. The interface could initially strip at the rich Bi zone with the effect of shear stress.

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.

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.

Corrosion of Graphite Aluminum Metal Matrix Composites

DTIC Science & Technology

1991-02-01

cathodic protection of G/AI MMCs resulted in overprotection 13. Overprotection resulted from a local increase in pH near cathodic sites during...34Cathodic Overprotection of SiC/6061-T6 and G/6061- T6 Aluminum Alloy Metal Matrix Composites," Scripta Metallurgica, 22 (1988) 413-418. 14. R

Effects of high frequency current in welding aluminum alloy 6061

NASA Technical Reports Server (NTRS)

Fish, R. E.

1968-01-01

Uncontrolled high frequency current causes cracking in the heat-affected zone of aluminum alloy 6061 weldments during tungsten inert gas ac welding. Cracking developed when an improperly adjusted superimposed high frequency current was agitating the semimolten metal in the areas of grain boundary.

Modeling the Hot Ductility of AA6061 Aluminum Alloy After Severe Plastic Deformation

NASA Astrophysics Data System (ADS)

Khamei, A. A.; Dehghani, K.; Mahmudi, R.

2015-05-01

Solutionized AA6061 aluminum alloy was processed by equal-channel angular pressing followed by cold rolling. The hot ductility of the material was studied after severe plastic deformation. The hot tensile tests were carried out in the temperature range of 300-500°C and at the strain rates of 0.0005-0.01 s-1. Depending on the temperature and strain rate, the applied strain level exhibited significant effects on the hot ductility, strain-rate sensitivity, and activation energy. It can be suggested that the possible mechanism dominated the hot deformation during tensile testing is dynamic recovery and dislocation creep. Constitutive equations were developed to model the hot ductility of the severe plastic deformed AA6061 alloy.

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.

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.

Fabrication of superhydrophobic surface with improved corrosion inhibition on 6061 aluminum alloy substrate

NASA Astrophysics Data System (ADS)

Li, Xuewu; Zhang, Qiaoxin; Guo, Zheng; Shi, Tian; Yu, Jingui; Tang, Mingkai; Huang, Xingjiu

2015-07-01

This work has developed a simple and low-cost method to render 6061 aluminum alloy surface superhydrophobicity and excellent corrosion inhibition. The superhydrophobic aluminum alloy surface has been fabricated by hydrochloric acid etching, potassium permanganate passivation and fluoroalkyl-silane modification. Meanwhile, the effect of the etching and passivation time on the wettability and corrosion inhibition of the fabricated surface has also been investigated. Results show that with the etching time of 6 min and passivation time of 180 min the fabricated micro/nano-scale terrace-like hierarchical structures accompanying with the nanoscale coral-like network bulge structures after being modified can result in superhydrophobicity with a water contact angle (CA) of 155.7°. Moreover, an extremely weak adhesive force to droplets as well as an outstanding self-cleaning behavior of the superhydrophobic surface has also been proved. Finally, corrosion inhibition in seawater of the as-prepared aluminum alloy surface is characterized by potentiodynamic polarization curves and electrochemical impedance spectroscopy. Evidently, the fabricated superhydrophobic surface attained an improved corrosion inhibition efficiency of 83.37% compared with the traditional two-step processing consisting of etching and modification, which will extend the further applications of aluminum alloy especially in marine engineering fields.

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.

Compression Behavior and Energy Absorption of Aluminum Alloy AA6061 Tubes with Multiple Holes

NASA Astrophysics Data System (ADS)

Simhachalam, Bade; Lakshmana Rao, C.; Srinivas, Krishna

2014-05-01

In this article, compression behavior and energy absorption of aluminum alloy AA6061 tubes are investigated both experimentally and numerically. Static and dynamic simulations are done using LS-Dyna Software for AA6061 tubes. True stress-plastic strain curves from the tensile test are used in the static and dynamic simulations of AA6061 tubes. The energy absorption values between experimental compression results and numeral simulation are found to be in good agreement. Dynamic simulations are done with drop velocity of up to 10 m/s to understand the inertia effects on energy absorption. The deformed modes from the numerical simulation are compared between tubes with and without holes in static and dynamic conditions.

Light weight and high strength materials made of recycled steel and aluminum

NASA Astrophysics Data System (ADS)

Nounezi, Thomas

Recycling has proven not only to address today's economical, environmental and social issues, but also to be imperative for the sustainability of human technology. The current thesis has investigated the feasibility of a new philosophy for Recycling (Alloying-Recycling) using steel 1020 and aluminum 6061T6. The study was limited to the metallurgical aspects only and has highlighted the potential of recycled alloys made of recycled aluminum and steel to exhibit substantially increased wear resistance and strength-to-weight ratio as compared to initial primary materials. Three alloy-mixtures are considered: TN3 (5wt% 1020 +95wt% 6061T6); TN5 (0.7wt% 1020 + 99.3wt% 6061T6); and TN4 (10wt% 6061T6 + 90wt% 1020). A Tucker induction power supply system (3kW; 135-400 kHz) is used to melt the alloy mixtures for casting in graphite crucibles. Heat treatment of the cast samples is done using a radiation box furnace. Microscopy, Vickers hardness and pin-on-disc abrasive wear tests are performed. Casting destroyed the initial microstructures of the alloys leading to a hardness reduction in the as-cast and solution heat-treated aluminum rich samples to 60 Hv from 140 Hv. Ageing slightly increased the hardness of the cast samples and provided a wear resistance two times higher than that of the initial 6061T6 material. On the steel rich side, the hardness of the as-cast TN4 was 480 Hv, which is more than twice as high as the initial hardness of steel 1020 of 202 Hv; this hints to strong internal and residual stress, probably martensite formation during fast cooling following casting. Solution heat treatment lowered the hardness to the original value of steel 1020, but provided about ten (10) times higher wear resistance; this suggests higher ductility and toughness of normalised TN4 as compared to 1020. In addition, TN4 exhibits about 25% weight reduction as compared to 1020. The actual recycling process and the effect of non-metallic impurities shall be investigated in future

Effects of thermal cycling on graphie-fiber-reinforced 6061 aluminum

NASA Technical Reports Server (NTRS)

Dries, G. A.; Tompkins, S. S.

1986-01-01

Graphite-reinforced aluminum alloy metal-matrix composites are among materials being considered for structural components in dimensionally stable space structures. This application requires materials with low values of thermal expansions and high specific stiffnesses. They must remain stable during exposures to the space environment for periods extending to 20 years. The effects of thermal cycling on the thermal expansion behavior and mechanical properties of Thornel P100 graphite 6061 aluminum composites, as fabricated and after thermal processing to eliminate thermal strain hysteresis, have been investigated. Two groups of composites were studied: one was fabricated by hot roll bonding and the other by diffusion bonding. Processing significantly reduced strain hysteresis during thermal cycling in both groups and improved the ultimate tensile strength and modulus in the diffusion-bonded composites. Thermal cycling stabilized the as-fabricated composites by reducing the residual fabrication stress and increased the matrix strength by metallurgical aging. Thermal expansion behavior of both groups after processing was insensitive to thermal cycling. Data scatter was too large to determine effects of thermal cycling on the mechanical properties. The primary effects of processing and thermal cycling can be attributed to changes in the metallurgical condition and stress state of the matrix.

Microstructure Evolution and Mechanical Properties of High-Speed Friction Stir Welded Aluminum Alloy Thin Plate Joints

NASA Astrophysics Data System (ADS)

Liu, Fenjun; Fu, Li; Chen, Haiyan

2018-06-01

Sound friction stir welded (FSW) joints of 6061-T6 aluminum alloy sheets with an 0.8 mm thickness were obtained at conventional speed (2000 rpm, 300 mm/min) and high speed (11,000 rpm, 1500 mm/min). The recrystallization mechanism, precipitate evolution, mechanical properties and fracture behavior were investigated in detail. Microstructure analyses revealed that the grain structure evolution in the nugget zone (NZ) was dominated by continuous dynamic recrystallization. In the process of FSW, high speed facilitates the formation of finer equiaxed recrystallized grains, higher density of dislocations and substructures, and a larger number of precipitates in the NZ compared to the conventional speed, which further significantly improves the hardness and tensile strength of the joints. The maximum tensile strength was obtained with 292.6 MPa, 83.2% for the 6061-T6 aluminum alloy and 122.6% for the conventional-speed FSW joints. This work provides an effective method for preparing FSW aluminum alloy thin plate joints with excellent mechanical properties.

Gas tungsten arc welding of aluminum alloys 6XXX. Welding procedure specification. Supplement 1. Records of procedure qualification tests. [6061 and 6063

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

1986-06-01

Procedure WPS-1003 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 6061 and 6063 (P-23), in thickness range 0.035 to 0.516 inch; filler metal is ER4043 (F-23) or ER5356 (F-22); shielding gas is argon.

Reaction rates and prediction of thermal instability during aluminum alloy 6061 dissolution

DOE Office of Scientific and Technical Information (OSTI.GOV)

McFarlane, J.; DePaoli, D. W.; Mattus, C. H.

Here, chemical kinetics of dissolution of aluminum alloy 6061 was investigated for the processing of Pu-238 for deep space missions. The rate of dissolution was measured by the heat release and appeared to be controlled by the rate of release of Al(OH) 4 – from the metal surface. Rates of reaction were measured from 273 to 365 K, giving an activation energy of 72 ± 13 kJ•(mol Al) –1 and a pre-exponential factor of 5 ± 3 × 10 9 dm 3mol –1min –1. Minor alloying elements did not appear to affect the reaction kinetics. The average heat of dissolutionmore » was –360 ± 70 kJ•(mol NaAlO 2) –1. When extrapolated to an infinitely dilute solution of aluminum, kJ•(mol NaAlO 2) –1.« less

Reaction rates and prediction of thermal instability during aluminum alloy 6061 dissolution

DOE PAGES

McFarlane, J.; DePaoli, D. W.; Mattus, C. H.

2017-11-10

Here, chemical kinetics of dissolution of aluminum alloy 6061 was investigated for the processing of Pu-238 for deep space missions. The rate of dissolution was measured by the heat release and appeared to be controlled by the rate of release of Al(OH) 4 – from the metal surface. Rates of reaction were measured from 273 to 365 K, giving an activation energy of 72 ± 13 kJ•(mol Al) –1 and a pre-exponential factor of 5 ± 3 × 10 9 dm 3mol –1min –1. Minor alloying elements did not appear to affect the reaction kinetics. The average heat of dissolutionmore » was –360 ± 70 kJ•(mol NaAlO 2) –1. When extrapolated to an infinitely dilute solution of aluminum, kJ•(mol NaAlO 2) –1.« less

SLM processing-microstructure-mechanical property correlation in an aluminum alloy produced by additive manufacturing

NASA Astrophysics Data System (ADS)

Alejos, Martin Fernando

Additive manufacturing has become a highly researched topic in recent years all over the world. The current research evaluates the merits of additive manufacturing based on the mechanical, microstructural, and fracture properties of additive manufactured AlSi10Mg test specimens. The additive manufactured build plates consisted of tensile and fatigue test specimens. They were printed in the 0°, 30°, 60°, and 90° orientations relative to the build platform. Tensile and dynamic fatigue tests were conducted followed by microstructural characterization and fracture analysis. A wrought 6061 T6 aluminum alloy was also tested for comparison. Tensile tests revealed similar ultimate tensile strengths for all aluminum tensile specimens (350-380 MPa). Fatigue strength was greatest for wrought 6061 T6 aluminum (175 MPa). The fatigue behavior was a strong function of build orientation for the additive manufactured specimens. The 0°, 30°, and 60° orientations had fatigue strengths close to 104 MPa while the 90° orientation had a fatigue strength of 125 MPa. All test specimens failed primarily in a ductile manner. The effect of laser power, hatch spacing, and scan speed were also studied using microstructural analysis. Increasing laser power decreased grain size and void size. Increasing scan speed led to the formation of columnar grains. Increasing hatch spacing decreased grain size and the amount of voids present in the microstructure.

Time exposure studies on stress corrosion cracking of aluminum 2014-T6, 2219-T87, 2014-T651, 7075-T651, and titanium 6Al-4V

NASA Technical Reports Server (NTRS)

Terrell, J.

1973-01-01

The effect of a constant applied stress in crack initiation of aluminum 2014-T6, 2219-T87, 2014-T651, 7075-T651 and titanium 6Al-4V has been investigated. Aluminum c-ring specimens (1-inch diameter) and u-band titanium samples were exposed continuously to a 3.5% NaCl solution (pH 7) and organic fluids of ethyl, methyl, and iso-propyl alcohol (reagent purity), and demineralized distilled water. Corrosive action was observed to begin during the first and second day of constant exposure as evidenced by accumulation of hydrogen bubbles on the surface of stressed aluminum samples. However, titanium stressed specimens showed no reactions to its environment. Results of this investigation seems to suggest that aluminum 2014-T6, aluminum 7075-T651 and aluminum 2014-T651 are susceptible to stress corrosion cracking in chloride solution (NaCl), while aluminum 2219-T87 seem to resist stress corrosion cracking in sodium chloride at three levels of stress (25%, 50%, and 75% Y.S.). In organic fluids of methyl, ethyl, and iso-propyl alcohol, 2014-T6 and 7075-T651 did not fail by SCC; but 2014-T651 was susceptible to SCC in methly alcohol, but resistant in ethyl alcohol, iso-propyl alcohol and demineralized distilled water.

Microstructural variation through weld thickness and mechanical properties of peened friction stir welded 6061 aluminum alloy joints

DOE Office of Scientific and Technical Information (OSTI.GOV)

Abdulstaar, Mustafa A., E-mail: mustafa.abdulstaar

The current study examined the effect of microstructure variation on the development of mechanical properties in friction stir welded joints of 6061-T6 aluminum alloy, which were subsequently processed by shot peening (SP). Following to FSW, fatigue specimens were extracted perpendicularly to the welding direction. Surface Skimming to 0.5 mm from crown and root sides of the joint was made and SP was later applied on the two sides using ceramic shots of two different Almen intensities of 0.18 mmA and 0.24 mmA. Microstructural examination by electron back scattered diffraction (EBSD) indicated variation in the grain refinement of the weld zone,more » with coarsest grains (5 μm) at the crown side and finest grains (2 μm) at the root side. Reduction of microhardness to 60 HV occurred in the weld zone for samples in FSW condition. Application of SP promoted significant strain hardening at the crown side, with Almen intensities of 0.24 mmA providing maximum increase in microhardness to 120 HV. On the contrary, only a maximum microhardness of 75 HV was obtained at the root side. The difference in strain hardening capability at the two sides was strongly dependent on grain size. The two Almen intensities produced similar distribution of compressive residual stresses in the subsurface regions that led to enhance the fatigue strength to the level of base metal for N ≥ 10{sup 5} cycles. Yet, the increase in fatigue strength was more pronounced with increasing Almen intensity to 0.24 mmA, demonstrating further enhancement by strain hardening. - Highlights: • Grain refinement was observed after friction stir welding of AA 6061-T6. • Reduction in microhardness and fatigue strength were obtained after welding. • Variation in grain refinement led to different hardening behavior after peening. • Shot peening induced beneficial compressive residual stresses. • Shot peening and surface skimming markedly improved the fatigue performance.« less

Weldability of extruded aluminum-alumina composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gedeon, S.A.; Lane, C.; Altshuller, B.

1994-12-31

Acceptable procedure were developed for welding the following types of aluminum particle-reinforced aluminum: 6061/Al{sub 2}O{sub 3}/10p-T6, 6061/Al{sub x}/O{sub 3}20p-T6, and 7005Al{sub 2}O{sub 3}/10p-T6,. Automated and manual procedures were developed and using both gas tungsten arc welding (GTAW), with a cold wire feed, and gas metal arc welding (GMAW). The effect of welding procedures on porosity, reinforcing particulate distribution, and mechanical properties was determined. Postweld heat treatment and microhardness testing were used to understand the effect of the welded microstructure on the strength and ductility of the joint. Fracture surfaces and transverse microsections of mechanical test specimens were examined to determinemore » the origins and mechanisms of failure. Cleanliness of the joint and weld wire were found to be essential to eliminate porosity. Based on these experimentally determined data, general guidelines for welding aluminum oxide particle-reinforced aluminum composites are proposed. Discussion includes proper selection of weld joint geometry, filler metals, travel speed, voltage, and current ranges. These parameters are compared to those used in an actual production environment for composite products. Distinctions between welding these composites and others produced via powder metallurgy or with silicon carbide reinforcements are also discussed.« less

Effect of Preexisting Corrosion on Fatigue Cracking of Aluminum Alloys 2024-T3 and 7075-T6

DTIC Science & Technology

1995-08-01

alloys 2024 -T3 and 7075-T6. It was determined that preexisting corrosion has a detrimental effect on the fatigue life of aluminum alloys 2024 -T3 and...following conclusions were drawn: 1. Preexisting corrosion has a detrimental effect on the fatigue life of aluminum alloys 2024 -T3 and 7075-T6. The...corrosion has a detrimental effect on the fatigue life of aluminum alloys

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.

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.

Machinability of Al 6061 Deposited with Cold Spray Additive Manufacturing

NASA Astrophysics Data System (ADS)

Aldwell, Barry; Kelly, Elaine; Wall, Ronan; Amaldi, Andrea; O'Donnell, Garret E.; Lupoi, Rocco

2017-10-01

Additive manufacturing techniques such as cold spray are translating from research laboratories into more mainstream high-end production systems. Similar to many additive processes, finishing still depends on removal processes. This research presents the results from investigations into aspects of the machinability of aluminum 6061 tubes manufactured with cold spray. Through the analysis of cutting forces and observations on chip formation and surface morphology, the effect of cutting speed, feed rate, and heat treatment was quantified, for both cold-sprayed and bulk aluminum 6061. High-speed video of chip formation shows changes in chip form for varying material and heat treatment, which is supported by the force data and quantitative imaging of the machined surface. The results shown in this paper demonstrate that parameters involved in cold spray directly impact on machinability and therefore have implications for machining parameters and strategy.

Microstructure, accumulated strain, and mechanical behavior of AA6061 Al alloy severely deformed at cryogenic temperatures

NASA Astrophysics Data System (ADS)

Magalhães, D. C.; Kliauga, A. M.; Ferrante, M.; Sordi, V. L.

2017-05-01

The combination of Severe Plastic Deformation (SPD) and cryogenic temperatures can be an efficient way to obtain metals and alloys with very refined microstructure and thus optimize the strength-ductility pair. However, there is still a lack of studies on cryogenic SPD process and their effects on microstructure and mechanical properties, especially in precipitation-hardenable aluminum alloys. This study describes the effect of low temperature processing on microstructure, aging kinetic and tensile properties of AA6061 Al alloy after cryo-SPD. Samples of AA6061 Al alloy in the solutionized state was processed by Equal-channel angular pressing (ECAP) at 77 K and 298 K, up to accumulate true strains up to 4.2. Results indicated that the aging kinetic is accelerated when deformation is performed at cryogenic temperature, dislocation density measurement by x-ray and diffraction analysis at TEM achieved a saturation level of 2×1015 m-2 by ECAP at 298K and 5×1015 m-2 after cryogenic ECAP plus precipitation hardening. The same level of yield strength was observed in both deformation procedures but an improvement in uniform elongation was achieved by cryogenic ECAP followed by a T6 treatment

An electron back-scattered diffraction study on the microstructure evolution of severely deformed aluminum AI6061 alloy

NASA Astrophysics Data System (ADS)

Vaseghi, M.; Karimi Taheri, A.; Kim, H. S.

2014-08-01

In this paper dynamic strain ageing behavior in an Al-Mg-Si alloy related to equal channel angular pressing (ECAP) was investigated. In order to examine the combined plastic deformation and ageing effects on microstructure evolutions and strengthening characteristics, the Al6061 alloy were subjected to phi=90° ECAP die for up to 4 passes via route Bc at high temperatures. For investigating the effects of ageing temperature and strain rate in ECAP, Vickers hardness tests were performed. The combination of the ECAP process with dynamic ageing at higher temperatures resulted in a significant increase in hardness. The microstructural evolution of the samples was studied using electron back-scattering diffraction (EBSD). The grains of Al6061 aluminum alloy were refined significantly at 100 and 150 °C with greater pass numbers and the distributions of grain size tended to be more uniform with pass number increasing. Frequency of sub-boundaries and low angle grain boundaries (LAGBs) increased at initial stage of deformation, and sub-boundaries and LAGBs evolved into highangle grain boundaries (HAGBs) with further deformation, which resulted in the high frequency of HAGBs in the alloy after ECAP 4 passes.

Numerical Simulation of Ballistic Impact of Layered Aluminum Nitride Ceramic

DTIC Science & Technology

2015-09-01

tile(s) Aluminum nitride (AlN) 163 a Polymer layers Polyurethane foam 18 b Backing metal Aluminum 6061-T6 (Al) 23 c Projectile Tungsten heavy alloy...larger (a factor of 3.8) than the most dense polyurethane foam of the available constitutive models. Default options for element failure were imposed in...AlN), a polycrystalline ceramic. The total thickness of the tile(s) is 38.1 mm in all cases. A thin polyurethane laminate separates neighboring tiles

Enhancing Corrosion and Wear Resistance of AA6061 by Friction Stir Processing with Fe78Si9B13 Glass Particles

PubMed Central

Guo, Lingyu; Liu, Yan; Shen, Kechang; Song, Chaoqun; Yang, Min; Kim, Kibuem; Wang, Weimin

2015-01-01

The AA6061-T6 aluminum alloy samples including annealed Fe78Si9B13 particles were prepared by friction stir processing (FSP) and investigated by various techniques. The Fe78Si9B13-reinforced particles are uniformly dispersed in the aluminum alloy matrix. The XRD results indicated that the lattice parameter of α-Al increases and the preferred orientation factors F of (200) plane of α-Al reduces after friction stir processing. The coefficient of thermal expansion (CTE) for FSP samples increases at first with the temperature but then decreases as the temperature further increased, which can be explained by the dissolving of Mg and Si from β phase and Fe78Si9B13 particles. The corrosion and wear resistance of FSP samples have been improved compared with that of base metal, which can be attributed to the reduction of grain size and the CTE mismatch between the base metal and reinforced particles by FSP, and the lubrication effect of Fe78Si9B13 particles also plays a role in improving wear resistance. In particular, the FSP sample with reinforced particles in amorphous state exhibited superior corrosion and wear resistance due to the unique metastable structure. PMID:28793492

Effects of Forged Stock and Pure Aluminum Coating on Cryogenic Performance of Heat Treated Aluminum Mirrors

NASA Technical Reports Server (NTRS)

Toland, Ronald; Ohl, Raymond G.; Barthelmy, Michael P.; Zewari, S. Wahid; Greenhouse, Matthew A.; MacKenty, John W.

2003-01-01

In spite of its baseline mechanical stress relief, aluminum 6061-T651 harbors some residual stress that may relieve and distort mirror figure to unacceptable levels at cryogenic operating temperatures unless relieved during fabrication. Cryogenic instruments using aluminum mirrors for both ground-based and space IR astronomy have employed a variety of heat treatment formulae, with mixed results. We present the results of an on-going test program designed to empirically determine the effects of different stress relief procedures for aluminum mirrors. Earlier test results identified a preferred heat treatment for flat and spherical mirrors diamond turned from blanks cut out of Al6061-T651 plate stock. Further tests have been performed on mirrors from forged stock and one set from plate stock coated with Alumiplate(TM) aluminum coating to measure the effect of these variables on cryogenic performance. The mirrors are tested for figure error and radius of curvature at room temperature and at 80 K for three thermal cycles. We correlate the results of our optical testing with heat treatment and metallographic data.

On the Role of Processing Parameters in Producing Recycled Aluminum AA6061 Based Metal Matrix Composite (MMC-AlR) Prepared Using Hot Press Forging (HPF) Process.

PubMed

Ahmad, Azlan; Lajis, Mohd Amri; Yusuf, Nur Kamilah

2017-09-19

Solid-state recycling, which involves the direct recycling of scrap metal into bulk material using severe plastic deformation, has emerged as a potential alternative to the conventional remelting and recycling techniques. Hot press forging has been identified as a sustainable direct recycling technique that has fewer steps and maintains excellent material performance. An experimental investigation was conducted to explore the hardness and density of a recycled aluminum-based metal matrix composite by varying operating temperature and holding time. A mixture of recycled aluminum, AA6061, and aluminum oxide were simultaneously heated to 430, 480, and 530 °C and forged for 60, 90, and 120 min. We found a positive increase in microhardness and density for all composites. The hardness increased approximately 33.85%, while density improved by about 15.25% whenever the temperature or the holding time were increased. Based on qualitative analysis, the composite endures substantial plastic deformation due to the presence of hardness properties due to the aluminum oxide embedded in the aluminum matrix. These increases were significantly affected by the operating temperature; the holding time also had a subordinate role in enhancing the metal matrix composite properties. Furthermore, in an effort to curb the shortage of primary resources, this study reviewed the promising performance of secondary resources produced by using recycled aluminum and aluminum oxide as the base matrix and reinforcement constituent, respectively. This study is an outline for machining practitioners and the manufacturing industry to help increase industry sustainability with the aim of preserving the Earth for our community in the future.

On the Role of Processing Parameters in Producing Recycled Aluminum AA6061 Based Metal Matrix Composite (MMC-AlR) Prepared Using Hot Press Forging (HPF) Process

PubMed Central

Ahmad, Azlan; Lajis, Mohd Amri

2017-01-01

Solid-state recycling, which involves the direct recycling of scrap metal into bulk material using severe plastic deformation, has emerged as a potential alternative to the conventional remelting and recycling techniques. Hot press forging has been identified as a sustainable direct recycling technique that has fewer steps and maintains excellent material performance. An experimental investigation was conducted to explore the hardness and density of a recycled aluminum-based metal matrix composite by varying operating temperature and holding time. A mixture of recycled aluminum, AA6061, and aluminum oxide were simultaneously heated to 430, 480, and 530 °C and forged for 60, 90, and 120 min. We found a positive increase in microhardness and density for all composites. The hardness increased approximately 33.85%, while density improved by about 15.25% whenever the temperature or the holding time were increased. Based on qualitative analysis, the composite endures substantial plastic deformation due to the presence of hardness properties due to the aluminum oxide embedded in the aluminum matrix. These increases were significantly affected by the operating temperature; the holding time also had a subordinate role in enhancing the metal matrix composite properties. Furthermore, in an effort to curb the shortage of primary resources, this study reviewed the promising performance of secondary resources produced by using recycled aluminum and aluminum oxide as the base matrix and reinforcement constituent, respectively. This study is an outline for machining practitioners and the manufacturing industry to help increase industry sustainability with the aim of preserving the Earth for our community in the future. PMID:28925963

Microstructure and wear characterization of aluminum matrix composites reinforced with industrial waste fly ash particulates synthesized by friction stir processing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dinaharan, I., E-mail: dinaweld2009@gmail.com

Fly ash (FA) is a waste product of coal combustion in thermal power plants which is available in massive quantities all over the world causing land pollution. This paper reports the characterization of AA6061 aluminum matrix composites (AMCs) reinforced with FA particles synthesized using friction stir processing (FSP). The volume fraction of FA particles was varied from 0 to 18 in steps of 6. The prepared AMCs were characterized using optical microscopy (OM), scanning electron microscopy (SEM) and electron backscattered diagram (EBSD). The wear rate was estimated using a pin-on-disc wear apparatus. FA particles were observed to be distributed homogeneouslymore » in the AMC irrespective of the location within the stir zone. The EBSD micrographs revealed remarkable grain refinement in the AMC. The incorporation of FA particles enhanced the microhardness and wear resistance of the AMC. The strengthening mechanisms of the AMC were discussed and correlated to the observed microstructures. The wear mechanisms were identified by characterizing the wear debris and worn surfaces. - Highlights: •Industrial waste fly ash was used to produce aluminum matrix composites. •Friction stir processing was used to produce AA6061/Fly Ash composite. •Fly ash particles refined the grains of aluminum matrix. •Fly ash particles enhanced the hardness and wear resistance. •Successful utilization of fly ash to make aluminum composites reduces land pollution.« less

Spectral Dependence of Stratified Electrothermal Instability in Tamped Aluminum 6061 with Current in a Skin Layer

NASA Astrophysics Data System (ADS)

Bauer, Bruno; Hutchinson, Trevor; Awe, Thomas

2017-10-01

The stratified electrothermal instability (ETI) was recently observed on the surface of thick aluminum 6061 pulsed with rapidly rising lineal current density (3 ×1015 A m-1s-1) for 70 ns. A transparent 70- μm-thick Parylene-N coating tamped the aluminum expansion and suppressed surface plasma. The evolution of the aluminum surface emission pattern was recorded with time-resolved microscopy (3- μm resolution). The images were converted into a series of blackbody surface-temperature maps. Analysis of these temperature maps provides information on the evolution of temperature fluctuations, as a function of axial wavelength and azimuthal width. Perturbations with axial wavelength longer than 20 μm grow, while those with axial wavelength shorter than 10 μm decay. Comparing the spectral dependence of growth/decay rates with MHD simulations could test the modeling of ETI positive feedback and of damping by thermal conduction. Work supported by Sandia National Laboratories LDRD program, PO 1742766.

Mechanical Properties of SiC, Al2O3 Reinforced Aluminium 6061-T6 Hybrid Matrix Composite

NASA Astrophysics Data System (ADS)

Murugan, S. Senthil; Jegan, V.; Velmurugan, M.

2018-04-01

This paper contains the investigation of tensile, compression and impact characterization of SiC, Al2O3 reinforced Aluminium 6061-T6 matrix hybrid composite. Hybrid matrix composite fabrication was done by stir casting method. An attempt has been made by keeping Al2O3 percentage (7%) constant and increasing SiC percentage (10, 15, and 20%). After fabricating, the samples were prepared and tested to find out the various mechanical properties like tensile, compressive, and impact strength of the developed composites of different weight % of silicon carbide and Alumina in Aluminium alloy. The main objective of the study is to compare the values obtained and choose the best composition of the hybrid matrix composite from the mechanical properties point of view.

Microstructure and Mechanical Properties of Friction Stir Welded Aluminum Alloy/Stainless Steel Lap Joints

NASA Astrophysics Data System (ADS)

Ogura, Tomo; Nishida, Taichi; Nishida, Hidehito; Yoshikawa, Syuhei; Yoshida, Takumi; Omichi, Noriko; Fujimoto, Mitsuo; Hirose, Akio

The mechanical properties and interfacial microstructure of an aluminum alloy/stainless steel dissimilar lap joint using friction stir welding (FSW) were characterized. In an FSWed A3003 aluminum alloy-SUS304 steel lap joint, the strength on the advancing side was larger than that at the retreating side. TEM observation indicated that a sound joint can be obtained from the stage of the formation of the amorphous layer owing to the mechanical alloying effects before the formation of intermetallic compounds. This lap joining technique was also successfully applied to A6061-T6 aluminum alloy-grooved SUS304 plates. The maximum tensile strength of the lap joint was approximately the same as that of the base alloy, however, the proof stress of the joint decreased with the dissolution of the β″ phase in the A6061 aluminium alloy, which is caused by the generation of heat during friction stir welding.

Development of Al-Al3Ni Nanocomposite by Duplex Processing of Flame Spray and Friction Stir Processing, and Evaluation of Its Properties

NASA Astrophysics Data System (ADS)

Adel Mehraban, F.; Karimzadeh, F.; Abbasi, M. H.

2017-10-01

In this study, Al-Al3Ni nanocomposite was fabricated by friction stir processing (FSP) of a nickel-deposited Al6061-T6 plate. X-ray diffraction results showed that Al3Ni phase was formed because of an in situ reaction between the preplaced nickel and aluminum substrate. To predict the first phase formed during FSP, effective heat of formation (EHF) thermodynamic model was applied, and the results were in agreement with experimental data. The presence of facet nanoparticles in transmission electron microscopy micrographs of the stir zone (SZ) confirmed the formation of Al3Ni nano-reinforcements. Although microhardness and ultimate tensile strength in the SZ of nanocomposite degraded because of precipitates dissolution in Al6061-T6 during FSP, it showed improved tribological behavior at elevated temperatures.

Study of diffusion bond development in 6061 aluminum and its relationship to future high density fuels fabrication.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Prokofiev, I.; Wiencek, T.; McGann, D.

1997-10-07

Powder metallurgy dispersions of uranium alloys and silicides in an aluminum matrix have been developed by the RERTR program as a new generation of proliferation-resistant fuels. Testing is done with miniplate-type fuel plates to simulate standard fuel with cladding and matrix in plate-type configurations. In order to seal the dispersion fuel plates, a diffusion bond must exist between the aluminum coverplates surrounding the fuel meat. Four different variations in the standard method for roll-bonding 6061 aluminum were studied. They included mechanical cleaning, addition of a getter material, modifications to the standard chemical etching, and welding methods. Aluminum test pieces weremore » subjected to a bend test after each rolling pass. Results, based on 400 samples, indicate that at least a 70% reduction in thickness is required to produce a diffusion bond using the standard rollbonding method versus a 60% reduction using the Type II method in which the assembly was welded 100% and contained open 9mm holes at frame corners.« less

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.

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.

Design and Analysis of Wind Turbine Blade Hub using Aluminium Alloy AA 6061-T6

NASA Astrophysics Data System (ADS)

Ravikumar, S.; Jaswanthvenkatram, V.; Sai kumar, Y. J. N. V.; Sohaib, S. Md.

2017-05-01

This work presents the design and analysis of horizontal axis wind turbine blade hub using different material. The hub is very crucial part of the wind turbine, which experience the loads from the blades and the loads were transmitted to the main shaft. At present wind turbine is more expensive and weights more than a million pounds, with the nacelle, rotor hub and blades accounting for most of the weight. In this work Spheroidal graphite cast iron GGG 40.3 is replaced by aluminium alloy 6061-T6 to enhance the casting properties and also to improve the strength-weight ratio. This transition of material leads to reduction in weight of the wind turbine. All the loads caused by wind and extreme loads on the blades are transferred to the hub. Considering the IEC 61400-1 standard for defining extreme loads on the hub the stress and deflection were calculated on the hub by using Finite element Analysis. Result obtained from ANSYS is compared and discussed with the existing design.

Effect of Thermal Treatment on the Mechanical and Toughness Properties of Extruded Sic sub w/Aluminum 6061 Metal Matrix Composite.

DTIC Science & Technology

1987-01-31

Charpy V-Notch_,,... i9,, STRACT (Continue on reverse if necessary and identify by block number) Mechanical, instrumented\\ Charpy V-potch (CVN) energy and...authors express their appreciation to Messrs. W. Willard and R. Gray for the fracture testing, Ensign M. Rennie for the instrumented Charpy V-notch...TO ALUMINUM GRAIN BOUNDARIES . . . . . . . . . 12 5 INSTRUMENTED CHARPY V-NOTCH LOAD AND ENERGY AGAINST TIME OUTPUTS FOR L-C ORIENTATION SiCwJAI 6061

Friction Stir Welding in Wrought and Cast Aluminum Alloys: Weld Quality Evaluation and Effects of Processing Parameters on Microstructure and Mechanical Properties

NASA Astrophysics Data System (ADS)

Pan, Yi; Lados, Diana A.

2017-04-01

Friction stir welding (FSW) is a solid-state process widely used for joining similar and dissimilar materials for critical applications in the transportation sector. Understanding the effects of the process on microstructure and mechanical properties is critical in design for structural integrity. In this study, four aluminum alloy systems (wrought 6061-T651 and cast A356, 319, and A390) were processed in both as-fabricated and pre-weld heat-treated (T6) conditions using various processing parameters. The effects of processing and heat treatment on the resulting microstructures, macro-/micro-hardness, and tensile properties were systematically investigated and mechanistically correlated to changes in grain size, characteristic phases, and strengthening precipitates. Tensile tests were performed at room temperature both along and across the welding zones. A new method able to evaluate weld quality (using a weld quality index) was developed based on the stress concentration calculated under tensile loading. Optimum processing parameter domains that provide both defect-free welds and good mechanical properties were determined for each alloy and associated with the thermal history of the process. These results were further related to characteristic microstructural features, which can be used for component design and materials/process optimization.

Dynamic Response and Microstructure Evolution of AA2219-T4 and AA2219-T6 Aluminum Alloys

NASA Astrophysics Data System (ADS)

Olasumboye, A.; Owolabi, G.; Odeshi, A.; Zeytinci, A.; Yilmaz, N.

2018-02-01

In this study, the dynamic deformation behavior of AA2219 aluminum alloy was investigated in two different temper conditions: T4 and T6, with a view to determining the effect of heat treatment on the microstructure and flow behavior of the material under high strain rates. Split Hopkinson pressure bar experiment was used in determining the dynamic response of the alloy while a digital image correlation system was employed in visualizing and tracking the surface deformation of the specimens. Optical microscopy and scanning electron microscopy were used to assess the microstructure of the material after following standard metallographic specimen preparation techniques. The results obtained showed heterogeneous deformation of the alloy in the two temper conditions. It was observed that the dynamic mechanical behavior of each sample preparation was dependent on its strength properties due to aging type, which in turn controls the metamorphosis of the strengthening precipitates and the initial microstructure. At the maximum strain rate of 3500 s-1, transformed bands leading to crack nucleation was observed in the AA2219-T4 aluminum alloy while AA2219-T6 had fractured at the same strain rate. The modes of crack formation and growth in the two alloys were found to be similar: nucleation, growth and coalescence of voids. However, shear band bifurcation phenomenon was observed only in the AA2219-T6 alloy.

Dynamic Response and Microstructure Evolution of AA2219-T4 and AA2219-T6 Aluminum Alloys

NASA Astrophysics Data System (ADS)

Olasumboye, A.; Owolabi, G.; Odeshi, A.; Zeytinci, A.; Yilmaz, N.

2018-06-01

In this study, the dynamic deformation behavior of AA2219 aluminum alloy was investigated in two different temper conditions: T4 and T6, with a view to determining the effect of heat treatment on the microstructure and flow behavior of the material under high strain rates. Split Hopkinson pressure bar experiment was used in determining the dynamic response of the alloy while a digital image correlation system was employed in visualizing and tracking the surface deformation of the specimens. Optical microscopy and scanning electron microscopy were used to assess the microstructure of the material after following standard metallographic specimen preparation techniques. The results obtained showed heterogeneous deformation of the alloy in the two temper conditions. It was observed that the dynamic mechanical behavior of each sample preparation was dependent on its strength properties due to aging type, which in turn controls the metamorphosis of the strengthening precipitates and the initial microstructure. At the maximum strain rate of 3500 s-1, transformed bands leading to crack nucleation was observed in the AA2219-T4 aluminum alloy while AA2219-T6 had fractured at the same strain rate. The modes of crack formation and growth in the two alloys were found to be similar: nucleation, growth and coalescence of voids. However, shear band bifurcation phenomenon was observed only in the AA2219-T6 alloy.

Gas tungsten arc welding of aluminum alloys 6XXX. Welding procedure specification

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wodtke, C.H.; Frizzell, D.R.; Plunkett, W.A.

1985-08-01

Procedure WPS-1003 is qualified under Section IX of the ASME Boiler and Pressure Vessel Code for gas tungsten arc welding of aluminum alloys 6061 and 6063 (P-23), in thickness range 0.035 to 0.516 in.; filler metal is ER4043 (F-23) or ER5356 (F-22); shielding gas is argon.

Development of Surface Nanocomposite Based on Al-Ni-O Ternary System on Al6061 Alloy by Friction-Stir Processing and Evaluation of Its Properties

NASA Astrophysics Data System (ADS)

Adel Mehraban, F.; Karimzadeh, F.; Abbasi, M. H.

2015-05-01

In this study, an Al/Al2O3-Al3Ni hybrid nanocomposite was developed on the surface of Al6061-T6 plate with preplaced NiO powder on its surface using friction-stir processing (FSP). The x-ray diffraction results showed that NiO particles were reduced by Al during FSP and Al3Ni and Al2O3 were formed as in situ reaction products. A thermodynamic analysis indicated that the reaction is thermodynamically possible and exothermic. Thus, the reaction that is initiated by the severe plastic deformation and friction associated with FSP could continue by the heat that is generated by the exothermic reaction. During each FSP pass, the FSP products are detached quickly from the interface and the growth of the particles is limited and nanometer-sized reinforcements were produced. The presence of facet and hexagonal nanoparticles in transmission electron microscopy micrographs of the stir zone confirmed the formation of Al3Ni and Al2O3 nanoreinforcements, respectively. Mechanical test results showed that the microhardness and ultimate tensile strength in the stir zone of nanocomposite decreased due to the dissolution of precipitates in Al6061-T6 during FSP. The tribological properties of Al6061 at 350°C were significantly improved by developing surface Al/Al2O3-Al3Ni nanocomposite.

Effects of high thermal and high fast fluences on the mechanical properties of type 6061 aluminum in the HFBR

DOE Office of Scientific and Technical Information (OSTI.GOV)

Weeks, J.R.; Czajkowski, C.J.; Tichler, P.R.

The High Flux Beam Reactor (HFBR) at Brookhaven National Laboratory (BNL) is an epithermal, externally moderated (by D/sub 2/O) facility designed to produce neutron beams for research. Type 6061 T-6 aluminum was used for the beam tubes, pressure vessel, fuel cladding, and most other components in the high flux area. The HFBR has operated since 1965. The epithermal, external moderation of the HFBR means that materials irradiated in different areas of the facility receive widely different flux spectra. Thus, specimens from a control rod drive follower tube (CRDF) have received 1.5 /times/ 10/sup 22/ n/cm/sup 2/ (E > 0.1 MeV)more » and 3.2 /times/ 10/sup 23/ n/cm/sup 2/ thermal fluence, while those from a vertical thimble flow shroud received 1.9 /times/ 10/sup 23/ n/cm/sup 2/ (E > 0.1 MeV) and 1.0 /times/ 10/sup 23/ n/cm/sup 2/ thermal. These numbers correspond to fast to thermal fluence ratios ranging from 0.05 to 1.9. Irradiations are occurring at approximately 333/degree/K. The data indicate that the increase in tensile strength and decrease in ductility result primarily from the thermal fluence, i.e., the transmutation of aluminum to silicon. These effects appear to be saturating at fluences above approximately 1.8 /times/ 10/sup 23/ n/cm/sup 2/ thermal at values of 90,000 psi (6700 Kg/mm/sup 2/) and 9%, respectively. The specimens receiving the highest fluence ratios appear to have less increase in tensile strength and less decrease in ductility than specimens with a lower fast to thermal fluence ratio and the same thermal fluence, suggesting a possible beneficial effect of the high energy neutrons in preventing formation of silicon crystallites. 7 refs., 11 figs., 3 tabs.« less

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.

Nano Precipitation and Hardening of Die-Quenched 6061 Aluminum Alloy.

PubMed

Utsunomiya, Hiroshi; Tada, Koki; Matsumoto, Ryo; Watanabe, Katsumi; Matsuda, Kenji

2018-03-01

Die quenching is applied to an age-hardenable aluminium alloys to obtain super-saturated solid solution. The application is advantageous because it can reduce number of manufacturing processes, and may increase strength by strain aging. If die quenching is realized in forging as well as sheet forming, it may widen industrial applicability further. In this study, Al-Mg-Si alloy AA6061 8 mm-thick billets were reduced 50% in height without cracks by die-quench forging. Supersaturated solid solution was successfully obtained. The die-quenched specimen shows higher hardness with nano precipitates at shorter aging time than the conventional water-quenched specimen.

Interdiffusion and reaction between pure magnesium and aluminum alloy 6061

DOE PAGES

Kammerer, C. C.; Fu, Mian; Zhou, Le; ...

2015-06-01

Using solid-to-solid couples investigation, this study characterized the reaction products evolved and quantified the diffusion kinetics when pure Mg bonded to AA6061 is subjected to thermal treatment at 300°C for 720 hours, 350°C for 360 hours, and 400°C for 240 hours. Characterization techniques include optical microscopy, scanning electron microscopy with X-ray energy dispersive spectroscopy, and transmission electron microscopy. Parabolic growth constants were determined for γ-Mg 17Al 12, β-Mg 2Al 3, and the elusive ε-phase. Similarly, the average effective interdiffusion coefficients of major constituents were calculated for Mg (ss), γ-Mg 17Al 12, β-Mg 2Al 3, and AA6061. The activation energies andmore » pre-exponential factors for both parabolic growth constant and average effective interdiffusion coefficients were computed using the Arrhenius relationship. The activation energy for growth of γ-Mg 17Al 12 was significantly higher than that for β-Mg 2Al 3 while the activation energy for interdiffusion of γ-Mg 17Al 12 was only slightly higher than that for β-Mg 2Al 3. As a result, comparisons are made between the results of this study and those of diffusion studies between pure Mg and pure Al to examine the influence of alloying additions in AA6061.« less

Microstructure and hardness performance of AA6061 aluminium composite using friction stir processing

NASA Astrophysics Data System (ADS)

Marini, C. D.; Fatchurrohman, N.

2018-04-01

Rice husk ash (RHA) is an industrial waste that has become a potential reinforced material for aluminium matrix composite (AMCs) due to low cost and abundantly available resources. Friction stir processing (FSP) has been introduced as a method to modify surface properties of the metal and alloy including theirs composite as well. The present work reports the production and characterization of AA6061 and AA6061/5 vol% RHA using FSP using parameters rotation speed 1000 rpm and traversed speed 25 mm/min. The microstructure was studied using optical microscopy (OM). A homogenous dispersion of RHA particles was obtained in the composite. No agglomeration or segregation was observed. The produced composite exhibited a fine grain structure. An improvement in hardness profile was observed as AA6061/5 vol% RHA improves in hardness compared to FSPed of AA6061 without reinforcement.

Effect of specimen thickness of fatigue-crack-growth behavior and fracture toughness of 7075-T6 and 7178-T6 aluminum alloys

NASA Technical Reports Server (NTRS)

Hudson, C. M.; Newman, J. C., Jr.

1973-01-01

A study was made to determine the effects of specimen thickness on fatigue crack growth and fracture behavior of 7075-T6 and 7178-T6 aluminum alloy sheet and plate. Specimen thicknesses ranged from 5.1 to 12.7 mm (0.20 to 0.50 in.) for 7075-T6 and from 1.3 to 6.4 mm (0.05 to 0.25 in.) for 7178-T6. The stress ratios R used in the crack growth experiments were 0.02 and 0.50. For 7075-T6, specimen thickness had relatively little effect on fatigue-crack growth. However, the fracture toughness of the thickness of the thickest gage of 7075-T6 was about two-thirds of the fracture toughness of the thinner gages of 7075-T6. For 7178-T6, fatigue cracks generally grew somewhat faster in the thicker gages than in the thinnest gage. The fracture toughness of the thickest gage of 7178-T6 was about two-thirds of the fracture toughness of the thinner gages of 7178-T6. Stress intensity methods were used to analyze the experimental results. For a given thickness and value of R, the rate of fatigue crack growth was essentially a single-valued function of the stress intensity range for 7075-T6 and 7178-T6. An empirical equation developed by Forman, Kearney, and Engle fit the 7075-T6 and 7178-T6 crack growth data reasonably well.

Effect of service usage on tensile, fatigue, and fracture properties of 7075-T6 and 7178-T6 aluminum alloys

NASA Technical Reports Server (NTRS)

Everett, R. A., Jr.

1975-01-01

A study has been made to determine the effects of extensive service usage on some basic material properties of 7075-T6 and 7178-T6 aluminum alloy materials. The effects of service usage were determined by comparing material properties for new material (generally obtained from the literature) with those for material cut from the center wing box of a C-130B transport airplane with 6385 flight-hours of service. The properties investigated were notched and unnotched fatigue strengths, fatigue-crack-growth rate, fracture toughness, and tensile properties. For the properties investigated and the parameter ranges considered (crack length, stress ratio, etc.), the results obtained showed no significant difference between service and new materials.

Low velocity impact of 6082-T6 aluminum plates

NASA Astrophysics Data System (ADS)

Mocian, Oana Alexandra; Constantinescu, Dan Mihai; Sandu, Marin; Sorohan, Ştefan

2018-02-01

The low velocity domain covers vehicle impacts, ship collisions and even accidentally tool drops. Even though more and more research is needed into these fields, most of the papers concerning impact problems focus on impact at medium and high velocities. Understanding the behavior of structures subjected to low velocity impact is of major importance when referring to impact resistance and damage tolerance. The paper presents an experimental and numerical investigation on the low velocity behavior of 6082-T6 aluminum plates. Impact tests were performed using an Instron Ceast 9340 drop-weight testing machine. In the experimental procedure, square plates were mounted on a circular support, fixed with a pneumatic clamping system and impacted with a hemispherical steel projectile. Specimens were impacted at constant weight and different impact velocities. The effect of different impact energies was investigated. The impact event was then simulated using the nonlinear finite element code LS_DYNA in order to determine the effect of strain rate upon the mechanical behavior of the aluminum plates. Moreover, in order to capture the exact behavior of the material, a special attention has been given to the selection of the correct material model and its parameters, which, in large extent, depend on the observed behavior of the aluminum plate during the test and the actual response of the plate under simulation. The numerical predictions are compared with the experimental observations and the applicability of the numerical model for further researches is analyzed.

Higher Magnification Imaging of the Polished Aluminum Collector Returned from the Genesis Mission

NASA Technical Reports Server (NTRS)

Rodriquez, Melissa C.; Burkett, P. J.; Allton, J. H.

2011-01-01

The polished aluminum collector (previously referred to as the polished aluminum kidney) was intended for noble gas analysis for the Gene-sis mission. The aluminum collector, fabricated from alloy 6061T, was polished for flight with alumina, then diamond paste. Final cleaning was performed by soak-ing and rinsing with hexane, then isopropanol, and last-ly megasonically energized ultrapure water prior to installation. It was mounted inside the collector canister on the thermal shield at JSC in 2000. The polished aluminum collector was not surveyed microscopically prior to flight.

Laser-initiated combustion studies of selected aluminum, copper, iron, and nickel alloys

NASA Technical Reports Server (NTRS)

Bransford, J. W.; Clark, A. F.

1981-01-01

The results of combustion studies at atmospheric pressure on ten metal alloys are presented. The alloys studied were aluminum alloys 1100, 2219, 6061, and tensile-50; 304, 347 and 21-6-9 stainless steel; inconel 600; beryllium copper and a bronze. It was found that once ignition was achieved all alloys would generally burn to completion. The overall combustion process appears to obey a first order rate process. Preliminary conclusions are presented along with recommendations for future work.

Nugget Structure Evolution with Rotation Speed for High-Rotation-Speed Friction-Stir-Welded 6061 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Zhang, H. J.; Wang, M.; Zhu, Z.; Zhang, X.; Yu, T.; Wu, Z. Q.

2018-03-01

High-rotation-speed friction stir welding (HRS-FSW) is a promising technique to reduce the welding loads during FSW and thus facilitates the application of FSW for in situ fabrication and repair. In this study, 6061 aluminum alloy was friction stir welded at high-rotation speeds ranging from 3000 to 7000 rpm at a fixed welding speed of 50 mm/min, and the effects of rotation speed on the nugget zone macro- and microstructures were investigated in detail in order to illuminate the process features. Temperature measurements during HRS-FSW indicated that the peak temperature did not increase consistently with rotation speed; instead, it dropped remarkably at 5000 rpm because of the lowering of material shear stress. The nugget size first increased with rotation speed until 5000 rpm and then decreased due to the change of the dominant tool/workpiece contact condition from sticking to sliding. At the rotation speed of 5000 rpm, where the weld material experienced weaker thermal effect and higher-strain-rate plastic deformation, the nugget exhibited relatively small grain size, large textural intensity, and high dislocation density. Consequently, the joint showed superior nugget hardness and simultaneously a slightly low tensile ductility.

Measurement and analysis of applied power, forces and material response in friction stir welding of aluminum alloy 6061

NASA Astrophysics Data System (ADS)

Avila, Ricardo E.

The process of Friction Stir Welding (FSW) 6061 aluminum alloy is investigated, with focus on the forces and power being applied in the process and the material response. The main objective is to relate measurements of the forces and power applied in the process with mechanical properties of the material during the dynamic process, based on mathematical modeling and aided by computer simulations, using the LS-DYNA software for finite element modeling. Results of measurements of applied forces and power are presented. The result obtained for applied power is used in the construction of a mechanical variational model of FSW, in which minimization of a functional for the applied torque is sought, leading to an expression for shear stress in the material. The computer simulations are performed by application of the Smoothed Particle Hydrodynamics (SPH) method, in which no structured finite element mesh is used to construct a spatial discretization of the model. The current implementation of SPH in LS-DYNA allows a structural solution using a plastic kinematic material model. This work produces information useful to improve understanding of the material flow in the process, and thus adds to current knowledge about the behavior of materials under processes of severe plastic deformation, particularly those processes in which deformation occurs mainly by application of shear stress, aided by thermoplastic strain localization and dynamic recrystallization.

Synthesis and wear behavior of aluminum 6061 alloy reinforced with carbon nanotubes

NASA Astrophysics Data System (ADS)

Khalil, Abdullah

In the present work, Al6061 alloy was uniformly reinforced with 0.5, 0.75, 1 and 2 wt. % Carbon Nanotubes (CNTs) using two way dispersion method. For consolidation, Spark Plasma Sintering (SPS) was used which resulted in very high densification for the matrix as well as composite. Results showed that addition of CNTs lead to increased hardness of the material and maximum hardness was found for 1 wt. % CNTs. So this composition was selected for detailed wear analysis. Pin-on-disk wear tests were conducted for the monolithic Al6061 and the composite at a constant speed of 0.5 m/s with varying load from 5 N to 30 N under dry sliding conditions using AISI 4140 steel disk as a counterface. The composite displayed lower wear rate and friction coefficient at lower levels of applied stress (0.175 to 0.525 MPa). Under higher stresses (0.700 to 1.050 MPa), the increased brittleness and porosity of the composite caused severe fracturing and delamination resulting in excessive wear rate and friction coefficient for the composite as compared to monolithic Al6061. The transition from mild to severe wear regime in composite occurred also at lower stress as compared to monolith. Analysis of the worn surfaces revealed abrasion as the dominant wear mechanism for both the materials at lower stresses. At higher stress levels, adhesion was found to be dominant in monolithic Al6061 whereas in composite, excessive sub-surface fracturing and delamination was mainly observed.

Treatments To Produce Stabilized Aluminum Mirrors for Cryogenic Uses

NASA Technical Reports Server (NTRS)

Zewari, Wahid; Barthelmy, Michael; Ohl, Raymond

2005-01-01

Five metallurgical treatments have been tested as means of stabilizing mirrors that are made of aluminum alloy 6061 and are intended for use in cryogenic applications. Aluminum alloy 6061 is favored as a mirror material by many scientists and engineers. Like other alloys, it shrinks upon cool-down from room temperature to cryogenic temperature. This shrinkage degrades the optical quality of the mirror surfaces. Hence, the metallurgical treatments were tested to determine which one could be most effective in minimizing the adverse optical effects of cooldown to cryogenic temperatures. Each of the five metallurgical treatments comprises a multistep process, the steps of which are interspersed with the steps of the mirror-fabrication process. The five metallurgical-treatment/fabrication.- process combinations were compared with each other and with a benchmark fabrication process, in which a mirror is made from an alloy blank by (1) symmetrical rough machining, (2) finish machining to within 0.006 in. (. 0.15 mm) of final dimensions, and finally (3) diamond turning to a mirror finish.

Effects of Forged Stock and Pure Aluminum Coating on Cryogenic Performance of Heat Treated Aluminum Mirrors

NASA Technical Reports Server (NTRS)

Toland, Ronald W.; Ohl, Raymond G.; Barthelmy, Michael P.; Zewari, S. Wahid; Greenhouse, Matthew A.; MacKenty, John W.

2003-01-01

We present the results of an on-going test program designed to empirically determine the effects of different stress relief procedures for aluminum mirrors. Earlier test results identified a preferred heat treatment for flat and spherical mirrors diamond turned from blanks cut out of Al 6061-T651 plate stock. Further tests have been performed on mirrors from forged stock and one set from plate stock coated with Alumiplate(trademark) aluminum coating to measure the effect of these variables on cryogenic performance. The mirrors are tested for figure error and radius of curvature at room temperature and at 80 K for three thermal cycles. We correlate the results of our optical testing with heat treatment and metallographic data.

Tritium migration to the surfaces of Type 316 stainless steel; aluminum 6061; and oxygen-free, high-conductivity copper

DOE PAGES

Sharpe, M.; Shmayda, W. T.; Schroder, W. U.

2016-05-25

The migration of tritium to the surfaces of aluminum 6061, oxygen-free, high-conductivity copper (OFHC), and stainless-steel 316 from the bulk metal was studied using low-pressure Tonks–Langmuir argon plasma. The plasma is shown to be effective at removing tritium from metal surfaces in a controlled manner. Tritium is removed in decreasing quantities with successive plasma exposures, which suggests a depletion of the surface and near-surface tritium inventories. A diffusion model was developed to predict tritium migration from the bulk and its accumulation in the water layers present on the metal surface. The model reproduces the rate of tritium re-growth on themore » surface for all three metals and can be used to calculate the triton solubility in the water layers present on metal surfaces. The ratio of surface-to-bulk solubilities at the water-layer/bulk-metal interface uniquely determines the concentration ratio between these two media. Removing the tritium-rich water layers induces tritium to migrate from the bulk to the surface. Furthermore, this process is driven by a concentration gradient that develops in the bulk because of the perturbation on the surface.« less

The young's modulus of 1018 steel and 67061-T6 aluminum measured from quasi-static to elastic precursor strain-rates

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rae, Philip J; Trujillo, Carl; Lovato, Manuel

2009-01-01

The assumption that Young's modulus is strain-rate invariant is tested for 6061-T6 aluminium alloy and 1018 steel over 10 decades of strain-rate. For the same billets of material, 3 quasi-static strain-rates are investigated with foil strain gauges at room temperature. The ultrasonic sound speeds are measured and used to calculate the moduli at approximately 10{sup 4} s{sup -1}. Finally, ID plate impact is used to generate an elastic pre-cursor in the alloys at a strain-rate of approximately 10{sup 6} s{sup -1} from which the longitudinal sound speed may be obtained. It is found that indeed the Young's modulus is strain-ratemore » independent within the experimental accuracy.« less

Corrosion Inhibition of Sodium Benzoate on Aluminum Alloys in Tropical Seawater

NASA Astrophysics Data System (ADS)

Rosliza, R.; Senin, H. B.

2008-05-01

The corrosion inhibition of aluminum and its alloys is the subject of remarkable technological importance due to their increased industrial applications. This paper reports the results of the corrosion inhibition properties of AA6061 and AA6063 aluminum alloys in tropical seawater using sodium benzoate as an inhibitor. It was found that the corrosion inhibition occurred through the adsorption on the surfactant on the metal surface without modifying the mechanism of corrosion processes.

Hot deformation behaviors and processing maps of B{sub 4}C/Al6061 neutron absorber composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, Yu-Li

In this study, the hot deformation behaviors of 30 wt.% B{sub 4}C/Al6061 neutron absorber composites (NACs) have been investigated by conducting isothermal compression tests at temperatures ranging from 653 K to 803 K and strain rates from 0.01 to 10 s{sup −1}. It was found that, during hot compression, the B{sub 4}C/Al6061 NACs exhibited a steady flow characteristic which can be expressed by the Zener-Hollomon parameter as a hyperbolic-sine function of flow stress. High average activation energy (185.62 kJ/mol) of B{sub 4}C/Al6061 NACs is noted in current study owing to the high content of B{sub 4}C particle. The optimum hotmore » working conditions for B{sub 4}C/Al6061 NACs are found to be 760–803 K/0.01–0.05 s{sup −1} based on processing map and microstructure evolution. Typical material instabilities are thought to be attributed to void formation, adiabatic shear bands (ASB), particle debonding, and matrix cracking. Finally, the effect of the plastic deformation zones (PDZs) on the microstructure evolution in this 30 wt.% B{sub 4}C/Al6061 composite is found to be very important. - Highlights: •The hot deformation behavior of the 30 wt.% B{sub 4}C/Al6061 NACs was first analyzed. •The 3D efficiency map and the instability map are developed. •The optimum hot working conditions were identified and validated by SEM and TEM. •The hot deformation schematic diagram of 30 wt.% B{sub 4}C/Al6061 NACs is developed.« less

Formability analysis of aluminum alloys through deep drawing process

NASA Astrophysics Data System (ADS)

Pranavi, U.; Janaki Ramulu, Perumalla; Chandramouli, Ch; Govardhan, Dasari; Prasad, PVS. Ram

2016-09-01

Deep drawing process is a significant metal forming process used in the sheet metal forming operations. From this process complex shapes can be manufactured with fewer defects. Deep drawing process has different effectible process parameters from which an optimum level of parameters should be identified so that an efficient final product with required mechanical properties will be obtained. The present work is to evaluate the formability of Aluminum alloy sheets using deep drawing process. In which effects of punch radius, lubricating conditions, die radius, and blank holding forces on deep drawing process observed for AA 6061 aluminum alloy sheet of 2 mm thickness. The numerical simulations are performed for deep drawing of square cups using three levels of aforesaid parameters like lubricating conditions and blank holding forces and two levels of punch radii and die radii. For numerical simulation a commercial FEM code is used in which Hollomon's power law and Hill's 1948 yield criterions are implemented. The deep drawing setup used in the FEM code is modeled using a CAD tool by considering the modeling requirements from the literature. Two different strain paths (150x150mm and 200x200mm) are simulated. Punch forces, thickness distributions and dome heights are evaluated for all the conditions. In addition failure initiation and propagation is also observed. From the results, by increasing the coefficient of friction and blank holding force, punch force, thickness distribution and dome height variations are observed. The comparison has done and the optimistic parameters were suggested from the results. From this work one can predict the formability for different strain paths without experimentation.

High temperature dynamic modulus and damping of aluminum and titanium matrix composites

NASA Technical Reports Server (NTRS)

Dicarlo, J. A.; Maisel, J. E.

1979-01-01

Dynamic modulus and damping capacity property data were measured from 20 to over 500 C for unidirectional B/Al (1100), B/Al (6061), B/SiC/Al (6061), Al2O3/Al, SiC/Ti-6Al-4V, and SiC/Ti composites. The measurements were made under vacuum by the forced vibration of composite bars at free-free flexural resonance near 2000 Hz and at amplitudes below 0.000001. Whereas little variation was observed in the dynamic moduli of specimens with approximately the same fiber content (50 percent), the damping of B/Al composites was found at all temperatures to be significantly greater than the damping of the Al2O3/Al and SiC/Ti composites. For those few situations where slight deviations from theory were observed, the dynamic data were examined for information concerning microstructural changes induced by composite fabrication and thermal treatment. The 270 C damping peak observed in B/Al (6061) composites after heat treatment above 460 C appears to be the result of a change in the 6061 aluminum alloy microstructure induced by interaction with the boron fibers. The growth characteristics of the damping peak suggest its possible value for monitoring fiber strength degration caused by excess thermal treatment during B/Al (6061) fabrication and use.

Ballistic Experiments with Titanium and Aluminum Targets

DOE Office of Scientific and Technical Information (OSTI.GOV)

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 ballisticmore » 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.« less

Aluminum Target Dissolution in Support of the Pu-238 Program

DOE Office of Scientific and Technical Information (OSTI.GOV)

McFarlane, Joanna; Benker, Dennis; DePaoli, David W

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 datamore » 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.« less

45 CFR 606.1 - Purpose.

Code of Federal Regulations, 2013 CFR

2013-10-01

... 45 Public Welfare 3 2013-10-01 2013-10-01 false Purpose. 606.1 Section 606.1 Public Welfare Regulations Relating to Public Welfare (Continued) NATIONAL SCIENCE FOUNDATION ENFORCEMENT OF NONDISCRIMINATION ON THE BASIS OF HANDICAP IN PROGRAMS OR ACTIVITIES CONDUCTED BY THE NATIONAL SCIENCE FOUNDATION § 606.1 Purpose. The purpose of this part is to...

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

Building A Simulation Model For The Prediction Of Temperature Distribution In Pulsed Laser Spot Welding Of Dissimilar Low Carbon Steel 1020 To Aluminum Alloy 6061

NASA Astrophysics Data System (ADS)

Yousef, Adel K. M.; Taha, Ziad. A.; Shehab, Abeer A.

2011-01-01

This paper describes the development of a computer model used to analyze the heat flow during pulsed Nd: YAG laser spot welding of dissimilar metal; low carbon steel (1020) to aluminum alloy (6061). The model is built using ANSYS FLUENT 3.6 software where almost all the environments simulated to be similar to the experimental environments. A simulation analysis was implemented based on conduction heat transfer out of the key hole where no melting occurs. The effect of laser power and pulse duration was studied. Three peak powers 1, 1.66 and 2.5 kW were varied during pulsed laser spot welding (keeping the energy constant), also the effect of two pulse durations 4 and 8 ms (with constant peak power), on the transient temperature distribution and weld pool dimension were predicated using the present simulation. It was found that the present simulation model can give an indication for choosing the suitable laser parameters (i.e. pulse durations, peak power and interaction time required) during pulsed laser spot welding of dissimilar metals.

Microstructure and Mechanical Property Change During FSW and GTAW of Al6061 Alloy

NASA Astrophysics Data System (ADS)

Fahimpour, V.; Sadrnezhaad, S. K.; Karimzadeh, F.

2013-05-01

The variation of morphology and mechanical properties of Al6061 automotive aluminum alloy due to friction stir welding (FSW) and gas tungsten arc welding (GTAW) was investigated by optical metallography, scanning electron microscopy, microhardness measurement, X-ray diffraction, tensile testing, and fractography. The center-line dendrite emergence and microhardness reduction in the heat-affected zone were observed in the GTAW process. Although similar microhardness reduction with respect to the base metal was observed in the FSW samples, higher HVs were obtained for the FSW rather than the GTAW process at almost all heat-affected locations. Ultimate tensile strengths of the FSW and the GTAW samples in the transverse direction were ~0.57 and ~0.35 of the base metal, respectively. Post-weld aging improved the strength, but reduced the ductility of the welding.

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

Influences of post weld heat treatment on tensile strength and microstructure characteristics of friction stir welded butt joints of AA2014-T6 aluminum alloy

NASA Astrophysics Data System (ADS)

Rajendran, C.; Srinivasan, K.; Balasubramanian, V.; Balaji, H.; Selvaraj, P.

2016-08-01

Friction stir welded (FSWed) joints of aluminum alloys exhibited a hardness drop in both the advancing side (AS) and retreating side (RS) of the thermo-mechanically affected zone (TMAZ) due to the thermal cycle involved in the FSW process. In this investigation, an attempt has been made to overcome this problem by post weld heat treatment (PWHT) methods. FSW butt (FSWB) joints of Al-Cu (AA2014-T6) alloy were PWHT by two methods such as simple artificial aging (AA) and solution treatment followed by artificial aging (STA). Of these two treatments, STA was found to be more beneficial than the simple aging treatment to improve the tensile properties of the FSW joints of AA2014 aluminum alloy.

Experimental transient and permanent deformation studies of steel-sphere-impacted or explosively-impulsed aluminum panels

NASA Technical Reports Server (NTRS)

Witmer, E. A.; Merlis, F.; Rodal, J. J. A.; Stagliano, T. R.

1977-01-01

The sheet explosive loading technique (SELT) was employed to obtain elastic-plastic, large deflection 3-d transient and/or permanent strain data on simple well defined structural specimens and materials: initially-flat 6061-T651 aluminum panels with all four sides ideally clamped via integral construction. The SELT loading technique was chosen since it is both convenient and provides "forcing function information" of small uncertainty. These data will be useful for evaluating pertinent 3-d structural response prediction methods.

Experimental processing and the effects of cenosphere on some mechanical properties of Al6061-SiC composites

NASA Astrophysics Data System (ADS)

Ashoka, E.; Sharanaprabhu, C. M.; Krishnaraja, G. Kodancha; Kudari, S. K.

2018-04-01

In this paper, stir casting technique was utilized to fabricate the hybrid Aluminium alloy (Al 6061) metal matrix reinforced with silicon carbide (SiC) and cenosphere particulates. An Al6061-SiC-Cenosphere hybrid composite is selected with 3wt% of silicon carbide and 3wt%, 6wt% and 9wt% proportions of cenosphere particulates. The uniform distribution of these two reinforcement particulates in Al6061matrix was achieved by stirring and pouring the hybrid composite mixture into the steel mould to accomplish the rectangular shaped casting. These various hybrid composites were studied with respect to its microstructure and some mechanical properties. The rectangular shaped casting of various hybrid composites was machined according to ASTM tensile specimens standards to estimate some mechanical properties. For various cast hybrid composites a comparative study is done with respect to modulus of elasticity, yield stress, percentage elongation and microhardness. Finally, the distribution of particulates and the nature of the tensile specimen fractured surface of various hybrid composites were understood using scanning electron microscope.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Randolph, B.

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 describedmore » along with some considerations for future composite liners requirements in the HEDP Program.« less

Friction Stir Processing of Copper-Coated SiC Particulate-Reinforced Aluminum Matrix Composite

PubMed Central

Huang, Chih-Wei; Aoh, Jong-Ning

2018-01-01

In the present work, we proposed a novel friction stir processing (FSP) to produce a locally reinforced aluminum matrix composite (AMC) by stirring copper-coated SiC particulate reinforcement into Al6061 alloy matrix. Electroless-plating process was applied to deposit the copper surface coating on the SiC particulate reinforcement for the purpose of improving the interfacial adhesion between SiC particles and Al matrix. The core-shell SiC structure provides a layer for the atomic diffusion between aluminum and copper to enhance the cohesion between reinforcing particles and matrix on one hand, the dispersion of fine copper in the Al matrix during FSP provides further dispersive strengthening and solid solution strengthening, on the other hand. Hardness distribution and tensile results across the stir zone validated the novel concept in improving the mechanical properties of AMC that was realized via FSP. Optical microscope (OM) and Transmission Electron Microscopy (TEM) investigations were conducted to investigate the microstructure. Energy dispersive spectrometer (EDS), electron probe micro-analyzer (EPMA), and X-ray diffraction (XRD) were explored to analyze the atomic inter-diffusion and the formation of intermetallic at interface. The possible strengthening mechanisms of the AMC containing Cu-coated SiC particulate reinforcement were interpreted. The concept of strengthening developed in this work may open a new way of fabricating of particulate reinforced metal matrix composites. PMID:29652846

Evaluation Of Four Welding Arc Processes Applied To 6061 Aluminium Alloy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Benoit, A.; Laboratoire de Genie des Materiaux et Procedes Associes; Paillard, P.

At a time when greenhouse gas emissions must be reduced, the use of the aluminium alloys is expanding, in particular in the transportation industry. In order to extend the possibilities of aluminium assembly design, new Metal Inert Gas (MIG) welding processes have been conceived. They work at lower temperatures than usual arc processes (classic MIG or Tungsten Inert Gas). This study compares four arc welding processes, applied to the 6061 aluminium alloy. These four weld processes have been studied through the metallurgical analysis of the weld beads. Metallography, micro-hardness testings, X Ray radiography have been carried out on the producedmore » weld beads. The processes are classified according to the quality of the beads like geometry of beads, size of the heat affected zone and presence of defects.« less

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.

Carbon Nanotube-Reinforced Aluminum Matrix Composites Produced by High-Energy Ball Milling

NASA Astrophysics Data System (ADS)

Travessa, Dilermando N.; da Rocha, Geovana V. B.; Cardoso, Kátia R.; Lieblich, Marcela

2017-05-01

Although multiwall carbon nanotubes (MWCNT) are promising materials to strengthen lightweight aluminum matrix composites, their dispersion into the metallic matrix is challenge. In the present work, MWCNT were dispersed into age-hardenable AA6061 aluminum alloy by high-energy ball milling and the blend was subsequently hot-extruded. The composite bars obtained were heat-treated by solution heat treatment at 520 °C and artificially aged at 177 °C for 8 h, in order to reach the T6 temper. Special attention was given to the integrity of the MWCNT along the entire composite production. The microstructure of the obtained bars was evaluated by optical and scanning electron microscopy, and the mechanical properties were evaluated by Vickers microhardness tests. Raman spectroscopy, x-ray diffraction and transmission electron microscopy were employed to evaluate the structural integrity of MWCNT. It was found that milling time is critical to reach a proper dispersion of the reinforcing phase. The composite hardness increased up to 67% with the dispersion of 2% in weight of MWCNT, when comparing with un-reinforced bars produced by similar route. However, age hardening was not observed in composite bars after heat treatment. It was also found that MWCNT continuously degraded along the process, being partially converted into Al4C3 in the final composite.

Quasi-Static Tensile Stress-Strain Curves. 1, 2024-T3510 Aluminum Alloy

DTIC Science & Technology

1976-02-01

herein were conducted as part of the Core Materials Program of the Solid Mechanics Branch of the Terminal Ballistics Laboratory. The objective of this...describing the results of the Core Materials Program, covers quasi-static terVsile tests of 2024-T3510 aluminum E’lloy. The results include Young’s...11.31 4 580.6 9.94 TABLE II MATERIAL PROPERTIES OF 2024-T3510 ALUMINUM ALLOYa Results of Results of Results of Tensileb Compres ion Sonic Testing

Comparison of dry sliding wear and friction behavior of Al6061/SiC PMMC with Al6061 alloy

NASA Astrophysics Data System (ADS)

Murthy, A. G. Shankara; Mehta, N. K.; Kumar, Pradeep

2018-04-01

Dry sliding wear and friction behavior tests were conducted on Al6061 alloy and Al6061/SiC particle reinforced metal matrix composites (PMMCs) reinforced with fine particles of 5, 10 and 15 µm size having 5,7.5 and 10% weight content fabricated by stir-casting route. Cylindrical sample pins produced as per ASTM standard were tested for various parameters like SiC size, weight content, load and sliding distance affecting the wear rate or resistance and friction. Results indicated that Al6061/SiCp composites exhibited good wear resistance compared to Al6061 alloy for the tested parameters.

45 CFR 606.1 - Purpose.

Code of Federal Regulations, 2010 CFR

2010-10-01

... 45 Public Welfare 3 2010-10-01 2010-10-01 false Purpose. 606.1 Section 606.1 Public Welfare Regulations Relating to Public Welfare (Continued) NATIONAL SCIENCE FOUNDATION ENFORCEMENT OF NONDISCRIMINATION ON THE BASIS OF HANDICAP IN PROGRAMS OR ACTIVITIES CONDUCTED BY THE NATIONAL SCIENCE FOUNDATION...

A Comparative Study on Permanent Mold Cast and Powder Thixoforming 6061 Aluminum Alloy and Sicp/6061Al Composite: Microstructures and Mechanical Properties.

PubMed

Zhang, Xuezheng; Chen, Tijun; Qin, He; Wang, Chong

2016-05-24

Microstructural and mechanical characterization of 10 vol% SiC particles (SiC p ) reinforced 6061 Al-based composite fabricated by powder thixoforming (PTF) was investigated in comparison with the PTF and permanent mold cast (PMC) 6061 monolithic alloys. The results reveal that the microstructure of the PMC alloy consists of coarse and equiaxed α dendrites and interdendritic net-like eutectic phases. However, the microstructure of the PTF composite, similar to that of the PTF alloy, consists of near-spheroidal primary particles and intergranular secondarily solidified structures except SiC p , which are distributed in the secondarily solidified structures. The eutectics amount in the PTF materials is distinctly lower than that in the PMC alloy, and the microstructures of the former materials are quite compact while that of the latter alloy is porous. Therefore, the PTF alloy shows better tensile properties than the PMC alloy. Owing to the existence of the SiC reinforcing particles, the PTF composite attains an ultimate tensile strength and yield strength of 230 MPa and 128 MPa, representing an enhancement of 27.8% and 29.3% than those (180 MPa and 99 MPa) of the PTF alloy. A modified model based on three strengthening mechanisms was proposed to calculate the yield strength of the PTF composite. The obtained theoretical results were quite consistent with the experimental data.

Improving 6061-Al Grain Growth and Penetration across HIP-Bonded Clad Interfaces in Monolithic Fuel Plates: Initial Studies

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hackenberg, Robert E.; McCabe, Rodney J.; Montalvo, Joel D.

2013-05-06

Grain penetration across aluminum-aluminum cladding interfaces in research reactor fuel plates is desirable and was obtained by a legacy roll-bonding process, which attained 20-80% grain penetration. Significant grain penetration in monolithic fuel plates produced by Hot Isostatic Press (HIP) fabrication processing is equally desirable but has yet to be attained. The goal of this study was to modify the 6061-Al in such a way as to promote a much greater extent of crossinterface grain penetration in monolithic fuel plates fabricated by the HIP process. This study documents the outcomes of several strategies attempted to attain this goal. The grain responsemore » was characterized using light optical microscopy (LOM) electron backscatter diffraction (EBSD) as a function of these prospective process modifications done to the aluminum prior to the HIP cycle. The strategies included (1) adding macroscopic gaps in the sandwiches to enhance Al flow, (2) adding engineering asperities to enhance Al flow, (3) adding stored energy (cold work), and (4) alternative cleaning and coating. Additionally, two aqueous cleaning methods were compared as baseline control conditions. The results of the preliminary scoping studies in all the categories are presented. In general, none of these approaches were able to obtain >10% grain penetration. Recommended future work includes further development of macroscopic grooving, transferred-arc cleaning, and combinations of these with one another and with other processes.« less

Bilayer lift-off process for aluminum metallization

NASA Astrophysics Data System (ADS)

Wilson, Thomas E.; Korolev, Konstantin A.; Crow, Nathaniel A.

2015-01-01

Recently published reports in the literature for bilayer lift-off processes have described recipes for the patterning of metals that have recommended metal-ion-free developers, which do etch aluminum. We report the first measurement of the dissolution rate of a commercial lift-off resist (LOR) in a sodium-based buffered commercial developer that does not etch aluminum. We describe a reliable lift-off recipe that is safe for multiple process steps in patterning thin (<100 nm) and thick aluminum devices with micron-feature sizes. Our patterning recipe consists of an acid cleaning of the substrate, the bilayer (positive photoresist/LOR) deposition and development, the sputtering of the aluminum film along with a palladium capping layer and finally, the lift-off of the metal film by immersion in the LOR solvent. The insertion into the recipe of postexposure and sequential develop-bake-develop process steps are necessary for an acceptable undercut. Our recipe also eliminates any need for accompanying sonication during lift-off that could lead to delamination of the metal pattern from the substrate. Fine patterns were achieved for both 100-nm-thick granular aluminum/palladium bilayer bolometers and 500-nm-thick aluminum gratings with 6-μm lines and 4-μm spaces.

Diffusion bonded boron/aluminum spar-shell fan blade

NASA Technical Reports Server (NTRS)

Carlson, C. E. K.; Cutler, J. L.; Fisher, W. J.; Memmott, J. V. W.

1980-01-01

Design and process development tasks intended to demonstrate composite blade application in large high by-pass ratio turbofan engines are described. Studies on a 3.0 aspect radio space and shell construction fan blade indicate a potential weight savings for a first stage fan rotor of 39% when a hollow titanium spar is employed. An alternate design which featured substantial blade internal volume filled with titanium honeycomb inserts achieved a 14% potential weight savings over the B/M rotor system. This second configuration requires a smaller development effort and entails less risk to translate a design into a successful product. The feasibility of metal joining large subsonic spar and shell fan blades was demonstrated. Initial aluminum alloy screening indicates a distinct preference for AA6061 aluminum alloy for use as a joint material. The simulated airfoil pressings established the necessity of rigid air surfaces when joining materials of different compressive rigidities. The two aluminum alloy matrix choices both were successfully formed into blade shells.

Direct-reading design charts for 75S-T6 aluminum-alloy flat compression panels having longitudinal extruded Z-section stiffeners

NASA Technical Reports Server (NTRS)

Hickman, William A; Dow, Norris F

1951-01-01

Direct-reading design charts are presented for 75S-T6 aluminum-alloy flat compression panels having longitudinal extruded Z-section stiffeners. These charts, which cover a wide range of proportions, make possible the direct determination of the stress and all panel dimensions required to carry a given intensity of loading with a given skin thickness and effective length of panel.

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.

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

Dissolution and Separation of Aluminum and Aluminosilicates

DOE PAGES

McFarlane, Joanna; Benker, Dennis; DePaoli, David W.; ...

2015-12-19

The selection of an aluminum alloy for target irradiation affects post-irradiation target dissolution and separations. Recent tests with aluminum alloy 6061 yielded greater than expected precipitation in the dissolver, forming up to 10 wt.% solids of aluminum hydroxides and aluminosilicates. Aluminosilicate dissolution presents challenges in a number of different areas, metals extraction from minerals, flyash treatment, and separations from aluminum alloys. We present experimental work that attempts to maximize dissolution of aluminum metal, 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 amore » function of time and temperature, using X-ray diffraction. Solutions have been analyzed using wet chemical methods and X-ray fluorescence. Our data have been compared with published calculations of aluminum phase diagrams. Approaches are given to enhance the dissolution of aluminum and aluminosilicate phases in caustic solution.« less

A Microsample Tensile Test Application: Local Strength of Impact Welds Between Sheet Metals

NASA Astrophysics Data System (ADS)

Benzing, J. T.; He, M.; Vivek, A.; Taber, G. A.; Mills, M. J.; Daehn, G. S.

2017-03-01

Microsample tensile testing was conducted to evaluate the quality of impact welds created by vaporizing foil actuator welding. Tensile test samples with a gauge length of 0.6 mm were electro-discharge machined out of welds created between 1-mm-thick aluminum alloy type 6061 (AA6061) sheets and 6-mm-thick copper (Cu110) plates. Aluminum sheets were used as flyers, while copper plates acted as targets. Flyer sheets in T6 as well as T4 temper conditions were utilized to create welds. Some of the welds made with T4 temper flyers were heat treated to a T6 temper. It was found that the welds made with T4 temper flyers were slightly stronger (max. of 270 MPa) than those produced with T6 temper flyers. Generally, failure propagated in a brittle manner across the weld interface; however, elemental mapping reveals material transfer on either member of the welded system. This work proves the feasibility to apply microsample tensile testing to assess impact welding, even when conducted with flyer sheets of 1 mm or less, and provides insight that is complementary to other test methods.

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.

Replacement of steel parts with extruded aluminum alloys in an automobile

NASA Astrophysics Data System (ADS)

Daggula, Manikantha Reddy

Over the past years, vehicle emissions have shown a negative impact on environment and human health. A new strategy has been used by automakers to reduce a vehicle's weight which significantly reduce fuel consumption and C02 emissions. A very light car consumes very less fuel as it needs to overcome less inertia, decreasing the required power to movie the vehicle. Reducing weight is the easiest way to increase fuel economy and making it by just 10% can increase its efficiency 6 to 8 percent. For a normal scale 80% of vehicles weight is shared among chassis, power train and other exterior components. Almost 60% of the vehicles weight is comprised of steel and the remaining is with cast and extruded aluminum and magnesium alloys. Our main aim is to look for the parts like Fuel tank holder, Fuel filler neck, Turbo inlet assembly, and Brake lines, Dash board frame which are made from steel and replace them with extruded aluminum alloys, to analyze a conventional rear wheel aluminum drive shaft and replace it with a new design and with a new aluminum alloy. The current project involves dismantling an automobile and looking for feasible steel parts and making samples, analyzing the hardness of the samples. These parts are optimally analyzed using Ansys Finite element analysis tool, these parts are subjected to the constraints such as three-point bending, tensile testing, hydrostatic pressure and also torsional stress action on the drive shaft, the deformation and stress are observed in these parts. The results show the current steel parts can be replaced with 3000 series aluminum alloy and the drive shaft can be replaced with new design with 6061-T6 Al-alloy which decreases 25% of the shaft weight.

An evaluation of corrosion protection by two epoxy primers on 2219-T87 and 7075-T73 aluminum

NASA Technical Reports Server (NTRS)

Mendrek, M. J.

1992-01-01

A comparison of the corrosion protection provided by two amine epoxy primers was made using salt fog, alternate immersion, and total immersion as exposure media. The study is the result of a request to use an unqualified low volatile organic carbon (VOC) primer (AKZO 463-6-78) in place of the current primer (AKZO 463-6-3) because environmental regulations have eliminated use of the current primer in many states. Primed, scribed samples of 2219-T87 and 7075-T73 aluminum were exposed to 5-percent NaCl salt fog and 3.5-percent NaCl alternate immersion for a period of 90 days. In addition, electrode samples immersed in 3.5-percent NaCl were tested using electrochemical impedance spectroscopy (EIS). The EG&G model 368 ac impedance measurement system was used to monitor changing properties of AKZO 463-6-78 and AKZO 463-6-3 primed 2219-T87 aluminum for a period of 30 days. The response of the corroding system of a frequency scan can be modeled in terms of an equivalent circuit consisting of resistors and capacitors in a specific arrangement. Each resistor/capacitor combination represents physical processes taking place within the electrolyte, at the electrolyte/primer surface, within the coating, and at the coating/substrate surface. Values for the resistors and capacitors are assigned following a nonlinear least squares fit of the data to the equivalent circuit. Changes in the values of equivalent circuit parameters during the 30-day exposure allow assessment of the time to and mechanism of coating breakdown.

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.

A study of fatigue and fracture in 7075-T6 aluminum alloy in vacuum and air environments

NASA Technical Reports Server (NTRS)

Hudson, C. M.

1973-01-01

Axial load fatigue life, fatigue-crack propagation, and fracture toughness experiments were conducted on sheet specimens made of 7075-T6 aluminum alloy. These experiments were conducted at pressures ranging from atmospheric to 5 x 10 to the minus 8th torr. Analysis of the results from the fatigue life experiments indicated that for a given stress level, lower air pressures produced longer fatigue lives. At a pressure of 5 x 10 to the minus 8th torr fatigue lives were 15 or more times as long as at atmospheric pressure. Analysis of the results from the fatigue crack propagation experiments indicated that for small stress intensity factor ranges the fatigue crack propagation rates were up to twice as high at atmospheric pressure as in vacuum. The fracture toughness of 7075-T6 was unaffected by the vacuum environment. Fractographic examination showed that specimens tested in both vacuum and air developed fatigue striations. Considerably more striations developed on specimens tested at atmospheric pressure, however.

Fracture mechanics correlation of boron/aluminum coupons containing stress risers

NASA Technical Reports Server (NTRS)

Adsit, N. R.; Waszczak, J. P.

1975-01-01

The mechanical behavior of boron/aluminum near stress risers has been studied and reported. This effort was directed toward defining the tensile behavior of both unidirectional and (0/ plus or minus 45) boron/aluminum using linear elastic fracture mechanics (LEFM). The material used was 5.6-mil boron in 6061 aluminum, consolidated using conventional diffusion bonding techniques. Mechanical properties are reported for both unidirectional and (0/ plus or minus 45) boron/aluminum, which serve as control data for the fracture mechanics predictions. Three different flawed specimen types were studied. In each case the series of specimens remained geometrically similar to eliminate variations in finite size correction factors. The fracture data from these tests were reduced using two techniques. They both used conventional LEFM methods, but the existence of a characteristic flaw was assumed in one case and not the other. Both the data and the physical behavior of the specimens support the characteristic flaw hypothesis. Cracks were observed growing slowly in the (0/ plus or minus 45) laminates, until a critical crack length was reached at which time catastrophic failure occurred.

Flow and fracture behavior of aluminum alloy 6082-T6 at different tensile strain rates and triaxialities.

PubMed

Chen, Xuanzhen; Peng, Yong; Peng, Shan; Yao, Song; Chen, Chao; Xu, Ping

2017-01-01

This study aims to investigate the flow and fracture behavior of aluminum alloy 6082-T6 (AA6082-T6) at different strain rates and triaxialities. Two groups of Charpy impact tests were carried out to further investigate its dynamic impact fracture property. A series of tensile tests and numerical simulations based on finite element analysis (FEA) were performed. Experimental data on smooth specimens under various strain rates ranging from 0.0001~3400 s-1 shows that AA6082-T6 is rather insensitive to strain rates in general. However, clear rate sensitivity was observed in the range of 0.001~1 s-1 while such a characteristic is counteracted by the adiabatic heating of specimens under high strain rates. A Johnson-Cook constitutive model was proposed based on tensile tests at different strain rates. In this study, the average stress triaxiality and equivalent plastic strain at facture obtained from numerical simulations were used for the calibration of J-C fracture model. Both of the J-C constitutive model and fracture model were employed in numerical simulations and the results was compared with experimental results. The calibrated J-C fracture model exhibits higher accuracy than the J-C fracture model obtained by the common method in predicting the fracture behavior of AA6082-T6. Finally, the Scanning Electron Microscope (SEM) of fractured specimens with different initial stress triaxialities were analyzed. The magnified fractographs indicate that high initial stress triaxiality likely results in dimple fracture.

Flow and fracture behavior of aluminum alloy 6082-T6 at different tensile strain rates and triaxialities

PubMed Central

Chen, Xuanzhen; Peng, Shan; Yao, Song; Chen, Chao; Xu, Ping

2017-01-01

This study aims to investigate the flow and fracture behavior of aluminum alloy 6082-T6 (AA6082-T6) at different strain rates and triaxialities. Two groups of Charpy impact tests were carried out to further investigate its dynamic impact fracture property. A series of tensile tests and numerical simulations based on finite element analysis (FEA) were performed. Experimental data on smooth specimens under various strain rates ranging from 0.0001~3400 s-1 shows that AA6082-T6 is rather insensitive to strain rates in general. However, clear rate sensitivity was observed in the range of 0.001~1 s-1 while such a characteristic is counteracted by the adiabatic heating of specimens under high strain rates. A Johnson-Cook constitutive model was proposed based on tensile tests at different strain rates. In this study, the average stress triaxiality and equivalent plastic strain at facture obtained from numerical simulations were used for the calibration of J-C fracture model. Both of the J-C constitutive model and fracture model were employed in numerical simulations and the results was compared with experimental results. The calibrated J-C fracture model exhibits higher accuracy than the J-C fracture model obtained by the common method in predicting the fracture behavior of AA6082-T6. Finally, the Scanning Electron Microscope (SEM) of fractured specimens with different initial stress triaxialities were analyzed. The magnified fractographs indicate that high initial stress triaxiality likely results in dimple fracture. PMID:28759617

Interactions of satellite-speed helium atoms with satellite surfaces. 3: Drag coefficients from spatial and energy distributions of reflected helium atoms

NASA Technical Reports Server (NTRS)

Sharma, P. K.; Knuth, E. L.

1977-01-01

Spatial and energy distributions of helium atoms scattered from an anodized 1235-0 aluminum surface as well as the tangential and normal momentum accommodation coefficients calculated from these distributions are reported. A procedure for calculating drag coefficients from measured values of spatial and energy distributions is given. The drag coefficient calculated for a 6061 T-6 aluminum sphere is included.

Influence of tool geometry and processing parameters on welding defects and mechanical properties for friction stir welding of 6061 Aluminium alloy

NASA Astrophysics Data System (ADS)

Daneji, A.; Ali, M.; Pervaiz, S.

2018-04-01

Friction stir welding (FSW) is a form of solid state welding process for joining metals, alloys, and selective composites. Over the years, FSW development has provided an improved way of producing welding joints, and consequently got accepted in numerous industries such as aerospace, automotive, rail and marine etc. In FSW, the base metal properties control the material’s plastic flow under the influence of a rotating tool whereas, the process and tool parameters play a vital role in the quality of weld. In the current investigation, an array of square butt joints of 6061 Aluminum alloy was to be welded under varying FSW process and tool geometry related parameters, after which the resulting weld was evaluated for the corresponding mechanical properties and welding defects. The study incorporates FSW process and tool parameters such as welding speed, pin height and pin thread pitch as input parameters. However, the weld quality related defects and mechanical properties were treated as output parameters. The experimentation paves way to investigate the correlation between the inputs and the outputs. The correlation between inputs and outputs were used as tool to predict the optimized FSW process and tool parameters for a desired weld output of the base metals under investigation. The study also provides reflection on the effect of said parameters on a welding defect such as wormhole.

Tensile properties of SiC/aluminum filamentary composites - Thermal degradation effects

NASA Technical Reports Server (NTRS)

Skinner, A.; Koczak, M. J.; Lawley, A.

1982-01-01

Aluminium metal matrix composites with a low cost fiber, e.g. SiC, provide for an attractive combination of high elastic modulus and longitudinal strengths coupled with a low density. SiC (volume fraction 0.55)-aluminum (6061) systems have been studied in order to optimize fiber composite strength and processing parameters. A comparison of two SiC/aluminum composites produced by AVCO and DWA is provided. Fiber properties are shown to alter composite tensile properties and fracture morphology. The room temperature tensile strengths appear to be insensitive to thermal exposures at 500 C up to 150 h. The elastic modulus of the composites also appears to be stable up to 400 C, however variations in the loss modulus are apparent. The fracture morphology reflects the quality of the interfacial bond, fiber strengths and fiber processing.

Completion Report on the Corps of Engineers Structural Engineering Conference Held in Portland, Oregon on 23-28 June 1985.

DTIC Science & Technology

1986-03-01

The domes are fabricated from extruded 6061-T6 aluminum, 6 in. deep, wide flange struts, approximately 8 ft long, forming triangular structural...Ice Breaker - snack lines laid out poorly and bar dismantled too quickly. Not a lot of nearby food choices on evening and weekends. 12. Wednesday

Experimental studies on the tripping behavior of narrow T-stiffened flat plates subjected to hydrostatic pressure and underwater shock

NASA Technical Reports Server (NTRS)

Budweg, H. L.; Shin, Y. S.

1987-01-01

An experimental investigation was conducted to determine the static and dynamic responses of a specific stiffened flat plate design. The air-backed rectangular flat plates of 6061-T6 aluminum with an externally machined longitudinal narrow-flanged T-stiffener and clamped boundary conditions were subjected to static loading by water hydropump pressure and shock loading from an eight pound TNT charge detonated underwater. The dynamic test plate was instrumented to measure transient strains and free field pressure. The static test plate was instrumented to measure transient strains, plate deflection, and pressure. Emphasis was placed upon forcing static and dynamic stiffener tripping, obtaining relevant strain and pressure data, and studying the associated plate-stiffener behavior.

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.

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.

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

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.

All-aluminum-alloy UHV chamber for molecular beam epitaxy, 1

NASA Astrophysics Data System (ADS)

Suemitsu, M.; Miyamoto, N.

1984-03-01

The first all aluminum alloy (ex. JIS.6263-t6,2219-t87 etc) MBE chamber is constructed and described. After exposure to atmosphere, the chamber is drown to 10(-9) torr in 24 hours, and reaches an ultrahigh vacuum of 1.6x10(-10) torr by a 115 C, 24 bakeout process. The light weight and low cost as well as the short pump-down time and the law outgassing rate of the all aluminum alloy vacuum system seems to have a considerable applicative potentiality for equipment used in semiconductor ultrahigh vacuum processes.

Microstructural Characterization of the U-9.1Mo Fuel/AA6061 Cladding Interface in Friction-Bonded Monolithic Fuel Plates Irradiated in the RERTR-6 Experiment

NASA Astrophysics Data System (ADS)

Keiser, Dennis D.; Jue, Jan-Fong; Miller, Brandon; Gan, Jian; Robinson, Adam; Medvedev, Pavel; Madden, James; Wachs, Dan; Clark, Curtis; Meyer, Mitch

2015-09-01

Low-enrichment (235U < 20 pct) U-Mo monolithic fuel is being developed for use in research and test reactors. The earliest design for this fuel that was investigated via reactor testing consisted of a nominally U-10Mo fuel foil encased in AA6061 (Al-6061) cladding. For a fuel design to be deemed adequate for final use in a reactor, it must maintain dimensional stability and retain fission products throughout irradiation, which means that there must be good integrity at the fuel foil/cladding interface. To investigate the nature of the fuel/cladding interface for this fuel type after irradiation, fuel plates were fabricated using a friction bonding process, tested in INL's advanced test reactor (ATR), and then subsequently characterized using optical metallography, scanning electron microscopy, and transmission electron microscopy. Results of this characterization showed that the fuel/cladding interaction layers present at the U-Mo fuel/AA6061 cladding interface after fabrication became amorphous during irradiation. Up to two main interaction layers, based on composition, could be found at the fuel/cladding interface, depending on location. After irradiation, an Al-rich layer contained very few fission gas bubbles, but did exhibit Xe enrichment near the AA6061 cladding interface. Another layer, which contained more Si, had more observable fission gas bubbles. In the samples produced using a focused ion beam at the interaction zone/AA6061 cladding interface, possible indications of porosity/debonding were found, which suggested that the interface in this location is relatively weak.

Multiphase aluminum equations of state via density functional theory

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sjostrom, Travis; Crockett, Scott; Rudin, Sven

2016-10-03

We have performed density functional theory (DFT) based calculations for aluminum in extreme conditions of both pressure and temperature, up to five times compressed ambient density, and over 1 000 000 K in temperature. In order to cover such a domain, DFT methods including phonon calculations, quantum molecular dynamics, and orbital-free DFT are employed. Our results are then used to construct a SESAME equation of state for the aluminum 1100 alloy, encompassing the fcc, hcp, and bcc solid phases as well as the liquid regime. We also provide extensive comparison with experiment, and based on this we also provide amore » slightly modified equation of state for the aluminum 6061 alloy.« less

Manufacturing Systems Demonstration: Bimetallic Friction STIR Joining of AA6061 and High Hardness Steel

DTIC Science & Technology

2013-05-31

fusion welding and virtually eliminates the material porosity inherent with liquid alloy processes. Also because less heat is input to the material...Fe intermetallic present. Mechanical load testing determined that the bimetallic FSP joint was stronger than similar AA6061-to-AA6061 fusion- welded and...5 b) Weld Coupon Fixture ........................................................................................ 5 2. Friction Stir Tools

Activities of the Boom and Chassis Group

NASA Technical Reports Server (NTRS)

Dell, Jason Scott; Meeks, Thomas Bayne; Merkel, Kelly; Nelson, Brent; Winchell, Tom

1992-01-01

Group One of the NASA Lunar Enabler Project has designed the primary chassis and boom structures for the lunar vehicle. Both components also feature V-clamps that were adapted to interface connections within the structure. The chassis features a front end, rear end section, middle cross-section, and face plate. The rear section contains an extra compartment for the engine, hydraulic pump, fuel bottles, and oil reservoir necessary for the wheel drives. Each section consists of tubular aluminum 6061-T6. The boom features four degrees of freedom system, where the minimum factor of safety of any part is 1.5 (but, normally much higher). It consists of a tapered upper boom, lower boom, and three elbows that complement the articulation joints. Each section of the boom has been constructed from aluminum 6061-T6. There are four joints and eight V-clamps in the boom assembly. The V-clamps feature support rings that prevent axial rotation. They provide easy adaptability and assembly.

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.

20 CFR 606.1 - Purpose and scope.

Code of Federal Regulations, 2011 CFR

2011-04-01

... 20 Employees' Benefits 3 2011-04-01 2011-04-01 false Purpose and scope. 606.1 Section 606.1... and scope. (a) In general. The regulations in this part 606 are issued to implement the tax credit... title XII of the Social Security Act. (b) Scope. This part 606 covers general matters relating to this...

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.

Ocean Engineering Studies Compiled 1991. Volume 11. Pressure-Resistant Glass Light Enclosures

DTIC Science & Technology

1991-01-01

resting on this gasket than when they were resting on bare type 316 stainless steel end closures, aluminum gasket, or glass fiber- phenolic laminate ...316 2.58 inches thick Brass (naval) 2.58 inches thick Titanium (Ti-6AI-4V) 1.82 inches thick Phenolic resin-glass fiber laminate 4.40 inches thick...The 6061-T6 aluminum and the 94 spcimen s phenolic resin-impregnated glass fiber 18,000 imploded at -- /- laminate materials performed the best 18,000

Equal channel angular pressing of powder processed Al6061/SiC nano metal matrix composites and study of its wear properties

NASA Astrophysics Data System (ADS)

Bongale, Arunkumar M.; Kumar, Satish

2018-03-01

Nano Metal Matrix Composites were fabricated by a novel approach by combining powder metallurgy and equal channel angular pressing (ECAP) using aluminium alloy 6061 (Al6061) as matrix phase and 2, 4 and 6 wt% of silicon carbide nanoparticles (SiCnp) as reinforcements. Alloying elements of Al6061 in their elemental form are blended together using high energy planetary ball mill and calculated wt% of SiCnp were mixed with it. Thus formed composite powder mixture is compacted in a uniaxial compaction die and then subjected to ECAP up to three passes. Density and porosity of samples were estimated using Archimedes’ principle. Pin on disc setup is used to evaluate the wear properties of the composites under different speed and loading conditions. Tests revealed that increase in wt% of SiCnp reduces the wear rate of the composites whereas increasing the load and speed increases wear rate of the composite samples. SEM micrographs of worn surfaces indicated different types of wear mechanism responsible for wear of the specimens under different testing conditions. Also, wt% of SiCnp and the number of passes through ECAP were found to increase the hardness value of the composite material.

Experimental Research on Fatigue Failure for 2219-T6 Aluminum Alloy Friction Stir-Welded Joints

NASA Astrophysics Data System (ADS)

Sun, Guo-Qin; Niu, Jiang-Pei; Chen, Ya-Jing; Sun, Feng-Yang; Shang, De-Guang; Chen, Shu-Jun

2017-08-01

The fatigue experiment was executed for the 2219-T6 aluminum alloy friction stir-welded joints at the rotation speed of 800 r/min and the welding velocity of 150 mm/min. Most fatigue failures occurred in the weld nugget zone (WNZ), the thermo-mechanical affected zone and the nearby areas. The experimental results demonstrated that the sudden hardness gradient increases sites corresponding to the fatigue failure locations. The high-angle grain boundaries with the highest concentration were scattered within the WNZ. The microcracks initiated at the intersection of the soft grains. More than one crack initiation site was observed within the WNZ and the thermo-mechanical affected zone, when the fracture occurred in these areas. The rough surface of the welding area should be one of the main reasons for the fatigue failure occurrence. The fatigue crack growth rate in the WNZ at the first stage was fastest in comparison with the fatigue crack growth rate in the other areas of the joint.

Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

DOE PAGES

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

Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rabby, Reza; Tang, Wei; Reynolds, A. P.

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

Data-Enabled Quantification of Aluminum Microstructural Damage Under Tensile Loading

NASA Astrophysics Data System (ADS)

Wayne, Steven F.; Qi, G.; Zhang, L.

2016-08-01

The study of material failure with digital analytics is in its infancy and offers a new perspective to advance our understanding of damage initiation and evolution in metals. In this article, we study the failure of aluminum using data-enabled methods, statistics and data mining. Through the use of tension tests, we establish a multivariate acoustic-data matrix of random damage events, which typically are not visible and are very difficult to measure due to their variability, diversity and interactivity during damage processes. Aluminium alloy 6061-T651 and single crystal aluminium with a (111) orientation were evaluated by comparing the collection of acoustic signals from damage events caused primarily by slip in the single crystal and multimode fracture of the alloy. We found the resulting acoustic damage-event data to be large semi-structured volumes of Big Data with the potential to be mined for information that describes the materials damage state under strain. Our data-enabled analyses has allowed us to determine statistical distributions of multiscale random damage that provide a means to quantify the material damage state.

Characterization of the dimensional stability of advanced metallic materials using an optical test bench structure

NASA Technical Reports Server (NTRS)

Hsieh, Cheng; O'Donnell, Timothy P.

1991-01-01

The dimensional stability of low-density high specific-strength metal-matrix composites (including 30 vol pct SiC(p)/SXA 24-T6 Al, 25 vol pct SiC(p)/6061-T6 Al, 40 vol pct graphite P100 fiber/6061 Al, 50 vol pct graphite P100 fiber/6061 Al, and 40 vol pct P100 graphite fiber/AZ91D Mg composites) and an Al-Li-Mg metal alloy was evaluated using a specially designed five-strut optical test bench structure. The structure had 30 thermocouple locations, one retroreflector, one linear interferometer multilayer insulation, and various strip heaters. It was placed in a 10 exp -7 torr capability vacuum chamber with a laser head positioned at a window port, and a laser interferometer system for collecting dimensional change data. It was found that composite materials have greater 40-C temporal dimensional stability than the AL-Li-Mg alloy. Aluminum-based composites demonstrated better 40-C temporal stability than Mg-based composites.

Effect of Backing Plate Thermal Property on Friction Stir Welding of 25-mm-Thick AA6061

NASA Astrophysics Data System (ADS)

Upadhyay, Piyush; Reynolds, Anthony

2014-04-01

By using backing plates made out of materials with widely varying thermal diffusivity this work seeks to elucidate the effects of the root side thermal boundary condition on weld process variables and resulting joint properties. Welds were made in 25.4-mm-thick AA6061 using ceramic, titanium, steel, and aluminum as backing plate (BP) material. Welds were also made using a "composite backing plate" consisting of longitudinal narrow strip of low diffusivity material at the center and two side plates of high diffusivity aluminum. Stir zone temperature during the welding was measured using two thermocouples spot welded at the core of the probe: one at the midplane height and another near the tip of the probe corresponding to the root of the weld. Steady state midplane probe temperatures for all the BPs used were found to be very similar. Near root peak temperature, however, varied significantly among weld made with different BPs all other things being equal. Whereas the near root and midplane temperature were the same in the case of ceramic backing plate, the root peak temperature was 318 K (45 °C) less than the midplane temperature in the case of aluminum BP. The trends of nugget hardness and grain size in through thickness direction were in agreement with the measured probe temperatures. Hardness and tensile test results show that the use of composite BP results in stronger joint compared to monolithic steel BP.

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.

Gas Metal Arc Weld (GMAW) Qualification of 7020-T651 Aluminum

DTIC Science & Technology

2015-11-01

ARL-TR-7515 ● NOV 2015 US Army Research Laboratory Gas Metal Arc Weld (GMAW) Qualification of 7020-T651 Aluminum by John F...Metal Arc Weld (GMAW) Qualification of 7020-T651 Aluminum by John F Chinella Weapons and Materials Research Directorate, ARL Nick Kapustka and...Seth Shira Edison Welding Institute, Columbus, Ohio Approved for public release; distribution is unlimited. ii REPORT

Scientific Background for Processing of Aluminum Waste

NASA Astrophysics Data System (ADS)

Kononchuk, Olga; Alekseev, Alexey; Zubkova, Olga; Udovitsky, Vladimir

2017-11-01

Changing the source of raw materials for producing aluminum and the emergence of a huge number of secondary alumina waste (foundry slag, sludge, spent catalysts, mineral parts of coal and others that are formed in various industrial enterprises) require the creation of scientific and theoretical foundations for their processing. In this paper, the aluminum alloys (GOST 4784-97) are used as an aluminum raw material component, containing the aluminum component produced as chips in the machine-building enterprises. The aluminum waste is a whole range of metallic aluminum alloys including elements: magnesium, copper, silica, zinc and iron. Analysis of the aluminum waste A1- Zn-Cu-Si-Fe shows that depending on the content of the metal the dissolution process of an aluminum alloy should be treated as the result of the chemical interaction of the metal with an alkaline solution. It is necessary to consider the behavior of the main components of alloys in an alkaline solution as applied to the system Na2O - Al2O3 - SiO2 - CO2 - H2O.

Dynamic mechanical characterization of aluminum: analysis of strain-rate-dependent behavior

NASA Astrophysics Data System (ADS)

Rahmat, Meysam

2018-05-01

A significant number of materials show different mechanical behavior under dynamic loads compared to quasi-static (Salvado et al. in Prog. Mater. Sci. 88:186-231, 2017). Therefore, a comprehensive study of material dynamic behavior is essential for applications in which dynamic loads are dominant (Li et al. in J. Mater. Process. Technol. 255:373-386, 2018). In this work, aluminum 6061-T6, as an example of ductile alloys with numerous applications including in the aerospace industry, has been studied under quasi-static and dynamic tensile tests with strain rates of up to 156 s^{-1}. Dogbone specimens were designed, instrumented and tested with a high speed servo-hydraulic load frame, and the results were validated with the literature. It was observed that at a strain rate of 156 s^{-1} the yield and ultimate strength increased by 31% and 33% from their quasi-static values, respectively. Moreover, the failure elongation and fracture energy per unit volume also increased by 18% and 52%, respectively. A Johnson-Cook model was used to capture the behavior of the material at different strain rates, and a modified version of this model was presented to enhance the capabilities of the original model, especially in predicting material properties close to the failure point. Finally, the fracture surfaces of specimens tested under quasi-static and dynamic loads were compared and conclusions about the differences were drawn.

Microstructure and mechanical properties of 2024-T3 and 7075-T6 aluminum alloys and austenitic stainless steel 304 after being exposed to hydrogen peroxide

NASA Astrophysics Data System (ADS)

Sofyan, Nofrijon Bin Imam

The effect of hydrogen peroxide used as a decontaminant agent on selected aircraft metallic materials has been investigated. The work is divided into three sections; bacterial attachment behavior onto an austenitic stainless steel 304 surface; effect of decontamination process on the microstructure and mechanical properties of aircraft metallic structural materials of two aluminum alloys, i.e. 2024-T3 and 7075-T6, and an austenitic stainless steel 304 as used in galley and lavatory surfaces; and copper dissolution rate into hydrogen peroxide. With respect to bacterial attachment, the results show that surface roughness plays a role in the attachment of bacteria onto metallic surfaces at certain extent. However, when the contact angle of the liquid on a surface increased to a certain degree, detachment of bacteria on that surface became more difficult. In its relation to the decontamination process, the results show that a corrosion site, especially on the austenitic stainless steel 304 weld and its surrounding HAZ area, needs more attention because it could become a source or a harborage of bio-contaminant agent after either incidental or intentional bio-contaminant delivery. On the effect of the decontamination process on the microstructure and mechanical properties of aircraft metallic structural materials, the results show that microstructural effects are both relatively small in magnitude and confined to a region immediately adjacent to the exposed surface. No systematic effect is found on the tensile properties of the three alloys under the conditions examined. The results of this investigation are promising with respect to the application of vapor phase hydrogen peroxide as a decontaminant agent to civilian aircraft, in that even under the most severe circumstances that could occur; only very limited damage was observed. The results from the dissolution of copper by concentrated liquid hydrogen peroxide showed that the rate of copper dissolution increased for

Research on the welding process of aluminum alloy based on high power fiber laser

NASA Astrophysics Data System (ADS)

Zhang, Jian; Zhang, Wei; Pan, Xiaoming; Huang, Shanshi; Liu, Wenwen

2017-08-01

To research the formation and variation principle of the weld seam and molten pool for aluminum alloy high power fiber laser welding, the welding experiments for 5052 aluminum alloy were carried out. The influences of laser power, scanning velocity and protection gas on the welding process were systematically researched. The results show that with the increase of power and scanning velocity, the depth to width ratio first increases and then decreases. The ratio reaches the maximum value at 2.6 KW and 30 mm/s, respectively. When the power located at 2.6 KW to 2.8 KW or the velocity located at 25 mm/s to 30 mm/s, stable deep penetration welding can be obtained. The weld seam shows relative flat appearance and the molten pool presents typical "T shape" topography. Moreover, the protection gas also influences the appearance of the weld seam. Using the independently designed fixture, the quality of the weld seam can be well improved.

Propellant Improvement Program. Volume 2. Iron Contamination Effect in HDA (High Density Acid)

DTIC Science & Technology

Density Acid ( HDA ) and the effect of iron impurity level up to 100 parts per million as Fe2O3 on HDA heat transfer. Thirty tests were conducted using...resistance heated, circular, 6061T6 aluminum tubes. Results showed that normal nucleate boiling did not occur with either of the HDA compositions. The

Yield strength measurement of shock-loaded metal by flyer-impact perturbation method

NASA Astrophysics Data System (ADS)

Ma, Xiaojuan; Shi, Zhan

2018-06-01

Yield strength is one of the most important physical properties of a solid material, especially far from its melting line. The flyer-impact perturbation method measures material yield strength on the basis of correlation between the yield strength under shock compression and the damping of oscillatory perturbations in the shape of a shock front passing through the material. We used flyer-impact experiments on targets with machined grooves on the impact surface of shock 6061-T6 aluminum to between 32 and 61 GPa and recorded the evolution of the shock front perturbation amplitude in the sample with electric pins. Simulations using the elastic-plastic model can be matched to the experiments, explaining well the form of the perturbation decay and constraining the yield strength of 6061-T6 aluminum to be 1.31-1.75 GPa. These results are in agreement with values obtained from reshock and release wave profiles. We conclude that the flyer-impact perturbation method is indeed a new means to measure material strength.

Highly porous micro-roughened structures developed on aluminum surface using the jet of rotating arc discharges at atmospheric pressure

NASA Astrophysics Data System (ADS)

Asadollahi, Siavash; Farzaneh, Masoud; Stafford, Luc

2018-02-01

Aluminum 6061 samples were exposed to the jet of an atmospheric pressure rotating arc discharge operated in either nitrogen or air. After multiple passes of treatment with an air-based plasma jet at very short source-to-substrate distances, scanning electron microscopy combined with x-ray photoelectron spectroscopy revealed a highly porous micro-roughened alumina-based structure on the surface of aluminum. Based on optical emission spectroscopy and high-speed optical imaging of the jet interacting with aluminum samples, it was found that the process is mainly driven by the energy transfer from the plasma source to the surface through transient plasma-transferred arcs. The occurrence of multiple arc discharges over very short time scales can induce rapid phase transformations of aluminum with characteristics similar to the ones usually observed during laser ablation of materials with femto- to nanosecond laser pulses or during the formation of cathode spots on the surface of metals.

Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing

DOE PAGES

Sridharan, Niyanth; Gussev, Maxim; Seibert, Rachel; ...

2016-09-01

Ultrasonic additive manufacturing (UAM) is a solid-state process, which uses ultrasonic vibrations at 20 kHz along with mechanized tape layering and intermittent milling operation, to build fully functional three-dimensional parts. In the literature, UAM builds made with low power (1.5 kW) exhibited poor tensile properties in Z-direction, i.e., normal to the interfaces. This reduction in properties is often attributed to the lack of bonding at faying interfaces. The generality of this conclusion is evaluated further in 6061 aluminum alloy builds made with very high power UAM (9 kW). Tensile deformation behavior along X and Z directions were evaluated with small-scalemore » in-situ mechanical testing equipped with high-resolution digital image correlation, as well as, multi-scale characterization of builds. Interestingly, even with complete metallurgical bonding across the interfaces without any discernable voids, poor Z-direction properties were observed. This reduction is correlated to coalescence of pre-existing shear bands at interfaces into micro voids, leading to strain localization and spontaneous failure on tensile loading.« less

Friction stir welding of T joints of dissimilar aluminum alloy: A review

NASA Astrophysics Data System (ADS)

Thakare, Shrikant B.; Kalyankar, Vivek D.

2018-04-01

Aluminum alloys are preferred in the mechanical design due to their advantages like high strength, good corrosion resistance, low density and good weldability. In various industrial applications T joints configuration of aluminum alloys are used. In different fields, T joints having skin (horizontal sheet) strengthen by stringers (vertical sheets) were used to increase the strength of structure without increasing the weight. T joints are usually carried out by fusion welding which has limitations in joining of aluminum alloy due to significant distortion and metallurgical defects. Some aluminum alloys are even non weldable by fusion welding. The friction stir welding (FSW) has an excellent replacement of conventional fusion welding for T joints. In this article, FSW of T joints is reviewed by considering aluminum alloy and various joint geometries for defect analysis. The previous experiments carried out on T joints shows the factors such as tool geometry, fixturing device and joint configurations plays significant role in defect free joints. It is essential to investigate the material flow during FSW to know joining mechanism and the formation of joint. In this study the defect occurred in the FSW are studied for various joint configurations and parameters. Also the effect of the parameters and defects occurs on the tensile strength are studied. It is concluded that the T-joints of different joint configurations can be pretended successfully. Comparing to base metal some loss in tensile strength was observed in the weldments as well as overall reduction of the hardness in the thermos mechanically affected zone also observed.

Modeling the effect of laser heating on the strength and failure of 7075-T6 aluminum

DOE PAGES

Florando, J. N.; Margraf, J. D.; Reus, J. F.; ...

2015-06-06

The effect of rapid laser heating on the response of 7075-T6 aluminum has been characterized using 3-D digital image correlation and a series of thermocouples. The experimental results indicate that as the samples are held under a constant load, the heating from the laser profile causes non-uniform temperature and strain fields, and the strain-rate increases dramatically as the sample nears failure. Simulations have been conducted using the LLNL multi-physics code ALE3D, and compared to the experiments. The strength and failure of the material was modeled using the Johnson–Cook strength and damage models. Here, in order to capture the response, amore » dual-condition criterion was utilized which calibrated one set of parameters to low temperature quasi-static strain rate data, while the other parameter set is calibrated to high temperature high strain rate data. The thermal effects were captured using temperature dependent thermal constants and invoking thermal transport with conduction, convection, and thermal radiation.« less

Wear behaviors of pure aluminum and extruded aluminum alloy (AA2024-T4) under variable vertical loads and linear speeds

NASA Astrophysics Data System (ADS)

Jung, Jeki; Oak, Jeong-Jung; Kim, Yong-Hwan; Cho, Yi Je; Park, Yong Ho

2017-11-01

The aim of this study was to investigate the transition of wear behavior for pure aluminum and extruded aluminum alloy 2024-T4 (AA2024-T4). The wear test was carried using a ball-on-disc wear testing machine at various vertical loads and linear speeds. The transition of wear behaviors was analyzed based on the microstructure, wear tracks, wear cross-section, and wear debris. The critical wear rates for each material are occurred at lower linear speed for each vertical load. The transition of wear behavior was observed in which abrasion wears with the generation of an oxide layer, fracture of oxide layer, adhesion wear, severe adhesion wear, and the generation of seizure occurred in sequence. In case of the pure aluminum, the change of wear debris occurred in the order of blocky, flake, and needle-like debris. Cutting chip, flake-like, and coarse flake-like debris was occurred in sequence for the extruded AA2024-T4. The transition in the wear behavior of extruded AA2024-T4 occurred slower than in pure aluminum.

The corrosion protection of 2219-T87 aluminum by anodizing

NASA Technical Reports Server (NTRS)

Danford, M. D.

1991-01-01

Various types of anodizing coatings were studied for 2219-T87 aluminum. These include both type II and type III anodized coats which were water sealed and a newly developed and proprietary Magnaplate HCR (TM) coat. Results indicate that type II anodizing is not much superior to type II anodizing as far as corrosion protection for 2219-T87 aluminum is concerned. Magnaplate HCR (TM) coatings should provide superior corrosion protection over an extended period of time using a coating thickness of 51 microns (2.0 mils).

Effect of tool offsetting on microstructure and mechanical properties dissimilar friction stir welded Mg-Al alloys

NASA Astrophysics Data System (ADS)

Baghdadi, Amir Hossein; Fazilah Mohamad Selamat, Nor; Sajuri, Zainuddin

2017-09-01

Automotive and aerospace industries are attempting to produce lightweight structure by using materials with low density such as aluminum and magnesium alloys to increase the fuel efficiency and consequently reduce the environmental pollution. It can be beneficial to join Mg to Al to acquire ideal performance in special applications. Friction stir welding (FSW) is solid state welding processes and relatively lower temperature of the process compared to fusion welding processes. This makes FSW a potential joining technique for joining of the dissimilar materials. In this study, Mg-Al butt joints were performed by FSW under different tool offset conditions, rotation rates (500-600 rpm) and traverse speeds (20 mm/min) with tool axis offset 1 mm shifted into AZ31B or Al6061 (T6), and without offset. During the welding process AZ31B was positioned at the advancing side (AS) and Al6061 (T6) was located at the retreating side (RS). Defect free AZ31B-Al6061 (T6) dissimilar metal FSW joints with good mechanical properties were obtained with the combination of intermediate rotation rate and low traverse speed pin is in the middle. When tool positioned in -1 mm or +1 mm offsetting, some defects were found in SZ of dissimilar FSWed joints such as cavity, tunnel, and crack. Furthermore, a thin layer of intermetallic compounds was observed in the stir zone at the interface between Mg-Al plates. The strength of the joint was influenced by FSW parameters. Good mechanical properties obtained with the combination of intermediate rotational speed of 600 rpm and low travelling speed of 20 mm/min by locating Mg on advancing side when pin is in the middle. Also, Joint efficiency of the welds prepared in the present study was between 29% and 68% for the different welding parameters.

Influence of SMAT Parameters on Microstructural and Mechanical Properties of Al-Mg-Si Alloy AA 6061

NASA Astrophysics Data System (ADS)

Anand Kumar, S.; Satish Kumar, P.; Ganesh Sundara Raman, S.; Sankara Narayanan, T. S. N.

2017-04-01

In the present work, the influence of surface mechanical attrition treatment (SMAT) parameters on the microstructural and mechanical properties of an aluminum-magnesium-silicon alloy AA 6061 was studied using design of experiment technique. Balls of three different diameters were used, and SMAT was done for three different durations. The microstructural features of the surface layer fabricated by SMAT were characterized by cross-sectional scanning electron microscopic observations, x-ray diffraction technique and transmission electron microscopy. The microindentation hardness, nanoindentation hardness and surface roughness were determined. Due to SMAT, nanocrystallites formed on the surface and near-surface regions, and hardness and surface roughness increased. The ball diameter was the most influencing SMAT parameter compared to the treatment duration. However, interaction between ball diameter and treatment duration could not be ignored. Regression equations were developed relating the process parameters to the surface properties. The ball diameter and treatment duration could thus be properly selected as per the required values of roughness and/or the hardness.

Evaluation of Various Cleaning Methods to Remove Bacillus Spores from Spacecraft Hardware Materials

NASA Technical Reports Server (NTRS)

Venkateswaran, Kasthuri; Chung, Shirley; Allton, Judith; Kern, Roger

2004-01-01

A detailed study was made of the biological cleaning effectiveness, defined in terms of the ability to remove bacterial spores, of a number of methods used to clean hardware surfaces. Aluminum (Al 6061) and titanium (Ti 6Al-4V) were chosen for the study as they were deemed the two materials most likely to be used in spacecraft extraterrestrial sampler construction. None of the cleaning protocols tested completely removed viable spores from the surface of the aluminum. In contrast, titanium was capable of being cleaned to sterility by two methods, the JPL standard and the commercial SAMS cleaning process. Further investigation showed that the passivation step employed in the JPL standard method is an effective surface sterilant on both metals but not compatible with aluminum. It is recommended that titanium (Ti 6Al-4V) be considered superior to aluminum (Al 6061) for use in spacecraft sampling hardware, both for its potential to be cleaned to sterilization and for its ability to withstand the most effective cleaning protocols.

42 CFR 60.61 - Responsibilities of a HEAL school.

Code of Federal Regulations, 2012 CFR

2012-10-01

... depart from the school without receiving an exit interview. A school may meet this requirement through... 42 Public Health 1 2012-10-01 2012-10-01 false Responsibilities of a HEAL school. 60.61 Section 60... EDUCATION ASSISTANCE LOAN PROGRAM The School § 60.61 Responsibilities of a HEAL school. (a) A HEAL school is...

42 CFR 60.61 - Responsibilities of a HEAL school.

Code of Federal Regulations, 2014 CFR

2014-10-01

... depart from the school without receiving an exit interview. A school may meet this requirement through... 42 Public Health 1 2014-10-01 2014-10-01 false Responsibilities of a HEAL school. 60.61 Section 60... EDUCATION ASSISTANCE LOAN PROGRAM The School § 60.61 Responsibilities of a HEAL school. (a) A HEAL school is...

42 CFR 60.61 - Responsibilities of a HEAL school.

Code of Federal Regulations, 2013 CFR

2013-10-01

... depart from the school without receiving an exit interview. A school may meet this requirement through... 42 Public Health 1 2013-10-01 2013-10-01 false Responsibilities of a HEAL school. 60.61 Section 60... EDUCATION ASSISTANCE LOAN PROGRAM The School § 60.61 Responsibilities of a HEAL school. (a) A HEAL school is...

Investigation on the effect of Friction Stir Processing Parameters on Micro-structure and Micro-hardness of Rice Husk Ash reinforced Al6061 Metal Matrix Composites

NASA Astrophysics Data System (ADS)

Fatchurrohman, N.; Farhana, N.; Marini, C. D.

2018-03-01

Friction stir processing (FSP) is an alternative way to produce the surface composites of aluminium alloy in order to modify the microstructure and improve the mechanical properties. In this experiment, Al6061 aluminium alloy has been chosen to be used as the matrix base plate for the FSP. Al606 has potential for the use in advanced application but it has low wear resistance. While, the reinforced used was rice husk ash (RHA) in order to produce surface composites which increased the micro hardness of the plate composites. The Al6061 was stirred individually and with 5 weight % of RHA at three different tool rotational speeds of 800 rpm, 1000 rpm and 1200 rpm. After running the FSP, the result in the distribution of particles and the micro hardness of the specimens were identified. The result showed that Al6061 plate with the existing 5 weight % of RHA reinforced at the highest of tool rotational speeds of 1200rpm has the best distribution of particles and the highest result in average of micro hardness with 80Hv.

The effects of pitting on fatigue crack nucleation in 7075-T6 aluminum alloy

NASA Technical Reports Server (NTRS)

Ma, LI; Hoeppner, David W.

1994-01-01

A high-strength aluminum alloy, 7075-T6, was studied to quantitatively evaluate chemical pitting effects of its corrosion fatigue life. The study focused on pit nucleation, pit growth, and fatigue crack nucleation. Pitting corrosion fatigue experiments were conducted in 3.5 percent NaCl aqueous solution under constant amplitude sinusoidal loading at two frequencies, 5 and 20 Hz. Smooth and unnotched specimens were used in this investigation. A video recording system was developed to allow in situ observation of the surface changes of the specimens during testing. The results indicated that pitting corrosion considerably reduces the fatigue strength by accelerating fatigue crack nucleation. A metallographic examination was conducted on the specimens to evaluate the nature of corrosion pits. First, the actual shapes of the corrosion pits were evaluated by cross-sectioning the pits. Secondly, the relation between corrosion pits and microstructure was also investigated. Finally, the possibility of another corrosion mechanism that might be involved in pitting was explored in this investigation. The fractography of the tested specimens showed that corner corrosion pits were responsible for fatigue crack nucleation in the material due to the associated stress concentration. The pits exhibited variance of morphology. Fatigue life for the experimental conditions appeared to be strongly dependent on pitting kinetics and the crack nucleation stage.

Composite containment systems for jet engine fan blades

NASA Technical Reports Server (NTRS)

Smith, G. T.

1981-01-01

The use of composites in fan blade containment systems is investigated and the associated structural benefits of the composite system design are identified. Two basic types of containment structures were investigated. The short finned concept was evaluated using Kevlar/epoxy laminates for fins which were mounted in a 6061 T-6 aluminum ring. The long fin concept was evaluated with Kevlar/epoxy, 6Al4V titanium, and 2024 T-3 aluminum fins. The unfinned configurations consisted of the base-line steel sheet, a circumferentially oriented aluminum honeycomb, and a Kevlar cloth filled ring. Results obtained show that a substantial reduction in the fan blade containment system weight is possible. Minimization of damage within the engine arising from impact interaction between blade debris and the engine structure is also achieved.

42 CFR 60.61 - Responsibilities of a HEAL school.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 42 Public Health 1 2011-10-01 2011-10-01 false Responsibilities of a HEAL school. 60.61 Section 60... EDUCATION ASSISTANCE LOAN PROGRAM The School § 60.61 Responsibilities of a HEAL school. (a) A HEAL school is... loan. The school must inform the loan recipient during the entrance interview of his or her rights and...

Validation of the Two-Parameter-Fracture Criterion for Various Crack Configurations Made of 2014-T6 (TL) Aluminum Alloy Using Finite Element Fracture Simulations

NASA Astrophysics Data System (ADS)

McQuilkin, Martin

The Two-Parameter- Fracture-Criterion (TPFC) was validated using an elastic-plastic two-dimensional (2D) finite-element code, ZIP2D, with the plane-strain- core concept. Fracture simulations were performed on three crack configurations: (1) middle-crack-tension, M(T), (2) single-edge- crack-tension, SE(T), and (3) single-edge crack-bend, SE(B), specimens. They were made of 2014-T6 (TL) aluminum alloy. Fracture test data from Thomas Orange work (NASA) were only available on M(T) specimens (one-half width, w = 1.5 to 6 in.) and they were all tested at cryogenic (-320 o F) temperature. All crack configurations were analysed over a very wide range of widths (w = 0.75 to 24 in.) and crack-length- to-width ratios ranged from 0.2 to 0.8. The TPFC was shown to fit the simulated fracture data fairly well (within 6.5%) for all crack configurations for net-section stresses less than the material proportional limit. For M(T) specimens, a simple approximation was shown to work well for net-section stresses greater than the proportional limit. Further study is needed for net-section stresses greater than the proportional limit for the SE(T) and SE(B) specimens.

In-situ thermal cycling in SEM of a graphite-aluminum composite

NASA Technical Reports Server (NTRS)

Cheong, Y. M.; Marcus, H. L.

1987-01-01

In situ SEM observations of a graphite-aluminum composite (unidirectional P100 graphite-fiber-reinforced 6061 aluminum MMC plates) were used to measure displacements within the graphite fiber relative to the interface between the graphite fiber and the aluminum matrix during thermal cycling. Specimens were thermally cycled from room temperature to 300 C or 500 C in a SEM chamber and then cooled to room temperature. The obtained shear strains within the fiber were then related to anomalous values of measured residual stresses and to the impact on the composite coefficient of expansion and potential damage under thermal fatigue loading. The shear mechanism was proposed as a source of temperature limits on the low coefficient of expansion of these composites, as well as a potential source of thermal fatigue degradation.

Effects of SiC whiskers and particles on precipitation in aluminum matrix composites

NASA Astrophysics Data System (ADS)

Papazian, John M.

1988-12-01

The age-hardening precipitation reactions in aluminum matrix composites reinforced with discontinuous SiC were studied using a calorimetric technique. Composites fabricated with 2124, 2219, 6061, and 7475 alloy matrices were obtained from commercial sources along with unreinforced control materials fabricated in a similar manner. The 7475 materials were made by a casting process while the others were made by powder metallurgy: the SiC reinforcement was in the form of whiskers or particulate. It was found that the overall age-hardening sequence of the alloy was not changed by the addition of SiC, but that the volume fractions of various phases and the precipitation kinetics were substantially modified. Precipitation and dissolution kinetics were generally accelerated. A substantial portion of this acceleration was found to be due to the powder metallurgy process employed to make the composites, but the formation kinetics of some particular precipitate phases were also strongly affected by the presence of SiC. It was observed that the volume fraction of GP zones able to form in the SiC containing materials was significantly reduced. The presence of SiC particles also caused normally quench insensitive materials such as 6061 to become quench sensitive. The microstructural origins of these effects are discussed.

Biaxial Testing of 2219-T87 Aluminum Alloy Using Cruciform Specimens

NASA Technical Reports Server (NTRS)

Dawicke, D. S.; Pollock, W. D.

1997-01-01

A cruciform biaxial test specimen was designed and seven biaxial tensile tests were conducted on 2219-T87 aluminum alloy. An elastic-plastic finite element analysis was used to simulate each tests and predict the yield stresses. The elastic-plastic finite analysis accurately simulated the measured load-strain behavior for each test. The yield stresses predicted by the finite element analyses indicated that the yield behavior of the 2219-T87 aluminum alloy agrees with the von Mises yield criterion.

Microstructural Characterization of the U-9.1Mo Fuel/AA6061 Cladding Interface in Friction-Bonded Monolithic Fuel Plates Irradiated in the RERTR-6 Experiment

DOE PAGES

Keiser, Dennis D.; Jue, Jan-Fong; Miller, Brandon; ...

2015-09-03

Low-enrichment (U-235 < 20%) U-Mo monolithic fuel is being developed for use in research and test reactors. The earliest design for this fuel that was investigated via reactor testing was comprised of a nominally U-10Mo fuel foil encased in AA6061 (Al-6061) cladding. For a fuel design to be deemed adequate for final use in a reactor, it must maintain dimensional stability and retain fission products throughout irradiation, which means that there must be good integrity at the fuel foil/cladding interface. To investigate the nature of the fuel/cladding interface for this fuel type after irradiation, fuel plates that were tested inmore » INL's Advanced Test Reactor (ATR) were subsequently characterized using optical metallography, scanning electron microscopy, and transmission electron microscopy. Results of this characterization showed that the fuel/cladding interaction layers present at the U-Mo fuel/AA6061 cladding interface after fabrication became amorphous during irradiation. Up to two main interaction layers, based on composition, could be found at the fuel/cladding interface, depending on location. After irradiation, an Al-rich layer contained very few fission gas bubbles, but did exhibit Xe enrichment near the AA6061 cladding interface. Another layer, which contained more Si, had more observable fission gas bubbles. Adjacent to the AA6061 cladding were Mg-rich precipitates, which was in close proximity to the region where Xe is observed to be enriched. In samples produced using a focused ion beam at the interaction zone/AA6061 cladding interface were possible indications of porosity/debonding, which suggested that the interface in this location is relatively weak.« less

The Study on the Overall Plasma Electrolytic Oxidation for 6061–7075 Dissimilar Aluminum Alloy Welded Parts Based on the Dielectric Breakdown Theory

PubMed Central

Song, Xiaocun; Zhou, Jixue; Liu, Hongtao; Yang, Yuansheng

2018-01-01

Electrical connection of dissimilar metals will lead to galvanic corrosion. Therefore, overall surface treatment is necessary for the protection of dissimilar metal welded parts. However, serious unbalanced reactions may occur during overall surface treatment, which makes it difficult to prepare integral coating. In this paper, an overall ceramic coating was fabricated by plasma electrolytic oxidation to wrap the 6061–7075 welded part integrally. Moreover, the growth mechanism of the coating on different areas of the welded part was studied based on the dielectric breakdown theory. The reaction sequence of each area during the treatment was verified through specially designed dielectric breakdown tests. The results showed that the high impedance overall of ceramic coating can inhibit the galvanic corrosion of the 6061–7075 welded part effectively. PMID:29301306

Aluminum-based one- and two-dimensional micro fin array structures: high-throughput fabrication and heat transfer testing

NASA Astrophysics Data System (ADS)

Primeaux, Philip A.; Zhang, Bin; Zhang, Xiaoman; Miller, Jacob; Meng, W. J.; KC, Pratik; Moore, Arden L.

2017-02-01

Microscale fin array structures were replicated onto surfaces of aluminum 1100 and aluminum 6061 alloy (Al1100/Al6061) sheet metals through room-temperature instrumented roll molding. Aluminum-based micro fin arrays were replicated at room temperature, and the fabrication process is one with high throughput and low cost. One-dimensional (1D) micro fin arrays were made through one-pass rolling, while two-dimensional (2D) micro fin arrays were made by sequential 90° cross rolling with the same roller sleeve. For roll molding of 1D micro fins, fin heights greater than 600 µm were achieved and were shown to be proportional to the normal load force per feature width. At a given normal load force, the fin height was further shown to scale inversely with the hardness of the sheet metal. For sequential 90° cross rolling, morphologies of roll molded 2D micro fin arrays were examined, which provided clues to understand how plastic deformation occurred under cross rolling conditions. A series of pool boiling experiments on low profile Al micro fin array structures were performed within Novec 7100, a widely used commercial dielectric coolant. Results for both horizontal and vertical surface orientations show that roll molded Al micro fin arrays can increase heat flux at fixed surface temperature as compared to un-patterned Al sheet. The present results further suggest that many factors beyond just increased surface area can influence heat transfer performance, including surface finish and the important multiphase transport mechanisms in and around the fin geometry. These factors must also be considered when designing and optimizing micro fin array structures for heat transfer applications.

Effect of in-situ formed Al3Ti particles on the microstructure and mechanical properties of 6061 Al alloy

NASA Astrophysics Data System (ADS)

Gupta, Rahul; Chaudhari, G. P.; Daniel, B. S. S.

2018-03-01

In this study, in situ Titanium-tri-aluminide (Al3Ti) particles reinforced Al 6061 alloy matrix composites were fabricated by the reaction of potassium hexafluorotitanate (K2TiF6) inorganic salt with molten Al 6061 alloy via liquid metallurgy route. The development of in-situ Al3Ti particles and their effects on the mechanical properties such as yield strength (YS), ductility, ultimate tensile strength (UTS) and hardness, and microstructure of Al 6061 alloy were studied. It was observed from the results that in-situ formed Al3Ti particles were blocky in morphology whose average size was around 2.6 ± 1.1 μm. Microstructure studies showed that grain size of Al matrix was reduced due to the nucleating effect of Al3Ti particles. It was observed from the mechanical properties analysis that when the volume fraction of Al3Ti particles was increased, the hardness, UTS and YS of the composites were also increased as compared to that of Al 6061 alloy. An improvement in ductility was observed with the dispersion of Al3Ti particles in base alloy which is contrary to many other composites.

Study on combined polishing process of aspherical aluminum mirrors

NASA Astrophysics Data System (ADS)

Deng, Jinqiu; Peng, Xiaoqiang; Hu, Hao; Ge, Kunpeng

2017-10-01

The aluminum mirrors are widely used as important optical components in some vital fields such as astronomical instruments or military installations due to the unique advantages of aluminum alloy. In order to simplify the structure of optical system and improve the performance at the same time, it's a tendency that the optics will be designed to aspherical or other freeform shapes. However, the traditional techniques are falling to have adequate abilities to deal with the increasing demands of aluminum optics. For example, the tool marks leaved on the surface from single point diamond turning (SPDT) has obvious adverse effects to optical system. The deterministic and sub-aperture polishing process has showed the potential to fabricate complex shapes over the few years. But it's still recognized as a problem to polish bare aluminum directly because of its soft surface and active chemical characteristics. Therefore, a combination of magnetorheological finishing (MRF) and small tool polishing (STP) is applied to obtain high performance aluminum optics in this paper. A paraboloid aluminum mirror was polished with this proposed method, and the results showed that the surface texture of the sample is restrained from rms 0.409λ (λ=632.8nm) to rms 0.025λ, and the surface roughness is improved from average Ra 6 7nm to Ra 3 4nm.

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.

Optimizing friction stir weld parameters of aluminum and copper using conventional milling machine

NASA Astrophysics Data System (ADS)

Manisegaran, Lohappriya V.; Ahmad, Nurainaa Ayuni; Nazri, Nurnadhirah; Noor, Amirul Syafiq Mohd; Ramachandran, Vignesh; Ismail, Muhammad Tarmizizulfika; Ahmad, Ku Zarina Ku; Daruis, Dian Darina Indah

2018-05-01

The joining of two of any particular materials through friction stir welding (FSW) are done by a rotating tool and the work piece material that generates heat which causes the region near the FSW tool to soften. This in return will mechanically intermix the work pieces. The first objective of this study is to join aluminum plates and copper plates by means of friction stir welding process using self-fabricated tools and conventional milling machine. This study also aims to investigate the optimum process parameters to produce the optimum mechanical properties of the welding joints for Aluminum plates and Copper plates. A suitable tool bit and a fixture is to be fabricated for the welding process. A conventional milling machine will be used to weld the aluminum and copper. The most important parameters to enable the process are speed and pressure of the tool (or tool design and alignment of the tool onto the work piece). The study showed that the best surface finish was produced from speed of 1150 rpm and tool bit tilted to 3°. For a 200mm × 100mm Aluminum 6061 with plate thickness of 2 mm at a speed of 1 mm/s, the time taken to complete the welding is only 200 seconds or equivalent to 3 minutes and 20 seconds. The Copper plates was successfully welded using FSW with tool rotation speed of 500 rpm, 700 rpm, 900 rpm, 1150 rpm and 1440 rpm and with welding traverse rate of 30 mm/min, 60 mm/min and 90 mm/min. As the conclusion, FSW using milling machine can be done on both Aluminum and Copper plates, however the weld parameters are different for the two types of plates.

Continuous internal channels formed in aluminum fusion welds

NASA Technical Reports Server (NTRS)

Gault, J.; Sabo, W.

1967-01-01

Process produces continuous internal channel systems on a repeatable basis in 2014-T6 aluminum. Standard machining forms the initial channel, which is filled with tungsten carbide powder. TIG machine fusion welding completes formation of the channel. Chem-mill techniques enlarge it to the desired size.

Influence of surface pretreatments on the quality of trivalent chromium process coatings on aluminum alloy

NASA Astrophysics Data System (ADS)

Viroulaud, Rémi; Światowska, Jolanta; Seyeux, Antoine; Zanna, Sandrine; Tardelli, Joffrey; Marcus, Philippe

2017-11-01

The effects of surface pretreatments (degreasing and pickling) on the characteristics of the Trivalent Chromium Process (TCP) coating on pure aluminum and on AA2024-T351 aluminum alloy were investigated here by means of surface sensitive techniques: X-ray photoelectron spectroscopy (XPS) and time-of-flight secondary ion mass spectrometry (ToF-SIMS). The XPS and ToF-SIMS results evidence that the TCP coating homogeneity is strongly dependent on the pretreatment process used. The TCP coverage factor, calculated from XPS results, is significantly lower, on both pure aluminum and AA2024-T351 alloy surface, when a pickling step is applied. One of the main effects of pickling pretreatment is strong metallic copper enrichment at the surface of the 2024 alloy, associated with chemical dissolution of Al-Cu intermetallic particles. However, it is evidenced here, that the copper enrichment is not detrimental for the quality of the TCP coating. The coating failure, observed when the pickling step is applied, can be assigned to a faster kinetics of the coating growth leading to formation of thicker conversion coating more susceptible to cracking or to the localized presence of aluminum fluoride species leading to the appearance of coating defects or detachment.

Effect of Localized Corrosion on Fatigue-Crack Growth in 2524-T3 and 2198-T851 Aluminum Alloys Used as Aircraft Materials

NASA Astrophysics Data System (ADS)

Moreto, J. A.; Broday, E. E.; Rossino, L. S.; Fernandes, J. C. S.; Bose Filho, W. W.

2018-03-01

Corrosion and fatigue of aluminum alloys are major issues for the in-service life assessment of aircraft structures and for the management of aging air fleets. The aim of this work was to evaluate the effect of localized corrosion on fatigue crack growth (FCG) resistance of the AA2198-T851 Al-Li alloy (Solution Heat Treated, Cold Worked, and Artificially Aged), comparing it with the FCG resistance of AA2524-T3 (Solution Heat Treated and Cold Worked), considering the effect of seawater fog environment. Before fatigue tests, the corrosion behavior of 2198-T851 and 2524-T3 aluminum alloys was verified using open circuit potential and potentiodynamic polarization techniques. Fatigue in air and corrosion fatigue tests were performed applying a stress ratio (R) of 0.1, 15 Hz (air) and 0.1 Hz (seawater fog) frequencies, using a sinusoidal waveform in all cases. The results showed that the localized characteristics of the 2198-T851 and 2524-T3 aluminum alloys are essentially related to the existence of intermetallic compounds, which, due to their different nature, may be cathodic or anodic in relation to the aluminum matrix. The corrosive medium has affected the FCG rate of both aluminum alloys, in a quite similar way.

Review and Study of Physics Driven Pitting Corrosion Modeling in 2024-T3 Aluminum Alloys (Postprint)

DTIC Science & Technology

2015-05-01

AFRL-RX-WP-JA-2015-0218 REVIEW AND STUDY OF PHYSICS DRIVEN PITTING CORROSION MODELING IN 2024-T3 ALUMINUM ALLOYS (POSTPRINT) Lingyu...2014 – 1 April 2015 4. TITLE AND SUBTITLE REVIEW AND STUDY OF PHYSICS DRIVEN PITTING CORROSION MODELING IN 2024-T3 ALUMINUM ALLOYS (POSTPRINT) 5a...18 Review and Study of Physics Driven Pitting Corrosion Modeling in 2024-T3 Aluminum Alloys Lingyu Yu 1*, Kumar V. Jata2 1Mechanical Engineering

Effect of Cryorolling and Aging on Fatigue Behavior of Ultrafine-grained Al6061

NASA Astrophysics Data System (ADS)

Yadollahpour, M.; Hosseini-Toudeshky, H.; Karimzadeh, F.

2016-05-01

The effects of cryorolling (rolling at liquid nitrogen temperature) and heat treatment on tensile and high-cycle fatigue properties and fatigue crack growth rate of Al6061 alloy have been investigated in the present work. First, the solid solution-treated bulk Al6061 alloy was subjected to cryorolling with 90% total thickness reduction and subsequent short annealing at 205°C for 5 min and peak aging at 148°C for 39 h to achieve grain refinement and simultaneous improvement of the strength and ductility. Then, hardness measurements, tensile tests, fatigue life, and fatigue crack growth rate tests including fractography analyses using scanning electron microscopy were performed on bulk Al6061 alloy, cryorolled (CR), and cryorolled material followed by peak aging (PA). The PA specimen showed improved yield strength by 24%, ultimate tensile strength by 20%, and ductility by 12% as compared with the bulk Al6061 alloy. It is shown that the fatigue strength of both CR and PA specimens under a high-cycle fatigue regime are larger than that of the bulk Al6061 alloy. Also, fatigue crack growth rates of the CR and PA specimens show significant enhancement in fatigue crack growth resistances as compared with the bulk Al6061 alloy, as a result of grain refinement.

Weld geometry strength effect in 2219-T87 aluminum

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.; Novak, H. L.; Mcilwain, M. C.

1981-01-01

A theory of the effect of geometry on the mechanical properties of a butt weld joint is worked out based upon the soft interlayer weld model. Tensile tests of 45 TIG butt welds and 6 EB beads-on-plate in 1/4-in. 2219-T87 aluminum plate made under a wide range of heat sink and power input conditions are analyzed using this theory. The analysis indicates that purely geometrical effects dominate in determining variations in weld joint strength with heat sink and power input. Variations in weld dimensions with cooling rate are significant as well as with power input. Weld size is suggested as a better indicator of the condition of a weld joint than energy input.

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.

Improving Joint Formation and Tensile Properties of Dissimilar Friction Stir Welding of Aluminum and Magnesium Alloys by Solving the Pin Adhesion Problem

NASA Astrophysics Data System (ADS)

Liu, Zhenlei; Ji, Shude; Meng, Xiangchen

2018-03-01

Friction stir welding (FSW), as a solid-state welding technology invented by TWI in 1991, has potential to join dissimilar Al/Mg alloys. In this study, the pin adhesion phenomenon affecting joint quality during FSW of 6061-T6 aluminum and AZ31B magnesium alloys was investigated. The adhesion phenomenon induced by higher heat input easily transformed the tapered-and-screwed pin into a tapered pin, which greatly reduced the tool's ability to drive the plasticized materials and further deteriorated joint formation. Under the condition without the pin adhesion, the complex intercalated interlayer at the bottom of stir zone was beneficial to mechanical interlocking of Al/Mg alloys, improving tensile properties. However, the formation of intermetallic compounds was still the main reason of the joint fracture, significantly deteriorating tensile properties. Under the welding speed of 60 mm/min without the pin adhesion phenomenon, the maximum tensile strength of 107 MPa and elongation of 1.2% were achieved.

Solid and liquid Equation of state for initially porous aluminum where specific heat is constant

NASA Astrophysics Data System (ADS)

Forbes, Jerry W.; Lemar, E. R.; Brown, Mary

2011-06-01

A porous solid's initial state is off the thermodynamic surface of the non-porous solid to start with but when pressure is high enough to cause total pore collapse or crush up, then the final states are on the condensed matter thermodynamic surfaces. The Hugoniot for the fully compacted solid is above the Principle Hugoniot with pressure, temperature and internal energy increased at a given v. There are a number of ways to define this hotter Hugoniot, which can be referenced to other thermodynamic paths on this thermodynamic surface. The choice here was to use the Vinet isotherm to define a consistent thermodynamic surface for the solid and melt phase of 6061 aluminum where specific heat is constant for the P-v-T space of interest. Analytical equations are developed for PH and TH.

Influence of Fluidized Bed Quenching on the Mechanical Properties and Quality Index of T6 Tempered B319.2-Type Aluminum Alloys

NASA Astrophysics Data System (ADS)

Ragab, Kh. A.; Samuel, A. M.; Al-Ahmari, A. M. A.; Samuel, F. H.; Doty, H. W.

2013-11-01

The current study aimed to investigate the effect of fluidized sand bed (FB) quenching on the mechanical performance of B319.2 aluminum cast alloys. Traditional water and conventional hot air (CF) quenching media were used to establish a relevant comparison with FB quenching. Quality charts were generated using two models of quality indices to support the selection of material conditions on the basis of the proposed quality indices. The use of an FB for the direct quenching-aging treatment of B319.2 casting alloys yields greater UTS and YS values compared to conventional furnace quenched alloys. The strength values of T6 tempered B319 alloys are greater when quenched in water compared with those quenched in an FB or CF. For the same aging conditions (170°C/4h), the fluidized bed quenched-aged 319 alloys show nearly the same or better strength values than those quenched in water and then aged in a CF or an FB. Based on the quality charts developed for alloys subjected to different quenching media, higher quality index values are obtained by conventional furnace quenched-aged T6-tempered B319 alloys. The modification factor has the most significant effect on the quality results of the alloys investigated, for all heat treatment cycles, as compared to other metallurgical parameters. The results of alloys subjected to multi-temperature aging cycles reveal that the optimum strength properties of B319.2 alloys, however, is obtained by applying multi-temperature aging cycles such as, for example, 240 °C/2 h followed by 170 °C/8 h, rather than T6 aging treatments. The regression models indicate that the mean quality values of B319 alloys are highly quench sensitive due to the formation of a larger percent of clusters in Al-Si-Cu-Mg alloys. These clusters act as heterogeneous nucleation sites for precipitation and enhance the aging process.

Reproducibility of Aluminum Foam by Combining Sintering and Dissolution Process with Precursor Foaming Process

NASA Astrophysics Data System (ADS)

Hangai, Yoshihiko; Matsushita, Hayato; Koyama, Shinji; Suzuki, Ryosuke; Matsubara, Masaaki

2017-07-01

A preliminary study of the reproducibility of aluminum foam was performed. Aluminum foam was fabricated by a sintering and dissolution process. It was found that aluminum foam containing a blowing agent can be fabricated without the decomposition of the blowing agent, namely, the densified aluminum foam can be used as a foamable precursor for refoaming. By heat treatment of the densified aluminum foam containing the blowing agent, pores were reproduced in the aluminum.

34 CFR 606.1 - What is the Developing Hispanic-Serving Institutions Program?

Code of Federal Regulations, 2010 CFR

2010-07-01

... 34 Education 3 2010-07-01 2010-07-01 false What is the Developing Hispanic-Serving Institutions Program? 606.1 Section 606.1 Education Regulations of the Offices of the Department of Education (Continued) OFFICE OF POSTSECONDARY EDUCATION, DEPARTMENT OF EDUCATION DEVELOPING HISPANIC-SERVING...

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

NASA Astrophysics Data System (ADS)

Reinhart, William

2011-06-01

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

Spin Forming of an Aluminum 2219-T6 Aft Bulkhead for the Orion Multi-Purpose Crew Vehicle: Phase II Supplemental Report

NASA Technical Reports Server (NTRS)

Piascik, Robert S.; Squire, Michael D.; Domack, Marcia S.; Hoffman, Eric K.

2015-01-01

The principal focus of this project was to assist the Orion Multi-Purpose Crew Vehicle (MPCV) Program in developing a spin forming fabrication process for manufacture of the aft bulkhead of the pressure vessel. The spin forming process will enable a single piece aluminum (Al) 2219 aft bulkhead which will eliminate the current multiple piece welded construction, simplify fabrication, and lead to an enhanced design that will reduce vehicle weight by eliminating welds. Phase I of this assessment explored spin forming the single-piece forward pressure vessel bulkhead from aluminum-lithium 2195.

Fabrication and properties of aluminum silicate fibrous materials with in situ synthesized K2Ti6O13 whiskers

NASA Astrophysics Data System (ADS)

Liu, Hao; Wei, Nan; Wang, Zhou-fu; Wang, Xi-tang; Ma, Yan

2017-11-01

To improve their mechanical and thermal insulation properties, aluminum silicate fibrous materials with in situ synthesized K2Ti6O13 whiskers were prepared by firing a mixture of short aluminum silicate fibers and gel powders obtained from a sol-gel process. During the preparation process, the fiber surface was coated with K2Ti6O13 whiskers after the fibers were subjected to a heat treatment carried out at various temperatures. The effects of process parameters on the microstructure, compressive strength, and thermal conductivity were analyzed systematically. The results show that higher treatment temperatures and longer treatment durations promoted the development of K2Ti6O13 whiskers on the surface of aluminum silicate fibers; in addition, the intersection structure between whiskers modulated the morphology and volume of the multi-aperture structure among fibers, substantially increasing the fibers' compressive strength and reducing their heat conduction and convective heat transfer at high temperatures.

Residual stress analysis on AA6061+22% Al2O3p simple shape demonstrators of a wheel hub

NASA Astrophysics Data System (ADS)

Giuliani, Alessandra; Albertini, Gianni; Fiori, Fabrizio; Girardin, Emmanuelle

2004-07-01

The effects of thermal treatments in a component for automotive industry are considered: the induced residual stresses in wheel hubs were investigated. Measurements have been carried out on two identical simple shape demonstrators made of AA6061+22% Al2O3p in order to evaluate the stress conditions after forging and T6 treatment and without taking into account the final design of the wheel hub. One sample was analysed in as-forged conditions while the second after forging and T6 treatment (560°C for 2h, 20°C water quenching, artificial aging at 177°C for 10h). Particular attention was given to the stresses in the radial and hoop directions, as the main consequences of the in-service fatigue are expected to be related to stresses along these two directions.

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.

Corrosion Behavior of Aluminum Alloys in Acidic Media

NASA Astrophysics Data System (ADS)

Ramli, Rosliza; Seoh, S. Y.; Nik, W. B. Wan; Senin, H. B.

2007-05-01

The corrosion inhibition of Al and its alloys are the subject of tremendous technological importance due to the increased industrial applications of these materials. This study will report the results of weight loss, polarization and electrochemical impedance spectroscopic (EIS) measurements on the corrosion inhibition of AA6061 and AA6063 aluminum alloys in acidic media using sodium benzoate as an inhibitor. The results showed that addition of sodium benzoate retards the rate of dissolution and hence inhibits the corrosion of the aluminum alloy in acidic media. The inhibition efficiency increases with the increase of immersion time in acetic acid however it displays a different behavior in sulfuric acid. Langmuir adsorption isotherm fits well with the experimental data. EIS studies showed that there was a significant increase in overall resistance after addition of sodium benzoate, when compared to the case without inhibitor. Langmuir adsorption isotherm fits well with the experimental data.

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.

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.

An investigation of plastic fracture in aluminum alloys

NASA Technical Reports Server (NTRS)

Low, J. R., Jr.; Vanstone, R. H.; Merchant, R. H.

1972-01-01

The brittle fracture of many high strength alloys such as steel, titanium, and aluminum was shown to occur by a process called plastic fracture. According to this process microscopic voids form at impurity particles, then grow and coalesce to cause the final rupture. To further understand the role of impurities, four aluminum alloys were investigated: 2024-T851, 2124-T851, 7075-T7351 and 7079-T651. Fractography, quantitative metallography, and microprobe studies assessed the roles of various impurity particles relative to these alloys.

Plastic Stress-strain Relations for 75S-T6 Aluminum Alloy Subjected to Biaxial Tensile Stresses

NASA Technical Reports Server (NTRS)

Marin, Joseph; Ulrich, B H; Hughes, W P

1951-01-01

In this investigation, the material tested was a 75S-T6 aluminum alloy and the stresses were essentially biaxial and tensile. The biaxial tensile stresses were produced in a specially designed testing machine by subjecting a thin-walled tubular specimen to axial tension and internal pressure. Plastic stress-strain relations for various biaxial stress conditions were obtained using a clip-type SR-4 strain gage. Three types of tests were made: Constant-stress-ratio tests, variable-stress-ratio tests, and special tests. The constant-stress-ratio test results gave control data and showed the influence of biaxial stresses on the yield, fracture, and ultimate strength of the material. By means of the variable-stress-ratio tests, it is possible to determine whether there is any significant difference between the flow and deformation type of theory. Finally, special tests were conducted to check specific assumptions made in the theories of plastic flow. The constant-stress-ratio tests show that the deformation theory based on the octahedral, effective; or significant stress-strain relations is in approximate agreement with the test results. The variable-stress-ratio tests show that both the deformation and flow theory are in equally good agreement with the test results.

Temperature-dependent tensile and shear response of graphite/aluminum

NASA Technical Reports Server (NTRS)

Fujita, T.; Pindera, M. J.; Herakovich, C. T.

1987-01-01

The thermo-mechanical response of unidirectional P100 graphite fiber/6061 aluminum matrix composites was investigated at four temperatures:-150, +75, +250, and +500 F. Two types of tests, off-axis tension and losipescu shear, were used to obtain the desired properties. Good experimental-theoretical correlation was obtained for Exx, vxy, and G12. It is shown that E11 is temperature independent, but E22, v12, and G12 generally decrease with increasing temperature. Compared with rather high longitudinal strength, very low transverse strength was obtained for the graphite/aluminum. The poor transverse strength is believed to be due to the low interfacial bond strength in this material. The strength decrease significantly with increasing temperature. The tensile response at various temperatures is greatly affected by the residual stresses caused by the mismatch in the coefficients of thermal expansion of fibers and matrix. The degradation of the aluminum matrix properties at higher temperatures has a deleterious effect on composite properties. The composite has a very low coefficient of thermal expansion in the fiber direction.

The aluminum smelting process and innovative alternative technologies.

PubMed

Kvande, Halvor; Drabløs, Per Arne

2014-05-01

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. This article is based on a study of the extensive chemical and medical literature on primary aluminum production. 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. 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.

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

Effects of filling material and laser power on the formation of intermetallic compounds during laser-assisted friction stir butt welding of steel and aluminum alloys

NASA Astrophysics Data System (ADS)

Fei, Xinjiang; Jin, Xiangzhong; Peng, Nanxiang; Ye, Ying; Wu, Sigen; Dai, Houfu

2016-11-01

In this paper, two kinds of materials, Ni and Zn, are selected as filling material during laser-assisted friction stir butt welding of Q235 steel and 6061-T6 aluminum alloy, and their influences on the formation of intermetallic compounds on the steel/aluminum interface of the joints were first studied. SEM was used to analyze the profile of the intermetallic compound layer and the fractography of tensile fracture surfaces. In addition, EDS was applied to investigate the types of the intermetallic compounds. The results indicate that a thin iron-abundant intermetallic compound layer forms and ductile fracture mode occurs when Ni is added, but a thick aluminum-abundant intermetallic compound layer generates and brittle fracture mode occurs when Zn is added. So the tensile strength of the welds with Ni as filling material is greater than that with Zn as filling material. Besides, the effect of laser power on the formation of intermetallic compound layer when Ni is added was investigated. The preheated temperature field produced by laser beam in the cross section of workpiece was calculated, and the tensile strength of the joints at different laser powers was tested. Results show that only when suitable laser power is adopted, can suitable preheating temperature of the steel reach, then can thin intermetallic compound layer form and high tensile strength of the joints reach. Either excessive or insufficient laser power will reduce the tensile strength of the joints.

Leaching Process Investigation of Secondary Aluminum Dross: The Effect of CO2 on Leaching Process of Salt Cake from Aluminum Remelting Process

NASA Astrophysics Data System (ADS)

Li, Peng; Guo, Min; Zhang, Mei; Teng, Lidong; Seetharaman, Seshadri

2012-10-01

For the recycling/disposal of aluminum dross/salt cake from aluminum remelting, aqueous leaching offers an interesting economic process route. One major obstacle is the reaction between the AlN present in the dross and the aqueous phase, which can lead to the emission of NH3 gas, posing a serious environmental problem. In the current work, a leaching process using CO2-saturated water is attempted with a view to absorb the ammonia formed in situ. The current results show that at a solid-to-liquid ratio of 1:20 and 3 hours at 291 K (18 °C), the extraction of Na and K from the dross could be kept as high as 95.6 pct and 95.9 pct respectively. At the same time, with continuous CO2 bubbling, the mass of escaping NH3 gas decreased from 0.25 mg in pure water down to <0.006 mg, indicating effective absorption of ammonia by carbonized water. Furthermore, the results in the case of the leaching experiments with synthetic AlN show that the introduction of CO2 causes hindrance to the hydrolysis of AlN. The plausible mechanisms for the observed phenomena are discussed. The concept of the leaching of the salt cake by carbonated water and the consequent retention of AlN in the leach residue opens up a promising route toward an environment-friendly recycling process for the salt cake viz. recovery of the salts, utilization of CO2, and further processing of the dross residue, toward the synthesis of AlON from the leach residues.

Tensile and Microindentation Stress-Strain Curves of Al-6061

DOE Data Explorer

Weaver, Jordan S [Los Alamos National Lab. (LANL), Los Alamos, NM (United States). Center for Integrated Nanotechnologies (CINT); Khosravani, Ali [Georgia Inst. of Technology, Atlanta, GA (United States); Castillo, Andrew [Georgia Inst. of Technology, Atlanta, GA (United States); Kalidind, Surya R [Georgia Inst. of Technology, Atlanta, GA (United States)

2016-07-13

Recent spherical microindentation stress-strain protocols were developed and validated on Al-6061 (DOI: 10.1186/s40192-016-0054-3). The scaling factor between the uniaxial yield strength and the indentation yield strength was determined to be about 1.9. The microindentation stress-strain protocols were then applied to a microstructurally graded sample in an effort to extract high throughput process-property relationships. The tensile and microindentation force-displacement and stress-strain data are presented in this data set.

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.

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.

Microstructural analysis of as-processed U-10 wt.%Mo monolithic fuel plate in AA6061 matrix with Zr diffusion barrier

NASA Astrophysics Data System (ADS)

Perez, E.; Yao, B.; Keiser, D. D., Jr.; Sohn, Y. H.

2010-07-01

For higher U-loading in low-enriched U-10 wt.%Mo fuels, monolithic fuel plate clad in AA6061 is being developed as a part of Reduced Enrichment for Research and Test Reactor (RERTR) program. This paper reports the first characterization results from a monolithic U-10 wt.%Mo fuel plate with a Zr diffusion barrier that was fabricated as part of a plate fabrication campaign for irradiation testing in the Advanced Test Reactor (ATR). Both scanning and transmission electron microscopy (SEM and TEM) were employed for analysis. At the interface between the Zr barrier and U-10 wt.%Mo, going from Zr to U(Mo), UZr 2, γ-UZr, Zr solid-solution and Mo 2Zr phases were observed. The interface between AA6061 cladding and Zr barrier plate consisted of four layers, going from Al to Zr, (Al, Si) 2Zr, (Al, Si)Zr 3 (Al, Si) 3Zr, and AlSi 4Zr 5. Irradiation behavior of these intermetallic phases is discussed based on their constituents. Characterization of as-fabricated phase constituents and microstructure would help understand the irradiation behavior of these fuel plates, interpret post-irradiation examination, and optimize the processing parameters of monolithic fuel system.

Corrosion Fatigue of Anodized Aluminum 7075-T73 in Salt Ladened Humid Air.

DTIC Science & Technology

1981-01-01

relative humidity and coating thickness on the fatigue of anodized 2024-T351 aluminum in reversed torsion . They also found no effect of coating ... fatigue resistance. Most of the previous corrosion fatigue work has been on the effect of relative humidity on the fatigue life of coated aluminum ...alloys. Eeles and 1hurston Iwere some of the early investigators

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.

Constitutive Model Constants for Al7075-T651 and Al7075-T6

NASA Astrophysics Data System (ADS)

Brar, N. S.; Joshi, V. S.; Harris, B. W.

2009-12-01

Aluminum 7075-T651 and 7075-T6 are characterized at quasi-static and high strain rates to determine Johnson-Cook (J-C) strength and fracture model constants. Constitutive model constants are required as input to computer codes to simulate projectile (fragment) impact or similar impact events on structural components made of these materials. Although the two tempers show similar elongation at breakage, the ultimate tensile strength of T651 temper is generally lower than the T6 temper. Johnson-Cook strength model constants (A, B, n, C, and m) for the two alloys are determined from high strain rate tension stress-strain data at room and high temperature to 250°C. The Johnson-Cook fracture model constants are determined from quasi-static and medium strain rate as well as high temperature tests on notched and smooth tension specimens. Although the J-C strength model constants are similar, the fracture model constants show wide variations. Details of the experimental method used and the results for the two alloys are presented.

Effect of water-cooling treatment times on properties of friction stir welded joints of 7N01-T4 aluminum alloy

NASA Astrophysics Data System (ADS)

Zhang, T. H.; Wang, Y.; Fang, X. F.; Liang, P.; Zhao, Y.; Li, Y. H.; Liu, X. M.

2018-02-01

Due to the deformation caused by residual stress in the welding process, welded components need treatment to reduce welding distortion. In this paper, several different times of flame-heating and water-cooling treatment were subjected to the friction stir welding joints of 15mm thick 7N01P-T4 aluminum alloy sheets to study the microstructure variation of friction stir welding joints of 7N01P-T4 aluminum alloy, and to analyze the effect on micro-hardness, tensile and fracture mechanical properties. This investigation will be helpful to optimize treatment methods and provide instruction on industrial production.

Finite element modelling of aluminum alloy 2024-T3 under transverse impact loading

NASA Astrophysics Data System (ADS)

Abdullah, Ahmad Sufian; Kuntjoro, Wahyu; Yamin, A. F. M.

2017-12-01

Fiber metal laminate named GLARE is a new aerospace material which has great potential to be widely used in future lightweight aircraft. It consists of aluminum alloy 2024-T3 and glass-fiber reinforced laminate. In order to produce reliable finite element model of impact response or crashworthiness of structure made of GLARE, one can initially model and validate the finite element model of the impact response of its constituents separately. The objective of this study was to develop a reliable finite element model of aluminum alloy 2024-T3 under low velocity transverse impact loading using commercial software ABAQUS. Johnson-Cook plasticity and damage models were used to predict the alloy's material properties and impact behavior. The results of the finite element analysis were compared to the experiment that has similar material and impact conditions. Results showed good correlations in terms of impact forces, deformation and failure progressions which concluded that the finite element model of 2024-T3 aluminum alloy under low velocity transverse impact condition using Johnson-Cook plastic and damage models was reliable.

Microstructures and Mechanical Properties of Friction Stir Spot Welded Aluminum Alloy AA2014

NASA Astrophysics Data System (ADS)

Babu, S.; Sankar, V. S.; Janaki Ram, G. D.; Venkitakrishnan, P. V.; Madhusudhan Reddy, G.; Prasad Rao, K.

2013-01-01

Friction stir spot welding (FSSW) is a relatively recent development, which can provide a superior alternative to resistance spot welding and riveting for fabrication of aluminum sheet metal structures. In the current work, FSSW experiments were conducted in 3-mm thick sheets of aluminum alloy 2014 in T4 and T6 conditions, with and without Alclad layers. The effects of tool geometry and welding process parameters on joint formation were investigated. A good correlation between process parameters, bond width, hook height, joint strength, and fracture mode was observed. The presence of Alclad layers and the base metal temper condition were found to have no major effect on joint formation and joint strength. Friction stir spot welds produced under optimum conditions were found to be superior to riveted joints in lap-shear and cross-tension tests. The prospects of FSSW in aluminum sheet metal fabrication are discussed.

Study of mechanical joint strength of aluminum alloy 7075-T6 and dual phase steel 980 welded by friction bit joining and weld-bonding under corrosion medium

DOE PAGES

Lim, Yong Chae; Squires, Lile; Pan, Tsung-Yu; ...

2014-12-30

We have employed a unique solid-sate joining process, called friction bit joining (FBJ), to spot weld aluminum alloy (AA) 7075-T6 and dual phase (DP) 980 steel. Static joint strength was studied in the lap shear tension configuration. In addition, weld-bonding (adhesive + FBJ) joints were studied in order to evaluate the ability of adhesive to mitigate the impact of corrosion on joint properties. Accelerated laboratory cyclic corrosion tests were carried out for both FBJ only and weld-bonding joints. Furthermore, the FBJ only joints that emerged from corrosion testing had lap shear failure loads that were significantly lower than freshly preparedmore » joints. However, weld-bonding specimens retained more than 80% of the lap shear failure load of the freshly prepared weld-bonding specimens. Moreover, examination of joint cross sections confirmed that the presence of adhesive in the weld-bonding joints mitigated the effect of the corrosion environment, compared to FBJ only joints.« less

Thermal conductance of gold plated metallic contacts at liquid helium temperatures

NASA Technical Reports Server (NTRS)

Kittel, Peter; Spivak, Alan L.; Salerno, Louis J.

1992-01-01

The thermal conductance of gold plated OFHC copper, 6061-T6 aluminum, free-machining brass, and 304 stainless steel contacts has been measured over the temperature range of 1.6 to 4.2 K, with applied forces from 22 N to 670 N. The contact surfaces were prepared with a 0.8 micron lapped finish prior to gold coating. It was found that for all materials, except stainless steel, the thermal conductance was significantly improved as the result of gold coating the contact surfaces.

Constitutive Model Constants for Al7075-T651 and Al7075-T6

NASA Astrophysics Data System (ADS)

Brar, Nachhatter; Joshi, Vasant; Harris, Bryan

2009-06-01

Aluminum 7075-T651 and 7075-T6 are characterized at quasi-static and high strain rates to determine Johnson-Cook (J-C) strength and fracture model constants. Constitutive model constants are required as input to computer codes to simulate projectile (fragment) impact or similar impact events on structural components made of these material. J-C strength model constants (A, B, n, C, and m) for the two alloys are determined from tension stress-strain data at room and high temperature to 250^oC. J-C strength model constants for Al7075-T651 are: A=527 MPa, B=676 MPa, n=0.71, C=0.017, and m=1.61 and for Al7075-T6: A = 546 MPa, B = 674 MPa, n = 0.72, C = 0.059, and m =1.56. J-C fracture model constants are determined form quasi-static and high strain rate/high temperature tests on notched and smooth tension specimens. J-C fracture model constants for the two alloys are: Al7075-T651; D1 = 0.110, D2 = 0.573, D3= -3.4446, D4 = 0.016, and D 5= 1.099 and Al7075-T6; D1= 0.451 D2= -0.952 D3= -.068, D4 =0.036, and D5 = 0.697.

Fatigue Crack-Growth Resistance of Aluminum Alloys Under Spectrum Loading. Volume 2. Aluminum Lithium Alloys.

DTIC Science & Technology

1985-12-01

Effects on Fatigue Crack Propagation in 2024 -T3 Aluminum Alloy ," Eng. Frac. Mech, * Vol. 8, 1976, p. 657...Retardation Behavior of 7075 * and 2024 Aluminum Alloys ," ASTNI STP 631, 1977. 89 hill". .A•, - . 34. Chanani, G.R., "Investigation of Effects of Saltwater...1.0 9,අ &M Ma ki-L6 &Ŗ &- La 06 lin "Ll Ull 1.25 "A Lm Wit Rtlc()FIV WtklLl’-"- ll*A FATIGUE CRACK-GROWTH RESISTANCE OF ALUMINUM ALLOYS

Investigation of Microstructure and Microhardness in Self-Reacting Friction Stir Welded AA2014-T6 and AA2219-T87

NASA Technical Reports Server (NTRS)

Horton, K. Renee; McGill, Preston; Barkey, Mark

2011-01-01

Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. This work reports on the microstructure and microhardness of SR-FSW between two dissimilar aluminum alloys. Specifically, the study examines the cross section of the weld joint formed between an AA2014-T6 plate on the advancing side and an AA2219-T87 plate on the retreating side. The microstructural analysis shows an irregularly displaced weld seam from the advancing side past the thermo-mechanical affected zone (TMAZ) into the weld nugget region. There are sharp variations in the microhardness across the weld. These variations are described in the paper and mechanisms for their formation are discussed.

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.

Effect of KOH to Na2SiO3 Ratio on Microstructure and Hardness of Plasma Electrolytic Oxidation Coatings on AA 6061 Alloy

NASA Astrophysics Data System (ADS)

Sharma, Ashutosh; Jang, Yong-Joo; Jung, Jae Pil

2017-10-01

In this study, plasma electrolytic oxidation (PEO) process has been employed to fabricate alumina coatings on AA 6061 aluminum alloy from an electrolyte containing water glass (Na2SiO3) and alkali (KOH). The effect of deposition time and the alkali to water glass (KOH: Na2SiO3) composition ratio on the coating morphology and properties are studied. The different phases of the oxide layer and microstructure are investigated by x-ray diffraction, scanning electron microscopy, and atomic force microscopy. The results indicate that initially γ-Al2O3 forms in the coating, and as the processing time is increased from 5 to 60 minutes, α-Al2O3 phase becomes prominent. Further, higher the content of Na2SiO3, higher is the hardness and coating growth rate due to the formation of stable α-Al2O3 and Al-Si-O phase. It has been reported that the optimum properties of the PEO coatings can be obtained at a ratio of KOH: Na2SiO3 ≈ 15:10 followed by 10:10.

Impact of Alternative Processes for Aluminum Production on Energy Requirements

NASA Astrophysics Data System (ADS)

Grjotheim, Kai; Welch, Barry

1981-09-01

Increasing prices and the shortage of large blocks of electrical energy have given greater impetus to the search for viable alternative processes for aluminum production. These include electrolysis of aluminum chloride, sulfide, and nitride; carbothermal reduction of either the ore or alumina; and disproportioning reactions of either aluminum sulfide or the monochloride route. Common to all these processes are the starting material—an ore containing aluminum oxide—and the final product—the metal. Thus, the thermodynamic cycle will invariably dictate similar theoretical energy requirements for the three processes. In practice, however, the achievable efficiencies and, more noticeably, the proportion of electrical to carbothermal energy required for the various stages of operation can vary. The present status of these alternative processes indicates that while alternative routes, such as the Alcoa-AlCl3-Smelting Process, show distinct potential for reducing electrical energy requirements, they offer little chance of reducing overall energy requirements. Furthermore, because of more stringent purity requirements, any gains made may be at the expense of production costs.

The Strength and Characteristics of VPPA Welded 2219-T87 Aluminum Alloy

NASA Technical Reports Server (NTRS)

Jemian, W. A.

1985-01-01

A study of the variable polarity plasma arc (VPPA) welding process and those factors that control the structure and properties of VPPA welded aluminum alloy 2219-T87 was conducted. The importance of joint preparation, alignment of parts and welding process variables are already established. Internal weld defects have been eliminated. However, a variation of properties was found to be due to the size variation of interdendritic particles in the fusion zone. These particles contribute to the void formation process, which controls the ultimate tensile strength of the welded alloy. A variation of 150 microns in particle size correlated with a 10 ksi variation of ultimate tensile strength. It was found that all fracture surfaces were of the dimple rupture type, with fracture initiating within the fusion zone.

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

Surface characterization of selected LDEF tray clamps

NASA Technical Reports Server (NTRS)

Cromer, T. F.; Grammer, H. L.; Wightman, J. P.; Young, Philip R.; Slemp, Wayne S.

1993-01-01

The surface characterization of chromic acid anodized 6061-T6 aluminum alloy tray clamps has shown differences in surface chemistry depending upon the position on the Long Duration Exposure Facility (LDEF). Water contact angle results showed no changes in wettability of the tray clamps. The overall surface topography of the control, trailing edge(E3) and leading edge(D9) samples was similar. The thickness of the aluminum oxide layer for all samples determined by Auger depth profiling was less than one micron. X-ray photoelectron spectroscopy (XPS) analysis of the tray clamps showed significant differences in the surface composition. Carbon and silicon containing compounds were the primary contaminants detected.

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. Copyright © 2014 Elsevier Ltd. All rights reserved.

Reactivity and Fragmentation of Aluminum-based Structural Energetic Materials under Explosive Loading

NASA Astrophysics Data System (ADS)

Glumac, Nick; Clemenson, Michael; Guadarrama, Jose; Krier, Herman

2015-06-01

Aluminum-cased warheads have been observed to generate enhanced blast and target damage due to reactivity of the aluminum fragments with ambient air. This effect can more than double the output of a conventional warhead. The mechanism by which the aluminum reacts under these conditions remains poorly understood. We undertake a highly controlled experimental study to investigate the phenomenon of aluminum reaction under explosive loading. Experiments are conducted with Al 6061 casings and PBX-N9 explosive with a fixed charge to case mass ratio of 1:2. Results are compared to inert casings (steel), as well as to tests performed in nitrogen environments to isolate aerobic and anaerobic effects. Padded walls are used in some tests to isolate the effects of impact-induced reactions, which are found to be non-negligible. Finally, blast wave measurements and quasi-static pressure measurements are used to isolate the fraction of case reaction that is fast enough to drive the primary blast wave from the later time reaction that generates temperature and overpressure only in the late-time fireball. Fragment size distributions, including those in the micron-scale range, are collected and quantified.

Chemical forms of tritium on the release from aluminum

NASA Astrophysics Data System (ADS)

Yokoyama, A.; Nakashima, M.; Tachikawa, E.

1981-10-01

The release-behavior of tritium from aluminum, where tritium has been injected into aluminum samples through 6Li(n,α)T transmutation reaction, has been investigated. When the aluminum samples were dissolved in NaOH/D 2O solutions, a majority of T has appeared as DT but a small fraction as HT, T 2 and DTO. It has been concluded that both HT and T 2 were formed inside of the aluminum. Their formations compete each other and their relative yields are correlated with the impurity content of protium in the sample. The time-profiles of the release rate of tritium on heating the sample have been compared with the results calculated with an appropriate assumption. A little difference between them can be reasonably ascribed to the presence of thin oxide film covering the sample surface.

Evaluation of microstructure stability at the interfaces of Al-6061 welds fabricated using ultrasonic additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sridharan, Niyanth S.; Gussev, Maxim N.; Parish, Chad M.

Here, ultrasonic additive manufacturing (UAM) is a solid-state additive manufacturing process that uses fundamental principles of ultrasonic welding and sequential layering of tapes to fabricate complex three-dimensional (3-D) components. One of the factors limiting the use of this technology is the poor tensile strength along the z-axis. Recent work has demonstrated the improvement of the z-axis properties after post-processing treatments. The abnormally high stability of the grains at the interface during post-weld heat treatments is, however, not yet well understood. In this work we use multiscale characterization to understand the stability of the grains during post-weld heat treatments. Aluminum alloymore » (6061) builds, fabricated using ultrasonic additive manufacturing, were post-weld heat treated at 180, 330 and 580 °C. The grains close to the tape interfaces are stable during post-weld heat treatments at high temperatures (i.e., 580 °C). This is in contrast to rapid grain growth that takes place in the bulk. Transmission electron microscopy and atom-probe tomography display a significant enrichment of oxygen and magnesium near the stable interfaces. Based on the detailed characterization, two mechanisms are proposed and evaluated: nonequilibrium nano-dispersed oxides impeding the grain growth due to grain boundary pinning, or grain boundary segregation of magnesium and oxygen reducing the grain boundary energy.« less

Evaluation of microstructure stability at the interfaces of Al-6061 welds fabricated using ultrasonic additive manufacturing

DOE PAGES

Sridharan, Niyanth S.; Gussev, Maxim N.; Parish, Chad M.; ...

2018-03-06

Here, ultrasonic additive manufacturing (UAM) is a solid-state additive manufacturing process that uses fundamental principles of ultrasonic welding and sequential layering of tapes to fabricate complex three-dimensional (3-D) components. One of the factors limiting the use of this technology is the poor tensile strength along the z-axis. Recent work has demonstrated the improvement of the z-axis properties after post-processing treatments. The abnormally high stability of the grains at the interface during post-weld heat treatments is, however, not yet well understood. In this work we use multiscale characterization to understand the stability of the grains during post-weld heat treatments. Aluminum alloymore » (6061) builds, fabricated using ultrasonic additive manufacturing, were post-weld heat treated at 180, 330 and 580 °C. The grains close to the tape interfaces are stable during post-weld heat treatments at high temperatures (i.e., 580 °C). This is in contrast to rapid grain growth that takes place in the bulk. Transmission electron microscopy and atom-probe tomography display a significant enrichment of oxygen and magnesium near the stable interfaces. Based on the detailed characterization, two mechanisms are proposed and evaluated: nonequilibrium nano-dispersed oxides impeding the grain growth due to grain boundary pinning, or grain boundary segregation of magnesium and oxygen reducing the grain boundary energy.« less

Brazing process provides high-strength bond between aluminum and stainless steel

NASA Technical Reports Server (NTRS)

Huschke, E. G., Jr.; Nord, D. B.

1966-01-01

Brazing process uses vapor-deposited titanium and an aluminum-zirconium-silicon alloy to prevent formation of brittle intermetallic compounds in stainless steel and aluminum bonding. Joints formed by this process maintain their high strength, corrosion resistance, and hermetic sealing properties.

Numerical Simulation and Experimental Validation of MIG Welding of T-Joints of Thin Aluminum Plates for Top Class Vehicles

NASA Astrophysics Data System (ADS)

Bonazzi, Enrico; Colombini, Elena; Panari, Davide; Vergnano, Alberto; Leali, Francesco; Veronesi, Paolo

2017-01-01

The integration of experiments with numerical simulations can efficiently support a quick evaluation of the welded joint. In this work, the MIG welding operation on aluminum T-joint thin plate has been studied by the integration of both simulation and experiments. The aim of the paper is to enlarge the global database, to promote the use of thin aluminum sheets in automotive body industries and to provide new data. Since the welding of aluminum thin plates is difficult to control due to high speed of the heat source and high heat flows during heating and cooling, a simulation model could be considered an effective design tool to predict the real phenomena. This integrated approach enables new evaluation possibilities on MIG-welded thin aluminum T-joints, as correspondence between the extension of the microstructural zones and the simulation parameters, material hardness, transient 3D temperature distribution on the surface and inside the material, stresses, strains, and deformations. The results of the mechanical simulations are comparable with the experimental measurements along the welding path, especially considering the variability of the process. The results could well predict the welding-induced distortion, which together with local heating during welding must be anticipated and subsequently minimized and counterbalance.

Lightweight Metal/Polymer/Metal Sandwich Composites for Automotive Applications

NASA Astrophysics Data System (ADS)

Ferrari, Federico

Sandwich composites are becoming increasingly popular in the automotive sector as they are lightweight and facilitate noise attenuation. However, given that sandwich composites are relatively new in the sector, there are questions as to whether they can effectively replace monolithic metals and damping patches without compromising mechanical performance. Quiet Aluminum RTM, a sandwich composite produced by Material Sciences Corporation (MSC), employs as skins two aluminum alloys that are common in automotive manufacturing: 5754-O and 6061-T4. The current study examines and compares the mechanical properties of Quiet AluminumRTM with the main Fiat Chrysler Automobiles (FCA) requirements for laminates with non-structural loads. The adhesion mechanism between the layers of the sandwich composites received was examined through: T-Peel test, roughness measurements and metallographic cross sectioning technique. The current study then employed tensile tests with different treatments applied to the sandwich materials, a Self-Piercing Riveting (SPR) joining evaluation, and hardness tests on the core section of the aluminum skins. The samples, which presented rolling mill-finish surface roughness Ra range of 0.46-0.56 micro m, met the FCA adhesion requirements with adhesive failure mode even after the paint bake-cycle simulation (20 min at 185 °C) and the hardening treatment applied on the sandwich with AA6061-T4 skin (1 h at 200 °C). The tensile properties, computed simulating stamping process (2% pre-applied strain), the paint-bake cycle and the hardening treatment were comparable to the monolithic ones. Finally, SPR technique, evaluated through lap shear test and macro-graphic measurements, successfully joined Quiet AluminumRTM samples (1.06 mm thickness) with structural High Strength Low Alloy steel (HSLA,1.8 mm thickness and 340 MPa minimum yield strength).

Cratering Equations for Zinc Orthotitanate Coated Aluminum

NASA Technical Reports Server (NTRS)

Hyde, James; Christiansen, Eric; Liou, Jer-Chyi; Ryan, Shannon

2009-01-01

The final STS-125 servicing mission (SM4) to the Hubble Space Telescope (HST) in May of 2009 saw the return of the 2nd Wide Field Planetary Camera (WFPC2) aboard the shuttle Discovery. This hardware had been in service on HST since it was installed during the SM1 mission in December of 1993 yielding one of the longest low Earth orbit exposure times (15.4 years) of any returned space hardware. The WFPC2 is equipped with a 0.8 x 2.2 m radiator for thermal control of the camera electronics (Figure 1). The space facing surface of the 4.1 mm thick aluminum radiator is coated with Z93 zinc orthotitanate thermal control paint with a nominal thickness of 0.1 0.2 mm. Post flight inspections of the radiator panel revealed hundreds of micrometeoroid/orbital debris (MMOD) impact craters ranging in size from less than 300 to nearly 1000 microns in diameter. The Z93 paint exhibited large spall areas around the larger impact sites (Figure 2) and the craters observed in the 6061-T651 aluminum had a different shape than those observed in uncoated aluminum. Typical hypervelocity impact craters in aluminum have raised lips around the impact site. The craters in the HST radiator panel had suppressed crater lips, and in some cases multiple craters were present instead of a single individual crater. Humes and Kinard observed similar behavior after the WFPC1 post flight inspection and assumed the Z93 coating was acting like a bumper in a Whipple shield. Similar paint behavior (spall) was also observed by Bland2 during post flight inspection of the International Space Station (ISS) S-Band Antenna Structural Assembly (SASA) in 2008. The SASA, with similar Z93 coated aluminum, was inspected after nearly 4 years of exposure on the ISS. The multi-crater phenomena could be a function of the density, composition, or impact obliquity angle of the impacting particle. For instance, a micrometeoroid particle consisting of loosely bound grains of material could be responsible for creating the

Stress corrosion cracking of an aluminum alloy used in external fixation devices.

PubMed

Cartner, Jacob L; Haggard, Warren O; Ong, Joo L; Bumgardner, Joel D

2008-08-01

Treatment for compound and/or comminuted fractures is frequently accomplished via external fixation. To achieve stability, the compositions of external fixators generally include aluminum alloy components due to their high strength-to-weight ratios. These alloys are particularly susceptible to corrosion in chloride environments. There have been several clinical cases of fixator failure in which corrosion was cited as a potential mechanism. The aim of this study was to evaluate the effects of physiological environments on the corrosion susceptibility of aluminum 7075-T6, since it is used in orthopedic external fixation devices. Electrochemical corrosion curves and alternate immersion stress corrosion cracking tests indicated aluminum 7075-T6 is susceptible to corrosive attack when placed in physiological environments. Pit initiated stress corrosion cracking was the primary form of alloy corrosion, and subsequent fracture, in this study. Anodization of the alloy provided a protective layer, but also caused a decrease in passivity ranges. These data suggest that once the anodization layer is disrupted, accelerated corrosion processes occur. (c) 2007 Wiley Periodicals, Inc.

Experimental Investigation and Optimization of TIG Welding Parameters on Aluminum 6061 Alloy Using Firefly Algorithm

NASA Astrophysics Data System (ADS)

Kumar, Rishi; Mevada, N. Ramesh; Rathore, Santosh; Agarwal, Nitin; Rajput, Vinod; Sinh Barad, AjayPal

2017-08-01

To improve Welding quality of aluminum (Al) plate, the TIG Welding system has been prepared, by which Welding current, Shielding gas flow rate and Current polarity can be controlled during Welding process. In the present work, an attempt has been made to study the effect of Welding current, current polarity, and shielding gas flow rate on the tensile strength of the weld joint. Based on the number of parameters and their levels, the Response Surface Methodology technique has been selected as the Design of Experiment. For understanding the influence of input parameters on Ultimate tensile strength of weldment, ANOVA analysis has been carried out. Also to describe and optimize TIG Welding using a new metaheuristic Nature - inspired algorithm which is called as Firefly algorithm which was developed by Dr. Xin-She Yang at Cambridge University in 2007. A general formulation of firefly algorithm is presented together with an analytical, mathematical modeling to optimize the TIG Welding process by a single equivalent objective function.

Design, fabrication and test of a hydrogen heat pipe. [extruding and grooving 6063-T6 aluminum tubes for cryogenic heat pipes

NASA Technical Reports Server (NTRS)

Alario, J.

1979-01-01

Re-entrant groove technology was extended to hydrogen heat pipes. Parametric analyses are presented which optimize the theoretical design while considering the limitations of state-of-the-art extrusion technology. The 6063-T6 aluminum extrusion is 14.6 mm OD with a wall thickness of 1.66 mm and contains 20 axial grooves which surround a central 9.3 mm diameter vapor core. Each axial groove is 0.775 mm diameter with a 0.33 mm opening. An excess vapor reservoir is provided at the evaporator to minimize the pressure containment hazard during ambient storage. Modifications to the basic re-entrant groove profile resulted in improved overall performance. While the maximum heat transport capacity decreased slightly to 103 w-m the static wicking height increased markedly to 4.5 cm. The heat pipe became operational between 20 and 30 K after a cooldown from 77 K without any difficulty. Steady state performance data taken over a 19 to 23 K temperature range indicated: (1) maximum heat transport capacity of 5.4 w-m; (2) static wicking height of 1.42 cm; and (3) overall heat pipe conductance of 1.7 watts/deg C.

Adhesive Bonding Experiments for Titanium 6 Aluminum 4 Vanadium (Ti6Al4V). Part I. Anodization Treatments.

DTIC Science & Technology

1979-12-01

Identification of Surface Treat- 4 ments of Ti 6-4 II Effect of Increasing Oxide Porosity on H20 Contact Angle on Titanium 6 Aluminum 4 Vanadium 26 viii SECTIONI...and a high SIMS yield. The lithium does not appear in the oxide formed on titanium by this mixture. Similarly porosity may be induced by anodization at...Porous Oxide (B). 25 TABLE II EFFECT OF INCREASING OXIDE POROSITY ON H2 0 CONTACT ANGLE ON TITANIUM 6 ALUMINUM 4 VANADIUM - I H 2 0Sample Electrolyte

Continuous Severe Plastic Deformation Processing of Aluminum Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Raghavan Srinivasan; Prabir K. Chaudhury; Balakrishna Cherukuri

2006-06-30

produced 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

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.

Corrosion fatigue of 2219-T87 aluminum alloy

NASA Technical Reports Server (NTRS)

Mcmillan, V. C.

1986-01-01

Corrosion fatigue studies were conducted on bare, chemical conversion coated, and anodized 2219-T87 aluminum alloy. These tests were performed using a rotating beam machine running at a velocity of 2500 rpm. The corrosive environments tested were distilled water, 100 ppm NaCl, and 3.5 percent NaCl. Results were compared to the endurance limit in air. An evaluation of the effect of protective coatings on corrosion fatigue was made by comparing the fatigue properties of specimens with coatings to those without.

Conductive aluminum line formation on aluminum nitride surface by infrared nanosecond laser

NASA Astrophysics Data System (ADS)

Kozioł, Paweł E.; Antończak, Arkadiusz J.; Szymczyk, Patrycja; Stępak, Bogusz; Abramski, Krzysztof M.

2013-12-01

In this paper the fabrication of conductive aluminum paths on AlN ceramic's surface due to the interaction of laser radiation Nd:YAG (1.064 μm) is presented. The metallization process produces an appropriate power value on the ceramics surface to ensure the correct temperature (2200 °C) for which aluminum and nitrogen bonds are broken. Studies have been undertaken on creating low-ohmic structures depending on the parameters such as radiation power, scanning speed, the coverage of subsequent pulses and the environmental impact of the process (air, nitrogen, argon). Furthermore, with regards to the application of this method, it was significant to determine the thickness of the functional layer. A structure of the resistivity of ρ = 0.64 × 10-6 Ω m and aluminum layer thickness of 10 μm was achieved for the process carried out on the inert gas, argon. In addition, a quantitative analysis of nitrogen and aluminum for laser-treated structures was conducted. The performed tests confirmed that the highest amount of aluminum was produced on the surface treated by laser radiation in the environment of the process gas, argon.

The feasibility of producing aluminum-lithium structures for cryogenic tankage applications by laser beam welding

NASA Technical Reports Server (NTRS)

Martukanitz, R. P.; Lysher, K. G.

1993-01-01

Aluminum-lithium alloys exhibit high strength, high elastic modulus, and low density as well as excellent cryogenic mechanical properties making them ideal material candidates for cryogenic tanks. NASA has proposed the use of 'built-up' structure for panels fabricated into cryogenic tanks replacing current conventional machining. Superplastically formed stiffeners would be joined to sheet (tank skin) that had been roll formed to the radius of the tank in order to produce panels. Aluminum-lithium alloys of interest for producing the built-up structure include alloy 2095-T6 stiffeners to 2095-T8 sheet and alloy 8090-T6 stiffeners to 2090-T83 sheet. Laser welding, with comparable joint properties, offers the following advantages over conventional welding: higher production rates, minimal degradation within the heat affected zones, and full process automation. This study established process parameters for laser beam welding, mechanical property determinations, metallographic characterization, and fabrication of prototype panels. Tensile tests representing partial penetration of the skin alloys provided joint efficiencies between 65 and 77 percent, depending upon alloy and degree of penetration. Results of tension shear tests of lap welds indicated that the combination of 2095-T6 to 2090-T8 exhibited significantly higher weld shear strength at the interface in comparison to welds of 8090-T6 to 2090-T83. The increased shear strength associated with 2095 is believed to be due to the alloy's ability to precipitation strengthening (naturally age) after welding.

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.

20 CFR 606.1 - Purpose and scope.

Code of Federal Regulations, 2010 CFR

2010-04-01

... standards for grant of such relief in the form of— (i) A cap on tax credit reduction, (ii) Avoidance of tax... Employees' Benefits EMPLOYMENT AND TRAINING ADMINISTRATION, DEPARTMENT OF LABOR TAX CREDITS UNDER THE FEDERAL UNEMPLOYMENT TAX ACT; ADVANCES UNDER TITLE XII OF THE SOCIAL SECURITY ACT General § 606.1 Purpose...

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.

Nanostructuring of Aluminum Alloy Powders by Cryogenic Attrition with Hydrogen-Free Process Control Agent

DTIC Science & Technology

2015-02-01

Nanostructuring of Aluminum Alloy Powders by Cryogenic Attrition with Hydrogen-Free Process Control Agent by Frank Kellogg , Clara Hofmeister...Process Control Agent Frank Kellogg Bowhead Science and Technology Clara Hofmeister Advanced Materials Processing and Analysis Center...NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) Frank Kellogg , Clara Hofmeister, Anit Giri, and Kyu Cho 5d. PROJECT NUMBER 5e

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

Investigation of Mixed-Type Craters and the Role of Bifluoride Additives to Produce Zirconia-Toughened Alumina-Based PEO Coating

NASA Astrophysics Data System (ADS)

Ur Rehman, Zeeshan; Shin, Seong Hun; Ahmad, Tanveer; Koo, Bon Heun

2018-05-01

Al2O3-ZrO2 composite ceramic coatings were prepared on Al6061 aluminum alloy by plasma electrolytic oxidation in Na3PO4-K2ZrF6-Na2SiF6-based alkaline electrolyte. Optimum processing time for the coating formation was found to be 50 min. Cross section and surface morphology of the coatings were analyzed using scanning electron microscope. From the phase and elemental composition analysis, the presence of m-ZrO2 and t-ZrO2 phases was confirmed. It was further observed that the peak intensities of t-ZrO2 and α-Al2O3 phases increased with processing time, which was attributed to the enhanced crystallinity caused by the efficient sintering conditions. Corrosion properties were investigated by potentiodynamic polarization test in 3.5 wt.% NaCl solution. The results showed high improvement in corrosion rate with minimum recorded value 0.25 mmy (mm/year) and corrosion current 0.15 × 10-6 A/cm2.

Secondary Aluminum Processing Waste: Salt Cake ...

EPA Pesticide Factsheets

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 leachable metal content may still pose a contamination concern and potential human and ecological exposure if uncontrollably released to the environment. As a result, salt cake should always be managed at facilities that utilize synthetic liner systems with leachate collection (the salt content of the leachate will increase the hydraulic conductivity of clay liners within a few years of installation). The mineral phase analysis showed that various species of aluminum are present in the salt cake samples with a large degree of variability. The relative abundance of various aluminum species was evaluated but it is noted that the method used is a semi-quantitative method and as a result there is a limitation for the data use. The analysis only showed a few aluminum species present in salt cake which does not exclude the presence of other crystalline species especially in light of the variability observed in the samples. Results presented in this document are of particular importance when trying to understand concerns associated with the disposal of salt cake in MSW landfills. From the end-of-life management perspective, data presented here suggest that salt cake should not be size reduce

Fabrication and tribological response of aluminium 6061 hybrid composite reinforced with bamboo char and boron carbide micro-fillers

NASA Astrophysics Data System (ADS)

Chethan, K. N.; Pai, Anand; Keni, Laxmikant G.; Singhal, Ashish; Sinha, Shubham

2018-02-01

Metal matrix composites (MMCs) have a wide scope of industrial applications and triumph over conventional materials due to their light weight, higher specific strength, good wear resistance and lower coefficient of thermal expansion. The present study aims at establishing the feasibility of using Bamboo charcoal particulate and boron carbide as reinforcements in Al-6061 alloy matrix and to investigate their effect on the wear of composites taking into consideration the interfacial adhesion of the reinforcements in the alloy. Al-6061 alloy was chosen as a base metallic alloy matrix. Sun-dried bamboo canes were used for charcoal preparation with the aid of a muffle furnace. The carbon content in the charcoal samples was determined by EDS (energy dispersive spectroscopy). In present study, stir casting technique was used to prepare the samples with 1%, 2%, and 3% weight of bamboo charcoal and boron carbide with Al-6061. The fabricated composites were homogenised at 570°C for 6 hours and cooled at room temperature. Wear studies were carried out on the specimens with different speed and loads. It was found that wear rate and coefficient of friction decreased with increase in the reinforcement content.

Experimental Study on Dissimilar Friction Stir welding of Aluminium Alloys (5083-H111 and 6082-T6) to investigate the mechanical properties

NASA Astrophysics Data System (ADS)

Kumar, H. M. Anil; Venkata Ramana, V.; Pawar, Mayur

2018-03-01

Friction stir welding is an innovative technology in the joining realm of metals and alloys. This technique is highly economical and suitable especially for non ferrous alloys compared to ferrous alloys. It finds many applications in various fields of aeronautics, automobile, ship building industries etc. The paper presents the comparative results of mechanical properties such as tensile strength, microstructure, macro structure and hardness on the similar and dissimilar aluminum alloys AA5083-H111 and AA6082-T6 under certain selected variables - constant tool rotational speed, its tilt angle, welding speed using friction stir welding process. It is observed from the experimental results that joint efficiency of dissimilar aluminium alloys is higher than the similar aluminum alloys.

Identification of modes of fracture in a 2618-T6 aluminum alloy using stereophotogrammetry

DOE Office of Scientific and Technical Information (OSTI.GOV)

Salas Zamarripa, A., E-mail: a.salaszamarripa@gmail.com; Pinna, C.; Brown, M.W.

2011-12-15

The identification and the development of a quantification technique of the modes of fracture in fatigue fracture surfaces of a 2618-T6 aluminum alloy were developed during this research. Fatigue tests at room and high temperature (230 Degree-Sign C) were carried out to be able to compare the microscopic fractographic features developed by this material under these testing conditions. The overall observations by scanning electron microscopy (SEM) of the fracture surfaces showed a mixture of transgranular and ductile intergranular fracture. The ductile intergranular fracture contribution appears to be more significant at room temperature than at 230 Degree-Sign C. A quantitative methodologymore » was developed to identify and to measure the contribution of these microscopic fractographic features. The technique consisted of a combination of stereophotogrammetry and image analysis. Stereo-pairs were randomly taken along the crack paths and were then analyzed using the profile module of MeX software. The analysis involved the 3-D surface reconstruction, the trace of primary profile lines in both vertical and horizontal directions within the stereo-pair area, the measurements of the contribution of the modes of fracture in each profile, and finally, the calculation of the average contribution in each stereo-pair. The technique results confirmed a higher contribution of ductile intergranular fracture at room temperature than at 230 Degree-Sign C. Moreover, there was no indication of a direct relationship between this contribution and the strain amplitudes range applied during the fatigue testing. - Highlights: Black-Right-Pointing-Pointer Stereophotogrammetry and image analysis as a measuring tool of modes of fracture in fatigue fracture surfaces. Black-Right-Pointing-Pointer A mixture of ductile intergranular and transgranular fracture was identified at room temperature and 230 Degree-Sign C testing. Black-Right-Pointing-Pointer Development of a quantitative

Multi Response Optimization of Process Parameters Using Grey Relational Analysis for Turning of Al-6061

NASA Astrophysics Data System (ADS)

Deepak, Doreswamy; Beedu, Rajendra

2017-08-01

Al-6061 is one among the most useful material used in manufacturing of products. The major qualities of Aluminium are reasonably good strength, corrosion resistance and thermal conductivity. These qualities have made it a suitable material for various applications. While manufacturing these products, companies strive for reducing the production cost by increasing Material Removal Rate (MRR). Meanwhile, the quality of surface need to be ensured at an acceptable value. This paper aims at bringing a compromise between high MRR and low surface roughness requirement by applying Grey Relational Analysis (GRA). This article presents the selection of controllable parameters like longitudinal feed, cutting speed and depth of cut to arrive at optimum values of MRR and surface roughness (Ra). The process parameters for experiments were selected based on Taguchi’s L9 array with two replications. Grey relation analysis being most suited method for multi response optimization, the same is adopted for the optimization. The result shows that feed rate is the most significant factor that influences MRR and Surface finish.

Fabrication and Wear Behavior of Nanostructured Plasma-Sprayed 6061Al-SiCp Composite Coating

NASA Astrophysics Data System (ADS)

Tailor, Satish; Mohanty, R. M.; Sharma, V. K.; Soni, P. R.

2014-10-01

6061Al powder with 15 wt.% SiC particulate (SiCp) reinforcement was mechanically alloyed (MA) in a high-energy attrition mill. The MA powder was then plasma sprayed onto weathering steel (Cor-Ten A242) substrate using an atmospheric plasma spray process. Results of particle size analysis and scanning electron microscopy show that the addition of SiC particles as the reinforcement influences on the matrix grain size and morphology. XRD studies revealed embedment of SiCp in the MA-processed composite powder, and nanocrystals in the MA powder and the coating. Microstructural studies showed a uniform distribution of reinforced SiC particles in the coating. The porosity level in the coating was as low as 2% while the coating hardness was increased to 232VHN. The adhesion strength of the coatings was high and this was attributed to higher degree of diffusion at the interface. The wear rate in the coatings was evaluated using a pin-on-disk type tribometer and found to decrease by 50% compared to the 6061Al matrix coating. The wear mechanism in the coating was delamination and oxidative type.

Critical assessment of precracked specimen configuration and experimental test variables for stress corrosion testing of 7075-T6 aluminum alloy plate

NASA Technical Reports Server (NTRS)

Domack, M. S.

1985-01-01

A research program was conducted to critically assess the effects of precracked specimen configuration, stress intensity solutions, compliance relationships and other experimental test variables for stress corrosion testing of 7075-T6 aluminum alloy plate. Modified compact and double beam wedge-loaded specimens were tested and analyzed to determine the threshold stress intensity factor and stress corrosion crack growth rate. Stress intensity solutions and experimentally determined compliance relationships were developed and compared with other solutions available in the literature. Crack growth data suggests that more effective crack length measurement techniques are necessary to better characterize stress corrosion crack growth. Final load determined by specimen reloading and by compliance did not correlate well, and was considered a major source of interlaboratory variability. Test duration must be determined systematically, accounting for crack length measurement resolution, time for crack arrest, and experimental interferences. This work was conducted as part of a round robin program sponsored by ASTM committees G1.06 and E24.04 to develop a standard test method for stress corrosion testing using precracked specimens.

High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Jingyi; Upadhyay, Piyush; Hovanski, Yuri

Friction-stir-welding (FSW) is a cost-effective and high quality joining process for aluminum alloys (especially heat-treatable allo ys) that has been applied successfully in the aerospace industry. However, the full potential of FSW on more cost-sensitive applications is still limited by the production rate, namely the welding speed of the process. The majority of literature evaluating FSW of aluminum alloys is based on welds made in the range of welding speeds around hundreds of millimeters per minute, and only a handful are at a moderate speed of 1 m/min. In this study we present a microstructural analysis of friction stir weldedmore » AA7075-T6 blanks with welding speeds up to 3 m/min. Textures, microstructures, mechanical properties, and weld quality are analyzed using TEM, EBSD, metallographic imaging, and Vickers hardness. Results are coupled with welding parameters to aid in the understanding of the complex material flow and texture gradients within the welds in an effort to optimize welding parameters for high speed processing.« less

Impact and residual fatigue behavior of ARALL and AS6/5245 composite material

NASA Technical Reports Server (NTRS)

Johnson, W. S.

1989-01-01

The impact sensitivity of aramide fiber-reinforced aluminum laminates (ARALL) was investigated by testing two types of ARALL (7075 aluminum prestrained and 2024 aluminum not prestrained), via static indentation, and the results were compared to those of sheet aluminum alloys 7075-T6 and 2024-T3 and to a state of the art composite AS6/5245. It was found that the impact resistance of the two ARALL samples was inferior to that of monolithic sheet aluminum samples, although the ARALL material made with 2024-T3 aluminum was superior to that made with 7075-T6 aluminum. The impact damage resistance of ARALL materials was at least equal to that of AS6/5245, and the AS6/5245 had higher residual tension-tension fatigue strength after impact than the ARALL samples. It was also found that the prestraining of the ARALL reduced the fatigue growth of impact damage.

Structural Analysis of Kufasat Using Ansys Program

NASA Astrophysics Data System (ADS)

Al-Maliky, Firas T.; AlBermani, Mohamed J.

2018-03-01

The current work focuses on vibration and modal analysis of KufaSat structure using ANSYS 16 program. Three types of Aluminum alloys (5052-H32, 6061-T6 and 7075-T6) were selected for investigation of the structure under design loads. Finite element analysis (FEA) in design static load of 51 g was performed. The natural frequencies for five modes were estimated using modal analysis. In order to ensure that KufaSat could withstand with various conditions during launch, the Margin of safety was calculated. The results of deformation and Von Mises stress for linear buckling analysis were also performed. The comparison of data was done to select the optimum material for KufaSat structures.

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.

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

Anodized aluminum coatings for thermal control. I - Coating process and stresses

NASA Technical Reports Server (NTRS)

Alwitt, R. S.; Mcclung, R. C.; Jacobs, S.

1992-01-01

Anodized aluminum is a candidate material for use as a thermal radiator surface on Space Station Freedom. Here, results of measurements of coating stress at room temperature are presented. The effects of coating process conditions and also subsequent exposure to different humidities, from above ambient to vacuum, are reported. The most important observation with regard to space applications is that the coating stress is very dependent on humidity, changing from compressive at ambient humidity to strongly tensile in 10 exp -6 torr vacuum. The increase in stress is accompanied by loss of water from the coating, and the process is reversible.

The Effect of Impurities on the Processing of Aluminum Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zi-Kui Liu; Shengjun Zhang; Qingyou Han

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 thatmore » 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

Selected fretting-wear-resistant coatings for titanium - 6-percent-aluminum - 4-percent-vanadium alloy

NASA Technical Reports Server (NTRS)

Bill, R. C.

1976-01-01

A titanium - 6-percent-aluminum - 4-percent-vanadium alloy (Ti-6Al-4V) was subjected to fretting-wear exposures against uncoated Ti-6Al-4V as a baseline and against various coatings and surface treatments applied to Ti-6Al-4V. The coatings evaluated included plasma-sprayed tungsten carbide with 12 percent cobalt, aluminum oxide with 13 percent titanium oxide, chromium oxide, and aluminum bronze with 10 percent aromatic polyester; polymer-bonded polyimide, polyimide with graphite fluoride, polyimide with molybdenum disulfide (MoS2), and methyl phenyl silicone bonded MoS2, preoxidation surface treatment, a nitride surface treatment, and a sputtered MoS2 coating. Results of wear measurements on both the coated and uncoated surfaces after 300,000 fretting cycles indicated that the polyimide coating was the most wear resistant and caused the least wear to the uncoated mating surface.

Effects of organic solutes on chemical reactions of aluminum

USGS Publications Warehouse

Lind, Carol J.; Hem, John David

1975-01-01

Concentrations of organic matter in the general range of 1-10 milligrams per litre organic carbon are common in natural water, and many naturally occurrin7 organic compounds form aluminum complexes. The aluminum concentrations in near-neutral pH solutions may be 10-100 times higher than the values predicted from solubility data if formation of such organic complexes is ignored. The processes of polymerization of aluminum hydroxide and precipitation of gibbsite are inhibited by the presence of the organic flavone compound quercetin in concentrations as low as 10 x -5.3 mole per litre. Quercetin forms a complex, with a probable molar ratio of 1:2 aluminum to quercetin, that has a formation constant (f12) of about 10 12. A complex with a higher aluminum-quercetin ratio also was observed, but this material tends to evolve into a compound of low solubility that removes aluminum from solution. In the presence of both dissolved aluminum and aqueous silica, low concentrations of quercetin improved the yield of crystallized kaolinite and halloysite. Small amounts of well-shaped kaolinite and halloysite crystals were identified by electron microscopy in solutions with pH's in the range 6.5-8.5 after 155 days aging in one experimer t and 481 days aging in a repeated experiment. The bulk of the precipitated material was amorphous to X-rays, and crystalline material was too small a proportion of the total to give identifiable X-ray diffraction peaks. The precipitates had aluminum-silicon ratios near 1, and their solubility corresponded to that found by Hem, Roberson, Lind, and Polzer (1973) for similar aluminosilicate precipitated in the absence of organic solutes. The improved yield of crystalline material obtained in the presence of quercetin probably is the result of the influence of the organic compound on the aluminum hydroxide polymerization process. Natural water containing color imparted by organic material tends to be higher in aluminum than would be predicted by p

Spectrum Fatigue of 7075-T651 Aluminum Alloy under Overloading and Underloading

DTIC Science & Technology

2016-03-15

underload, stress ratio, and environment on fatigue crack growth. Fatigue crack growth tests were conducted with a 7075-T651 aluminum alloy under constant...the UniGrow equation, the variation of crack length with number of loading cycle was predicted. The prediction and the fatigue test life were found to...Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std. Z39-18 REPORT NO. NAWCADPAX/TIM-2015/282 ii SUMMARY Fatigue tests of 7075-T651

Electron beam weld development on a Filter Pack Assembly

NASA Astrophysics Data System (ADS)

Dereskiewicz, J. P.

1994-06-01

A continuous electron beam welding procedure was developed to replace the manual gas tungsten arc welding procedure on the Filter Pack Assembly. A statistical study was used to evaluate the feasibility of electron beam welding 6061-T6 aluminum covers to A356 cast weldments throughout the joint tolerance range specified on product drawings. Peak temperature exposures were not high enough to degrade the heat sensitive electrical components inside the cast weldment. Actual weldments with alodine coating on the weld joint area were successfully cleaned using a nonmetallic fiberglass brush cleaning method.

Research on Melt Degassing Processes of High Conductivity Hard Drawn Aluminum Wire

NASA Astrophysics Data System (ADS)

Xu, Xuexia; Feng, Yanting; Wang, Qing; Li, Wenbin; Fan, Hui; Wang, Yong; Li, Guowei; Zhang, Daoqian

2018-03-01

Degassing effects of ultrasonic and vacuum processes on high conductivity hard drawn aluminum melt were studied. Results showed that the degassing efficiency improved with the increase of ultrasonic power within certain range, stabilizing at 70% with 240W. For vacuum degassing process, hydrogen content of aluminum melt decreased with the loading time and was linear with logarithm of vacuum degree. Comparison of degassing effects of ultrasonic, vacuum, vacuum-ultrasonic degassing process showed that vacuum-ultrasonic process presented optimal effect.

Fractal nature of aluminum alloys substructures under creep and its implications

NASA Astrophysics Data System (ADS)

Fernández, R.; Bruno, G.; González-Doncel, G.

2018-04-01

The present work offers an explanation for the variation of the power-law stress exponent, n, with the stress σ normalized to the shear modulus G in aluminum alloys. The approach is based on the assumption that the dislocation structure generated with deformation has a fractal nature. It fully explains the evolution of n with σ/G even beyond the so-called power law breakdown region. Creep data from commercially pure Al99.8%, Al-3.85%Mg, and ingot AA6061 alloy tested at different temperatures and stresses are used to validate the proposed ideas. Finally, it is also shown that the fractal description of the dislocation structure agrees well with current knowledge.

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

NASA Astrophysics Data System (ADS)

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

2016-01-01

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

High throughput exploration of process-property linkages in Al-6061 using instrumented spherical microindentation and microstructurally graded samples

DOE Office of Scientific and Technical Information (OSTI.GOV)

Weaver, Jordan S.; Khosravani, Ali; Castillo, Andrew

Recent spherical nanoindentation protocols have proven robust at capturing the local elastic-plastic response of polycrystalline metal samples at length scales much smaller than the grain size. In this work, we extend these protocols to length scales that include multiple grains to recover microindentation stress-strain curves. These new protocols are first established in this paper and then demonstrated for Al-6061 by comparing the measured indentation stress-strain curves with the corresponding measurements from uniaxial tension tests. More specifically, the scaling factors between the uniaxial yield strength and the indentation yield strength was determined to be about 1.9, which is significantly lower thanmore » the value of 2.8 used commonly in literature. Furthermore, the reasons for this difference are discussed. Second, the benefits of these new protocols in facilitating high throughput exploration of process-property relationships are demonstrated through a simple case study.« less

High throughput exploration of process-property linkages in Al-6061 using instrumented spherical microindentation and microstructurally graded samples

DOE PAGES

Weaver, Jordan S.; Khosravani, Ali; Castillo, Andrew; ...

2016-06-14

Recent spherical nanoindentation protocols have proven robust at capturing the local elastic-plastic response of polycrystalline metal samples at length scales much smaller than the grain size. In this work, we extend these protocols to length scales that include multiple grains to recover microindentation stress-strain curves. These new protocols are first established in this paper and then demonstrated for Al-6061 by comparing the measured indentation stress-strain curves with the corresponding measurements from uniaxial tension tests. More specifically, the scaling factors between the uniaxial yield strength and the indentation yield strength was determined to be about 1.9, which is significantly lower thanmore » the value of 2.8 used commonly in literature. Furthermore, the reasons for this difference are discussed. Second, the benefits of these new protocols in facilitating high throughput exploration of process-property relationships are demonstrated through a simple case study.« less

Fracture mechanics data for 2024-T861 and 2124-T851 aluminum

NASA Technical Reports Server (NTRS)

Pionke, L. J.; Linback, R. K.

1974-01-01

The fracture toughness and fatigue flaw growth characteristics of 2024-T861 and 2124-T851 aluminum were evaluated under plane stress conditions. Center cracked tension specimens were employed to evaluate these properties under a number of different test conditions which included variations in specimen thickness, specimen orientation, test environment, and initial flaw size. The effect of buckling was also investigated for all tests of thin gage specimens, and the effect of frequency and stress ratio was evaluated for the cyclic tests. Fracture toughness test results were analyzed and presented in terms of fracture resistance curves; fatigue flaw growth data was analyzed using empirical rate models. The results of the study indicate that both fracture toughness and resistance to fatigue crack growth improve with increasing temperature and decreasing thickness. The presence of buckling during testing of thin gage panels was found to degrade the resistance to fatigue flaw growth only at elevated temperatures.

The effect of aluminum nanoparticles on the structure, mechanical properties and failure of aluminum processed by accumulative roll bonding

NASA Astrophysics Data System (ADS)

Ivanov, K. V.; Fortuna, S. V.; Kalashnikova, T. A.; Rodkevich, N. G.

2017-12-01

The microstructure, mechanical properties, and fracture type of aluminum with and without aluminum nanoparticles processed by accumulative roll bonding (ARB) have been studied using transmission and scanning electron microscopy, microhardness measurements, and tensile tests. It is shown that the injection of aluminum nanoparticles increases the structure refinement rate during ARB due to the increasing tendency for dynamic recrystallization. It has a different effect on different mechanical characteristics. The different effect of nanoparticles on different structural features is the reason for the different effect on different mechanical properties related with these features. The fracture mechanism is shown to change from ductile in aluminum to mixed ductile-brittle in the composite with a 1.5-fold decrease in ductility as a result of nanoparticle injection.

Evaluation of various cleaning methods to remove bacillus spores from spacecraft hardware materials

NASA Technical Reports Server (NTRS)

Venkateswaran, Kasthuri; Chung, Shirley; Allton, Judith; Kern, Roger

2004-01-01

A detailed study was made of the biological cleaning effectiveness, defined in terms of the ability to remove bacterial spores, of a number of methods used to clean hardware surfaces. Aluminum (Al 6061) and titanium (Ti 6Al-4V) were chosen for the study as they were deemed the two materials most likely to be used in spacecraft extraterrestrial sampler construction. Metal coupons (1 cm x 2.5 cm) were precleaned and inoculated with 5.8 x 10(3) cultivable Bacillus subtilis spores, which are commonly found on spacecraft surfaces and in the assembly environments. The inoculated coupons were subsequently cleaned using: (1) 70% isopropyl alcohol wipe; (2) water wipe; (3) multiple-solvent flight-hardware cleaning procedures used at the Jet Propulsion Laboratory (JPL); (4) Johnson Space Center-developed ultrapure water rinse; and (5) a commercial, semi-aqueous, multiple-solvent (SAMS) cleaning process. The biological cleaning effectiveness was measured by agar plate assay, sterility test (growing in liquid media), and epifluorescent microscopy. None of the cleaning protocols tested completely removed viable spores from the surface of the aluminum. In contrast, titanium was capable of being cleaned to sterility by two methods, the JPL standard and the commercial SAMS cleaning process. Further investigation showed that the passivation step employed in the JPL standard method is an effective surface sterilant on both metals but not compatible with aluminum. It is recommended that titanium (Ti 6Al-4V) be considered superior to aluminum (Al 6061) for use in spacecraft sampling hardware, both for its potential to be cleaned to sterilization and for its ability to withstand the most effective cleaning protocols.

Evaluation of Various Cleaning Methods to Remove Bacillus Spores from Spacecraft Hardware Materials

NASA Astrophysics Data System (ADS)

Venkateswaran, Kasthuri; Chung, Shirley; Allton, Judith; Kern, Roger

2004-09-01

A detailed study was made of the biological cleaning effectiveness, defined in terms of the ability to remove bacterial spores, of a number of methods used to clean hardware surfaces. Aluminum (Al 6061) and titanium (Ti 6Al-4V) were chosen for the study as they were deemed the two materials most likely to be used in spacecraft extraterrestrial sampler construction. Metal coupons (1 cm × 2.5 cm) were precleaned and inoculated with 5.8 × 103 cultivable Bacillus subtilis spores, which are commonly found on spacecraft surfaces and in the assembly environments. The inoculated coupons were subsequently cleaned using: (1) 70% isopropyl alcohol wipe; (2) water wipe; (3) multiple-solvent flight-hardware cleaning procedures used at the Jet Propulsion Laboratory (JPL); (4) Johnson Space Center-developed ultrapure water rinse; and (5) a commercial, semi-aqueous, multiple-solvent (SAMS) cleaning process. The biological cleaning effectiveness was measured by agar plate assay, sterility test (growing in liquid media), and epifluorescent microscopy. None of the cleaning protocols tested completely removed viable spores from the surface of the aluminum. In contrast, titanium was capable of being cleaned to sterility by two methods, the JPL standard and the commercial SAMS cleaning process. Further investigation showed that the passivation step employed in the JPL standard method is an effective surface sterilant on both metals but not compatible with aluminum. It is recommended that titanium (Ti 6Al-4V) be considered superior to aluminum (Al 6061) for use in spacecraft sampling hardware, both for its potential to be cleaned to sterilization and for its ability to withstand the most effective cleaning protocols.

Evaluation of various cleaning methods to remove bacillus spores from spacecraft hardware materials.

PubMed

Venkateswaran, Kasthuri; Chung, Shirley; Allton, Judith; Kern, Roger

2004-01-01

A detailed study was made of the biological cleaning effectiveness, defined in terms of the ability to remove bacterial spores, of a number of methods used to clean hardware surfaces. Aluminum (Al 6061) and titanium (Ti 6Al-4V) were chosen for the study as they were deemed the two materials most likely to be used in spacecraft extraterrestrial sampler construction. Metal coupons (1 cm x 2.5 cm) were precleaned and inoculated with 5.8 x 10(3) cultivable Bacillus subtilis spores, which are commonly found on spacecraft surfaces and in the assembly environments. The inoculated coupons were subsequently cleaned using: (1) 70% isopropyl alcohol wipe; (2) water wipe; (3) multiple-solvent flight-hardware cleaning procedures used at the Jet Propulsion Laboratory (JPL); (4) Johnson Space Center-developed ultrapure water rinse; and (5) a commercial, semi-aqueous, multiple-solvent (SAMS) cleaning process. The biological cleaning effectiveness was measured by agar plate assay, sterility test (growing in liquid media), and epifluorescent microscopy. None of the cleaning protocols tested completely removed viable spores from the surface of the aluminum. In contrast, titanium was capable of being cleaned to sterility by two methods, the JPL standard and the commercial SAMS cleaning process. Further investigation showed that the passivation step employed in the JPL standard method is an effective surface sterilant on both metals but not compatible with aluminum. It is recommended that titanium (Ti 6Al-4V) be considered superior to aluminum (Al 6061) for use in spacecraft sampling hardware, both for its potential to be cleaned to sterilization and for its ability to withstand the most effective cleaning protocols.

Experimental Modal Analysis of Rectangular and Circular Beams

ERIC Educational Resources Information Center

Emory, Benjamin H.; Zhu, Wei Dong

2006-01-01

Analytical and experimental methods are used to determine the natural frequencies and mode shapes of Aluminum 6061-T651 beams with rectangular and circular cross-sections. A unique test stand is developed to provide the rectangular beam with different boundary conditions including clamped-free, clamped-clamped, clamped-pinned, and pinned-pinned.…

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.

Effect of an aggressive medium on discontinuous deformation of aluminum-magnesium alloy AlMg6

NASA Astrophysics Data System (ADS)

Shibkov, A. A.; Denisov, A. A.; Zolotov, A. E.; Kochegarov, S. S.

2017-01-01

It is experimentally shown that the molecular (chemical) process of surface etching of deformed aluminum-magnesium alloy AlMg6 causes the development of a macroscopic plastic strain step with an amplitude of a few percent. Using numerical simulation of the polycrystalline solid etching process, it is shown that the corrosion front morphology varies during etching from Euclid (flat) to fractal (rough). The results obtained show the key role of the surface state on the development of macroscopic mechanical instability of a material exhibiting the Portevin-Le Chatelier effect.

The Met Office Unified Model Global Atmosphere 6.0/6.1 and JULES Global Land 6.0/6.1 configurations

NASA Astrophysics Data System (ADS)

Walters, David; Boutle, Ian; Brooks, Malcolm; Melvin, Thomas; Stratton, Rachel; Vosper, Simon; Wells, Helen; Williams, Keith; Wood, Nigel; Allen, Thomas; Bushell, Andrew; Copsey, Dan; Earnshaw, Paul; Edwards, John; Gross, Markus; Hardiman, Steven; Harris, Chris; Heming, Julian; Klingaman, Nicholas; Levine, Richard; Manners, James; Martin, Gill; Milton, Sean; Mittermaier, Marion; Morcrette, Cyril; Riddick, Thomas; Roberts, Malcolm; Sanchez, Claudio; Selwood, Paul; Stirling, Alison; Smith, Chris; Suri, Dan; Tennant, Warren; Vidale, Pier Luigi; Wilkinson, Jonathan; Willett, Martin; Woolnough, Steve; Xavier, Prince

2017-04-01

We describe Global Atmosphere 6.0 and Global Land 6.0 (GA6.0/GL6.0): the latest science configurations of the Met Office Unified Model and JULES (Joint UK Land Environment Simulator) land surface model developed for use across all timescales. Global Atmosphere 6.0 includes the ENDGame (Even Newer Dynamics for General atmospheric modelling of the environment) dynamical core, which significantly increases mid-latitude variability improving a known model bias. Alongside developments of the model's physical parametrisations, ENDGame also increases variability in the tropics, which leads to an improved representation of tropical cyclones and other tropical phenomena. Further developments of the atmospheric and land surface parametrisations improve other aspects of model performance, including the forecasting of surface weather phenomena. We also describe GA6.1/GL6.1, which includes a small number of long-standing differences from our main trunk configurations that we continue to require for operational global weather prediction. Since July 2014, GA6.1/GL6.1 has been used by the Met Office for operational global numerical weather prediction, whilst GA6.0/GL6.0 was implemented in its remaining global prediction systems over the following year.

Optimization of Friction Stir Welding Tool Advance Speed via Monte-Carlo Simulation of the Friction Stir Welding Process

PubMed Central

Fraser, Kirk A.; St-Georges, Lyne; Kiss, Laszlo I.

2014-01-01

Recognition of the friction stir welding process is growing in the aeronautical and aero-space industries. To make the process more available to the structural fabrication industry (buildings and bridges), being able to model the process to determine the highest speed of advance possible that will not cause unwanted welding defects is desirable. A numerical solution to the transient two-dimensional heat diffusion equation for the friction stir welding process is presented. A non-linear heat generation term based on an arbitrary piecewise linear model of friction as a function of temperature is used. The solution is used to solve for the temperature distribution in the Al 6061-T6 work pieces. The finite difference solution of the non-linear problem is used to perform a Monte-Carlo simulation (MCS). A polynomial response surface (maximum welding temperature as a function of advancing and rotational speed) is constructed from the MCS results. The response surface is used to determine the optimum tool speed of advance and rotational speed. The exterior penalty method is used to find the highest speed of advance and the associated rotational speed of the tool for the FSW process considered. We show that good agreement with experimental optimization work is possible with this simplified model. Using our approach an optimal weld pitch of 0.52 mm/rev is obtained for 3.18 mm thick AA6061-T6 plate. Our method provides an estimate of the optimal welding parameters in less than 30 min of calculation time. PMID:28788627

Optimization of Friction Stir Welding Tool Advance Speed via Monte-Carlo Simulation of the Friction Stir Welding Process.

PubMed

Fraser, Kirk A; St-Georges, Lyne; Kiss, Laszlo I

2014-04-30

Recognition of the friction stir welding process is growing in the aeronautical and aero-space industries. To make the process more available to the structural fabrication industry (buildings and bridges), being able to model the process to determine the highest speed of advance possible that will not cause unwanted welding defects is desirable. A numerical solution to the transient two-dimensional heat diffusion equation for the friction stir welding process is presented. A non-linear heat generation term based on an arbitrary piecewise linear model of friction as a function of temperature is used. The solution is used to solve for the temperature distribution in the Al 6061-T6 work pieces. The finite difference solution of the non-linear problem is used to perform a Monte-Carlo simulation (MCS). A polynomial response surface (maximum welding temperature as a function of advancing and rotational speed) is constructed from the MCS results. The response surface is used to determine the optimum tool speed of advance and rotational speed. The exterior penalty method is used to find the highest speed of advance and the associated rotational speed of the tool for the FSW process considered. We show that good agreement with experimental optimization work is possible with this simplified model. Using our approach an optimal weld pitch of 0.52 mm/rev is obtained for 3.18 mm thick AA6061-T6 plate. Our method provides an estimate of the optimal welding parameters in less than 30 min of calculation time.

Flaw growth behavior in thick welded plates of 2219-T87 aluminum at room and cryogenic temperatures

NASA Technical Reports Server (NTRS)

Forman, R. G.; Glorioso, S. V.; Medlock, J. D.

1973-01-01

Axial load fatigue and fracture tests were conducted on thick welded plates of 2219-T87 aluminum alloy to determine the tensile strength properties and the flaw growth behavior in electron beam, gas metal arc, and pulse current gas tungsten arc welds for plates 6.35 centimeters (2.5 in.) thick. The tests were conducted in room temperature air and in liquid nitrogen environments. Specimens were tested in both the as-welded and the aged after welding conditions. The experimental crack growth rate were correlated with theoretical crack growth rate predictions for semielliptical surface flaws.

Microstructural characterization and mechanical property of active soldering anodized 6061 Al alloy using Sn-3.5Ag-xTi active solders

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wang, Wei-Lin, E-mail: wangwl77@gmail.com; Tsai, Yi-Chia, E-mail: tij@itri.org.tw

2012-06-15

Active solders Sn-3.5Ag-xTi varied from x = 0 to 6 wt.% Ti addition were prepared by vacuum arc re-melting and the resultant phase formation and variation of microstructure with titanium concentration were analyzed using X-ray diffraction, optical microscopy and scanning electron microscopy. The Sn-3.5Ag-xTi active solders are used as metallic filler to join with anodized 6061 Al alloy for potential applications of providing a higher heat conduction path. Their joints and mechanical properties were characterized and evaluated in terms of titanium content. The mechanical property of joints was measured by shear testing. The joint strength was very dependent on themore » titanium content. Solder with a 0.5 wt.% Ti addition can successfully wet and bond to the anodized aluminum oxide layers of Al alloy and posses a shear strength of 16.28 {+-} 0.64 MPa. The maximum bonding strength reached 22.24 {+-} 0.70 MPa at a 3 wt.% Ti addition. Interfacial reaction phase and chemical composition were identified by a transmission electron microscope with energy dispersive spectrometer. Results showed that the Ti element reacts with anodized aluminum oxide to form Al{sub 3}Ti-rich and Al{sub 3}Ti phases at the joint interfaces. - Highlights: Black-Right-Pointing-Pointer Active solder joining of anodized Al alloy needs 0.5 wt.% Ti addition for Sn-3.5Ag. Black-Right-Pointing-Pointer The maximum bonding strength occurs at 3 wt.% Ti addition. Black-Right-Pointing-Pointer The Ti reacts with anodized Al oxide to form Al{sub 3}Ti-rich and Al{sub 3}Ti at joint interface.« less

Influence of Welding Process and Post Weld Heat Treatment on Microstructure and Pitting Corrosion Behavior of Dissimilar Aluminium Alloy Welds

NASA Astrophysics Data System (ADS)

Venkata Ramana, V. S. N.; Mohammed, Raffi; Madhusudhan Reddy, G.; Srinivasa Rao, K.

2018-03-01

Welding of dissimilar Aluminum alloy welds is becoming important in aerospace, shipbuilding and defence applications. In the present work, an attempt has been made to weld dissimilar aluminium alloys using conventional gas tungsten arc welding (GTAW) and friction stir welding (FSW) processes. An attempt was also made to study the effect of post weld heat treatment (T4 condition) on microstructure and pitting corrosion behaviour of these welds. Results of the present investigation established the differences in microstructures of the base metals in T4 condition and in annealed conditions. It is evident that the thickness of the PMZ is relatively more on AA2014 side than that of AA6061 side. In FS welds, lamellar like shear bands are well noticed on the top of the stir zone. The concentration profile of dissimilar friction stir weld in T4 condition revealed that no diffusion has taken place at the interface. Poor Hardness is observed in all regions of FS welds compared to that of GTA welds. Pitting corrosion resistance of the dissimilar FS welds in all regions was improved by post weld heat treatment.

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.

6. Exterior view of Components Test Laboratory (T27), looking southwest. ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

6. Exterior view of Components Test Laboratory (T-27), looking southwest. The building wing on the left houses Test Cell 9 (fuel), and that on the right houses the equipment room. The corrugated aluminum shed that is taller than the main building in the left foreground houses a citric acid air pollution control room (also known as scrubber room), the interior of which may be seen in CO-88-A-21. - Air Force Plant PJKS, Systems Integration Laboratory, Components Test Laboratory, Waterton Canyon Road & Colorado Highway 121, Lakewood, Jefferson County, CO

Thermodynamic Analysis for the Refining Ability of Salt Flux for Aluminum Recycling

PubMed Central

Hiraki, Takehito; Miki, Takahiro; Nakajima, Kenichi; Matsubae, Kazuyo; Nakamura, Shinichiro; Nagasaka, Tetsuya

2014-01-01

The removability of impurities during the aluminum remelting process by oxidation was previously investigated by our research group. In the present work, alternative impurity removal with chlorination has been evaluated by thermodynamic analysis. For 43 different elements, equilibrium distribution ratios among metal, chloride flux and oxide slag phases in the aluminum remelting process were calculated by assuming the binary systems of aluminum and an impurity element. It was found that the removability of impurities isn’t significantly affected by process parameters such as chloride partial pressure, temperature and flux composition. It was shown that Ho, Dy, Li, La, Mg, Gd, Ce, Yb, Ca and Sr can be potentially eliminated into flux by chlorination from the remelted aluminum. Chlorination and oxidation are not effective to remove other impurities from the melting aluminum, due to the limited parameters which can be controlled during the remelting process. It follows that a proper management of aluminum scrap such as sorting based on the composition of the products is important for sustainable aluminum recycling. PMID:28788144

Simple and inexpensive micromachined aluminum microfluidic devices for acoustic focusing of particles and cells.

PubMed

Gautam, Gayatri P; Burger, Tobias; Wilcox, Andrew; Cumbo, Michael J; Graves, Steven W; Piyasena, Menake E

2018-05-01

We introduce a new method to construct microfluidic devices especially useful for bulk acoustic wave (BAW)-based manipulation of cells and microparticles. To obtain efficient acoustic focusing, BAW devices require materials that have high acoustic impedance mismatch relative to the medium in which the cells/microparticles are suspended and materials with a high-quality factor. To date, silicon and glass have been the materials of choice for BAW-based acoustofluidic channel fabrication. Silicon- and glass-based fabrication is typically performed in clean room facilities, generates hazardous waste, and can take several hours to complete the microfabrication. To address some of the drawbacks in fabricating conventional BAW devices, we explored a new approach by micromachining microfluidic channels in aluminum substrates. Additionally, we demonstrate plasma bonding of poly(dimethylsiloxane) (PDMS) onto micromachined aluminum substrates. Our goal was to achieve an approach that is both low cost and effective in BAW applications. To this end, we micromachined aluminum 6061 plates and enclosed the systems with a thin PDMS cover layer. These aluminum/PDMS hybrid microfluidic devices use inexpensive materials and are simply constructed outside a clean room environment. Moreover, these devices demonstrate effectiveness in BAW applications as demonstrated by efficient acoustic focusing of polystyrene microspheres, bovine red blood cells, and Jurkat cells and the generation of multiple focused streams in flow-through systems. Graphical abstract The aluminum acoustofluidic device and the generation of multinode focusing of particles.

The column strength of aluminum alloy 75S-T extruded shapes

NASA Technical Reports Server (NTRS)

Holt, Marshall; Leary, J R

1946-01-01

Because the tensile strength and tensile yield strength of alloy 75S-T are appreciably higher than those of the materials used in the tests leading to the use of the straight-line column curve, it appeared advisable to establish the curve of column strength by test rather than by extrapolation of relations determined empirically in the earlier tests. The object of this investigation was to determine the curve of column strength for extruded aluminum alloy 75S-T. In addition to three extruded shapes, a rolled-and-drawn round rod was included. Specimens of various lengths covering the range of effective slenderness ratios up to about 100 were tested.

Studies on mechanical properties of aluminium 6061 reinforced with titanium and E glass fibre metal matrix hybrid composites

NASA Astrophysics Data System (ADS)

Kumar, B. N. Ravi; Vidyasagar, H. N.; Shivanand, H. K.

2018-04-01

2Development of the mmc with fibers and filler materials as a replacement material for some engineering purpose such as automobiles, aerospace are indispensable. Therefore, the studies related to hybrid mmc's of Al6061 were noted in this paper. In this work, Al6061 reinforced with E glass fibers and micro Titanium particles. Hybrid composites was prepared by very feasible and commercially used technique Stir casting and by varying composition of Al6061, Titanium and E-glass fibre. Experiments were done by varying weight fraction of Titanium (0%, 1%, 3% and 5%) and E glass fibre (0%, 1%, 3% and 5%). Wire EDM were used to prepare the specimens required for tensile and hardness according to standards and tests conducted. The proportion of elements which are present the mmc's are identified by EDAX. Optical microscopy were conducted by SU3500 machine Scanning Electron Microscope and Microstructure shows the distribution of reinforced Ti particles and E glass fibres. The characterization of Al6061 hybrid mmc's is having significant impact on the mechanical properties.

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

NASA Astrophysics Data System (ADS)

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

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

Effect of pulsed current GTA welding parameters on the fusion zone microstructure of AA 6061 aluminium alloy

NASA Astrophysics Data System (ADS)

Kumar, T. Senthil; Balasubramanian, V.; Babu, S.; Sanavullah, M. Y.

2007-08-01

AA6061 aluminium alloy (Al-Mg-Si alloy) has gathered wide acceptance in the fabrication of food processing equipment, chemical containers, passenger cars, road tankers, and railway transport systems. The preferred process for welding these aluminium alloys is frequently Gas Tungsten Arc (GTA) welding due to its comparatively easy applicability and lower cost. In the case of single pass GTA welding of thinner sections of this alloy, the pulsed current has been found beneficial due to its advantages over the conventional continuous current processes. The use of pulsed current parameters has been found to improve the mechanical properties of the welds compared to those of continuous current welds of this alloy due to grain refinement occurring in the fusion zone. In this investigation, an attempt has been made to develop a mathematical model to predict the fusion zone grain diameter incorporating pulsed current welding parameters. Statistical tools such as design of experiments, analysis of variance, and regression analysis are used to develop the mathematical model. The developed model can be effectively used to predict the fusion grain diameter at a 95% confidence level for the given pulsed current parameters. The effect of pulsed current GTA welding parameters on the fusion zone grain diameter of AA 6061 aluminium alloy welds is reported in this paper.

Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach.

PubMed

Su, Zheng-Ming; Qiu, Qi-Hong; Lin, Pai-Chen

2016-08-09

A simple thermal-mechanical model for friction stir spot welding (FSSW) was developed to obtain similar weld performance for different weld tools. Use of the thermal-mechanical model and a combined approach enabled the design of weld tools for various sizes but similar qualities. Three weld tools for weld radii of 4, 5, and 6 mm were made to join 6061-T6 aluminum sheets. Performance evaluations of the three weld tools compared fracture behavior, microstructure, micro-hardness distribution, and welding temperature of welds in lap-shear specimens. For welds made by the three weld tools under identical processing conditions, failure loads were approximately proportional to tool size. Failure modes, microstructures, and micro-hardness distributions were similar. Welding temperatures correlated with frictional heat generation rate densities. Because the three weld tools sufficiently met all design objectives, the proposed approach is considered a simple and feasible guideline for preliminary tool design.

Effect of holding pressure on microstructure and fracture behavior of low-pressure die cast A356-T6 alloy

NASA Astrophysics Data System (ADS)

Wu, Xiaoyan; Yun, Ying; Zhang, Huarui; Ma, Zhen; Jia, Lina; Tao, Tongxiang; Zhang, Hu

2017-12-01

The effect of different holding pressures on microstructure, tensile properties and fracture behavior of A356-T6 aluminum alloy was investigated. It was observed that the ultimate strength, yield strength and elongation of A356-T6 aluminum alloy increased with the increasing of holding pressure from 85 kPa to 300 kPa. This was attributed to the finer microstructure and the elimination of porosity defects caused by high holding pressure. The fractographs of specimens obtained under lower holding pressure displayed mixed quasi-cleavage and dimple type morphology with flat dimples and large amount of porosities. However, the fractographs of specimens obtained under high holding pressure of 300 kPa clearly exhibited a dimple morphology with small and deep dimples. The differences in the tensile fracture were attributed to the different shape of eutectic Si particle and different amount of porosity defects.

Effectiveness of metal matrix and ceramic matrix composites as orbital debris shield materials

NASA Technical Reports Server (NTRS)

Mcgill, Preston B.; Mount, Angela R.

1992-01-01

The effectiveness of two metal matrix composites and one ceramic matrix material in defeating hypervelocity impacts at about 3.8 km/s are evaluated to determine the potential of these composites as spacecraft shield materials. The metal matrix composites investigated consist of SiC particles (70 percent by volume) in an aluminum matrix and Al2O3 particles (50 percent by volume) in an Al matrix. The ceramic composite consists of ZrB2 platelets in a ZrC matrix. Both the metal matrix and ceramic matrix composites are found to perform as well or better than 6061-T6 aluminum, which is presently used in the Whipple type bumper shield of Space Station Freedom. Test results indicate that the composites tested may have applications as micrometeoroid/orbital debris shield materials.

Plasma effects on the passive external thermal control coating of Space Station Freedom

NASA Technical Reports Server (NTRS)

Carruth, Ralph, Jr.; Vaughn, Jason A.; Holt, James M.; Werp, Richard; Sudduth, Richard D.

1992-01-01

The current baseline chromic acid anodized thermal control coating on 6061-T6 aluminum meteoroid debris (M/D) shields for SSF has been evaluated. The degradation of the solar absorptance, alpha, and the thermal emittance, epsilon, of chromic acid anodized aluminum due to dielectric breakdown in plasma was measured to predict the on-orbit lifetime of the SSF M/D shields. The lifetime of the thermal control coating was based on the surface temperatures achieved with degradation of the thermal control properties, alpha and epsilon. The temperatures of each M/D shield from first element launch (FEL) through FEL+15 years were analyzed. It is shown that the baseline thermal control coating cannot withstand the -140 V potential between the conductive structure of the SSF and the current plasma environment.

Modeling of heat transfer in compacted machining chips during friction consolidation process

NASA Astrophysics Data System (ADS)

Abbas, Naseer; Deng, Xiaomin; Li, Xiao; Reynolds, Anthony

2018-04-01

The current study aims to provide an understanding of the heat transfer process in compacted aluminum alloy AA6061 machining chips during the friction consolidation process (FCP) through experimental investigations and mathematical modelling and numerical simulation. Compaction and friction consolidation of machining chips is the first stage of the Friction Extrusion Process (FEP), which is a novel method for recycling machining chips to produce useful products such as wires. In this study, compacted machining chips are modelled as a continuum whose material properties vary with density during friction consolidation. Based on density and temperature dependent thermal properties, the temperature field in the chip material and process chamber caused by frictional heating during the friction consolidation process is predicted. The predicted temperature field is found to compare well with temperature measurements at select points where such measurements can be made using thermocouples.

A Survey of High Explosive-Induced Damage and Spall in Selected Metals Using Proton Radiography

NASA Astrophysics Data System (ADS)

Holtkamp, D. B.; Clark, D. A.; Ferm, E. N.; Gallegos, R. A.; Hammon, D.; Hemsing, W. F.; Hogan, G. E.; Holmes, V. H.; King, N. S. P.; Liljestrand, R.; Lopez, R. P.; Merrill, F. E.; Morris, C. L.; Morley, K. B.; Murray, M. M.; Pazuchanics, P. D.; Prestridge, K. P.; Quintana, J. P.; Saunders, A.; Schafer, T.; Shinas, M. A.; Stacy, H. L.

2004-07-01

Multiple spall and damage layers can be created in metal when the free surface reflects a Taylor wave generated by high explosives. These phenomena have been explored in different thicknesses of several metals (tantalum, copper, 6061 T6-aluminum, and tin) using high-energy proton radiography. Multiple images (up to 21) can be produced of the dynamic evolution of damaged material on the microsecond time scale with a <50 ns "shutter" time. Movies and multiframe still images of areal and (Abel inverted) volume densities are presented. An example of material that is likely melted on release (tin) is also presented.

Warm Temperature Deformation Behavior and Processing Maps of 5182 and 7075 Aluminum Alloy Sheets with Fine Grains

NASA Astrophysics Data System (ADS)

Jang, D. H.; Kim, W. J.

2018-05-01

The tensile deformation behavior and processing maps of commercial 5182 and 7075 aluminum alloy sheets with similarly fine grain sizes (about 8 μm) were examined and compared over the temperature range of 423-723 K. The 5182 aluminum alloy with equiaxed grains exhibited larger strain rate sensitivity exponent ( m) values than the 7075 aluminum alloy with elongated grains under most of the testing conditions. The fracture strain behaviors of the two alloys as a function of strain rate and temperature followed the trend in their m values. In the processing maps, the power dissipation parameter values of the 5182 aluminum alloy were larger than those of the 7075 aluminum alloy and the instability domains of the 5182 aluminum alloy were smaller compared to that of the 7075 aluminum alloy, implying that the 5182 aluminum alloy had a better hot workability than the 7075 aluminum alloy.

A laboratory means to produce tough aluminum sheet from powder

NASA Technical Reports Server (NTRS)

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

1990-01-01

The rapid solidification of aluminum alloys as powder and the subsequent fabrication processes can be used to develop and tailor alloys to satisfy specific aerospace design requirements, including high strength and toughness. Laboratory procedures to produce aluminum powder-metallurgy (PM) materials are efficient but require evidence that the laboratory methods used can produce a product with superior properties. This paper describes laboratory equipment and procedures which can be used to produce tough aluminum PM sheet. The processing of a 2124 + 0.9 percent Zr aluminum alloy powder is used as an example. The fully hardened sheet product is evaluated in terms of properties and microstructure. The key features of the vacuum hot press pressing operation used to consolidate the powder are described. The 2124 + 0.9 percent Zr - T8 temper aluminum sheet produced was both strong (460-490 MPa yield strength) and tough (Kahn Tear unit-propagation- energy values over three times those typical for ingot metallurgy 2024-T81). Both the longitudinal and longitudinal-transverse directions of the sheet were tested. The microstructure was well refined with subgrains of one or two micrometers. Fine dispersoids of Al3Zr in the precipitate free regions adjacent to boundaries are believed to contribute to the improved toughness.

Part I. Corrosion studies of continuous alumina fiber reinforced aluminum-matrix composites. Part II. Galvanic corrosion between continuous alumina fiber reinforced aluminum-matrix composites and 4340 steel

NASA Astrophysics Data System (ADS)

Zhu, Jun

Part I. The corrosion performance of continuous alumina fiber reinforced aluminum-matrix composites (CF-AMCs) was investigated in both the laboratory and field environments by comparing them with their respective monolithic matrix alloys, i.e., pure Al, A1-2wt%Cu T6, and Al 6061 T6. The corrosion initiation sites were identified by monitoring the changes in the surface morphology. Corrosion current densities and pH profiles at localized corrosion sites were measured using the scanning-vibrating electrode technique and the scanning ion-selective electrode technique, respectively. The corrosion damage of the materials immersed in various electrolytes, as well as those exposed in a humidity chamber and outdoor environments, was evaluated. Potentiodynamic polarization behavior was also studied. The corrosion initiation for the composites in 3.15 wt% NaCl occurred primarily around the Fe-rich intermetallic particles, which preferentially existed around the fiber/matrix interface on the composites. The corrosion initiation sites were also caused by physical damage (e.g., localized deformation) to the composite surface. At localized corrosion sites, the buildup of acidity was enhanced by the formation of micro-crevices resulting from fibers left in relief as the matrix corroded. The composites that were tested in exposure experiments exhibited higher corrosion rates than their monolithic alloys. The composites and their monolithic alloys were subjected to pitting corrosion when anodically polarized in the 3.15 wt% NaCl, while they passivated when anodically polarized in 0.5 M Na2SO4. The experimental results indicated that the composites exhibited inferior corrosion resistance compared to their monolithic matrix alloys. Part II. Galvanic corrosion studies were conducted on CF-AMCs coupled to 4340 steel since CF-AMCs have low density and excellent mechanical properties and are being considered as potential jacketing materials for reinforcing steel gun barrels. Coupled and

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.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Feng, Xiuli, E-mail: feng.97@osu.edu; State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001; Liu, Huijie, E-mail: liuhj@hit.edu.cn

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. Themore » 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.« less

FEA of the clinching process of short fiber reinforced thermoplastic with an aluminum sheet using LS-DYNA

NASA Astrophysics Data System (ADS)

Behrens, B.-A.; Bouguecha, A.; Vucetic, M.; Grbic, N.

2016-10-01

A structural concept in multi-material design is used in the automotive industry with the aim of achieving significant weight reductions of conventional car bodies. In this respect, the use of aluminum and short fiber reinforced plastics represents an interesting material combination. A wide acceptance of such a material combination requires a suitable joining technique. Among different joining techniques, clinching represents one of the most appealing alternative for automotive applications. This contribution deals with the FE simulation of the clinching process of two representative materials PA6GF30 and EN AW 5754 using the FE software LS-DYNA. With regard to the material modelling of the aluminum sheet, an isotropic material model based on the von Mises plasticity implemented in LS-DYNA was chosen. Analogous to aluminum, the same material model is used for modelling the short fiber reinforced thermoplastic. Additionally, a semi-analytical model for polymers (SAMP-1) also available in LS-DYNA was taken. Finally, the FEA of clinching process is carried out and the comparison of the simulation results is presented above.

Microstructural and strain rate effects on plastic deformation in aluminum 2219-T87

NASA Astrophysics Data System (ADS)

Rincon, Carlos D.

A fundamental investigation has been conducted on the effects of microstructure and strain rate on the plastic deformation of theta-prime-strengthened 2219 aluminum. The motivation for this work is based upon a previous study which showed inhomogeneous and locally extreme work hardening in the HAZ regions in VPPA 2219-T87 butt welds. This strongly suggests that the HAZ microstructure plays a major role in the deformation and fracture process in precipitation hardened aluminum alloy 2219. Tensile specimens of the weld joint exhibited more rapid work hardening in the heat-affected-zone (HAZ) at higher strain levels. Microhardness contour maps for these welds illustrated that late stage deformation was concentrated in two crossing bands at about 45sp° to the tensile axis. The width of the deformation bands and the ultimate tensile strength seemed to be dictated by the amount of work hardening in the HAZ. In this study, three different heat treatments were used to produce samples with different particle sizes and particle spacings, but all hardened by copper aluminide precipitates of the thetasp' structure. The heat treatments were categorized as being (A) as-received T87 condition, (B) T87 condition aged at approximately 204sp°C for 3 hours and (C) T87 over-aged at 204sp°C for 7 days. Uniaxial tensile tests consisted of two sets of experiments: (1) three heat treatments (A, B, and C) at two strain rates (0.02 minsp{-1} and 0.2 minsp{-1}) and (2) three heat treatments that were interrupted at select stress-strain levels (0.8% and 2% total strain) during the tensile tests at strain rate equal to 0.02 minsp{-1} at room temperature. Furthermore, a detailed transmission electron microscopy (TEM) study demonstrates the microstructural development during tensile deformation. The Voce equation of strain-hardening provides a slightly better fit to the tensile curves than the Ludwik-Hollomon equation. At higher strains, localized areas showed strain fields around thetasp

Mechanical joining of materials with limited ductility: Analysis of process-induced defects

NASA Astrophysics Data System (ADS)

Jäckel, M.; Coppieters, S.; Hofmann, M.; Vandermeiren, N.; Landgrebe, D.; Debruyne, D.; Wallmersberger, T.; Faes, K.

2017-10-01

The paper shows experimental and numerical analyses of the clinching process of 6xxx series aluminum sheets in T6 condition and the self-pierce riveting process of an aluminum die casting. In the experimental investigations the damage behavior of the materials when using different tool parameters is analyzed. The focus of the numerical investigations is the damage prediction by a comparison of different damage criteria. Moreover, strength-and fatigue tests were carried out to investigate the influence of the joining process-induced damages on the strength properties of the joints.

Influence of turning Treatments on Al6061 by Offline Inspection Technique

NASA Astrophysics Data System (ADS)

Annigeri, Ulhas K.; Sandeep, K. L. G.; Prasanna Chaitanya, M.; Sairam Varma, G.; Datta, B. Arun

2018-02-01

Aluminium is mostly extracted from bauxite and is frequently being utilised in the manufacture of sea, land and air vehicles. Since, it has the merit of resistance to corrosion it is frequently being used in sea vehicles. Another outstanding merit of aluminium is its weight which is very less compared to other ferrous materials. In our study, we have selected Al6061 as the material and based on full factorial design the surface roughness has been observed with three base parameters speed, feed and depth of cut. A mathematical model has been developed to predict the surface roughness and also the dominant factor affecting the turning process has been determined. The plots such as main effects, interaction and Pareto chart have been analysed to give an effective conclusion to the process followed in the study. The purpose of these experiments to compare the effect of process treatments in all possible pairs to select the best treatment to the process has been done satisfactorily.

Torsion Tests of 24S-T Aluminum-alloy Noncircular Bar and Tubing

NASA Technical Reports Server (NTRS)

Moore, R L; Paul, D A

1943-01-01

Tests of 24S-T aluminum alloy have been made to determine the yield and ultimate strengths in torsion of noncircular bar and tubing. An approximate basis for predicting these torsional strength characteristics has been indicated. The results show that the torsional stiffness and maximum shearing stresses within the elastic range may be computed quite closely by means of existing formulas based on mathematical analysis and the membrane analogy.

Aging Optimization of Aluminum-Lithium Alloy C458 for Application to Cryotank Structures

NASA Technical Reports Server (NTRS)

Sova, B. J.; Sankaran, K. K.; Babel, H.; Farahmand, B.; Rioja, R.

2003-01-01

Compared with aluminum alloys such as 2219, which is widely used in space vehicle for cryogenic tanks and unpressurized structures, aluminum-lithium alloys possess attractive combinations of lower density and higher modulus along with comparable mechanical properties. These characteristics have resulted in the successful use of the aluminum-lithium alloy 2195 (Al-1.0 Li-4.0 Cu-0.4 Mg-0.4 Ag-0.12 Zr) for the Space Shuttle External Tank, and the consideration of newer U.S. aluminum-lithium alloys such as L277 and C458 for future space vehicles. These newer alloys generally have lithium content less than 2 wt. % and their composition and processing have been carefully tailored to increase the toughness and reduce the mechanical property anisotropy of the earlier generation alloys such 2090 and 8090. Alloy processing, particularly the aging treatment, has a significant influence on the strength-toughness combinations and their dependence on service environments for aluminum-lithium alloys. Work at NASA Marshall Space Flight Center on alloy 2195 has shown that the cryogenic toughness can be improved by employing a two-step aging process. This is accomplished by aging at a lower temperature in the first step to suppress nucleation of the strengthening precipitate at sub-grain boundaries while promoting nucleation in the interior of the grains. Second step aging at the normal aging temperature results in precipitate growth to the optimum size. A design of experiments aging study was conducted for plate. To achieve the T8 temper, Alloy C458 (Al-1.8 Li-2.7 Cu-0.3 Mg-0.08 Zr-0.3 Mn-0.6 Zn) is typically aged at 300F for 24hours. In this study, a two-step aging treatment was developed through a comprehensive 2(exp 4) full factorial design of experiments study and the typical one-step aging used as a reference. Based on the higher lithium content of C458 compared with 2195, the first step aging temperature was varied between 175F and 250F. The second step aging temperatures was

Aging Optimization of Aluminum-Lithium Alloy C458 for Application to Cryotank Structures

NASA Technical Reports Server (NTRS)

Sova, B. J.; Sankaran, K. K.; Babel, H.; Farahmand, B.; Rioja, R.

2003-01-01

Compared with aluminum alloys such as 2219, which is widely used in space vehicle for cryogenic tanks and unpressurized structures, aluminum-lithium alloys possess attractive combinations of lower density and higher modulus along with comparable mechanical properties. These characteristics have resulted in the successful use of the aluminum-lithium alloy 2195 (Al-1.0 Li-4.0 Cu-0.4 Mg-0.4 Ag-0.12 Zr) for the Space Shuttle External Tank, and the consideration of newer U.S. aluminum-lithium alloys such as L277 and C458 for future space vehicles. These newer alloys generally have lithium content less than 2 wt. % and their composition and processing have been carefully tailored to increase the toughness and reduce the mechanical property anisotropy of the earlier generation alloys such 2090 and 8090. Alloy processing, particularly the aging treatment, has a significant influence on the strength-toughness combinations and their dependence on service environments for aluminum-lithium alloys. Work at NASA Marshall Space Flight Center on alloy 2195 has shown that the cryogenic toughness can be improved by employing a two-step aging process. This is accomplished by aging at a lower temperature in the first step to suppress nucleation of the strengthening precipitate at sub-grain boundaries while promoting nucleation in the interior of the grains. Second step aging at the normal aging temperature results in precipitate growth to the optimum size. A design of experiments aging study was conducted for plate. To achieve the T8 temper, Alloy C458 (Al-1.8 Li-2.7 Cu-0.3 Mg- 0.08 Zr-0.3 Mn-0.6 Zn) is typically aged at 300 F for 24 hours. In this study, a two-step aging treatment was developed through a comprehensive 24 full factorial design of experiments study and the typical one-step aging used as a reference. Based on the higher lithium content of C458 compared with 2195, the first step aging temperature was varied between 175 F and 250 F. The second step aging temperatures was

Aluminum adjuvants elicit fibrin-dependent extracellular traps in vivo

PubMed Central

Munks, Michael W.; McKee, Amy S.; MacLeod, Megan K.; Powell, Roger L.; Degen, Jay L.; Reisdorph, Nichole A.; Kappler, John W.

2010-01-01

It has been recognized for nearly 80 years that insoluble aluminum salts are good immunologic adjuvants and that they form long-lived nodules in vivo. Nodule formation has long been presumed to be central for adjuvant activity by providing an antigen depot, but the composition and function of these nodules is poorly understood. We show here that aluminum salt nodules formed within hours of injection and contained the clotting protein fibrinogen. Fibrinogen was critical for nodule formation and required processing to insoluble fibrin by thrombin. DNase treatment partially disrupted the nodules, and the nodules contained histone H3 and citrullinated H3, features consistent with extracellular traps. Although neutrophils were not essential for nodule formation, CD11b+ cells were implicated. Vaccination of fibrinogen-deficient mice resulted in normal CD4 T-cell and antibody responses and enhanced CD8 T-cell responses, indicating that nodules are not required for aluminum's adjuvant effect. Moreover, the ability of aluminum salts to retain antigen in the body, the well-known depot effect, was unaffected by the absence of nodules. We conclude that aluminum adjuvants form fibrin-dependent nodules in vivo, that these nodules have properties of extracellular traps, and the nodules are not required for aluminum salts to act as adjuvants. PMID:20876456

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.

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.

High-power Laser Welding of Thick Steel-aluminum Dissimilar Joints

NASA Astrophysics Data System (ADS)

Lahdo, Rabi; Springer, André; Pfeifer, Ronny; Kaierle, Stefan; Overmeyer, Ludger

According to the Intergovernmental Panel on Climate Change (IPCC), a worldwide reduction of CO2-emissions is indispensable to avoid global warming. Besides the automotive sector, lightweight construction is also of high interest for the maritime industry in order to minimize CO2-emissions. Using aluminum, the weight of ships can be reduced, ensuring lower fuel consumption. Therefore, hybrid joints of steel and aluminum are of great interest to the maritime industry. In order to provide an efficient lap joining process, high-power laser welding of thick steel plates (S355, t = 5 mm) and aluminum plates (EN AW-6082, t = 8 mm) is investigated. As the weld seam quality greatly depends on the amount of intermetallic phases within the joint, optimized process parameters and control are crucial. Using high-power laser welding, a tensile strength of 10 kN was achieved. Based on metallographic analysis, hardness tests, and tensile tests the potential of this joining method is presented.

Manufacturing Methods for Process Effects on Aluminum Casting Allowables

DTIC Science & Technology

1985-03-01

silicon ingot (25% Si) 4 . Copper as copper shot 5. Manganese as aluminum manganese ingot (10% Mn) 6 . Titanium and boron as titanium -boron wire 7. Silver...in stock form 4 . Silver in granule form. 5. Manganese (10 percent) in button form 6 . 201 refining salt ( Titanium -Boron) Melt chemistry is adjusted to...FAFB, OH 45433 4 . PERFORIN41N ORGANIZATION REPORT NUMBER(S) 5. MONITORING ORGANIZATION REPORT NUMSER(S) NOR 85-119 AFWAL-TR-.84- 4 117 I 6 *. NAME OF

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.

The corrosion mechanisms for primer coated 2219-T87 aluminum

NASA Technical Reports Server (NTRS)

Danford, Merlin D.; Knockemus, Ward W.

1987-01-01

To investigate metal surface corrosion and the breakdown of metal protective coatings, the ac Impedance Method was applied to zinc chromate primer coated 2219-T87 aluminum. The EG&GPARC Model 368 ac Impedance Measurement System, along with dc measurements with the same system using the Polarization Resistance Method, was used to monitor changing properties of coated aluminum disks immersed in 3.5 percent NaCl solutions buffered at pH 5.5 and pH 8.2 over periods of 40 days each. The corrosion system can be represented by an electronic analog called an equivalent circuit consisting of resistors and capacitors in specific arrangements. This equivalent circuit parallels the impedance behavior of the corrosion system during a frequency scan. Values for resistances and capacitances, that can be assigned in the equivalent circuit following a least squares analysis of the data, describe changes occurring on the corroding metal surface and in the protective coatings. A suitable equivalent circuit has been determined which predicts the correct Bode phase and magnitude for the experimental sample. The dc corrosion current density data are related to equivalent circuit element parameters.

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.

Proof test and fatigue crack growth modeling on 2024-T3 aluminum alloy

NASA Technical Reports Server (NTRS)

Newman, J. C., Jr.; Poe, C. C., Jr.; Dawicke, D. S.

1990-01-01

Pressure proof testing of aircraft fuselage structures has been suggested as a means of screening critical crack sizes and of extending their useful life. The objective of this paper is to study the proof-test concept and to model the crack-growth process on a ductile material. Simulated proof and operational fatigue life tests have been conducted on cracked panels made of 2024-T3 aluminum alloy sheet material. A fatigue crack-closure model was modified to simulate the proof test and operational fatigue cycling. Using crack-growth rate and resistance-curve data, the model was able to predict crack growth during and after the proof load. These tests and analyses indicate that the proof test increases fatigue life; but the beneficial life, after a 1.33 or 1.5 proof, was less than a few hundred cycles.

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.

Microstructural development from interdiffusion and reaction between Usbnd Mo and AA6061 alloys annealed at 600° and 550 °C

NASA Astrophysics Data System (ADS)

Perez, E.; Keiser, D. D.; Sohn, Y. H.

2016-08-01

The U.S. Material Management and Minimization Reactor Conversion Program is developing low enrichment fuel systems encased in Al-alloy for use in research and test reactors. Monolithic fuel plates have local regions where the Usbnd Mo fuel plate may come into contact with the Al-alloy 6061 (AA6061) cladding. This results in the development of interdiffusion zones with complex microstructures with multiple phases. In this study, the microstructural development of diffusion couples, Usbnd 7 wt%Mo, Usbnd 10 wt%Mo, and Usbnd 12 wt%Mo vs. AA6061, annealed at 600 °C for 24 h and at 550 °C for 1, 5, and 20 h, were analyzed by scanning electron microscopy with x-ray energy dispersive spectroscopy. The microstructural development and kinetics were compared to diffusion couples Usbnd Mo vs. high purity Al and binary Alsbnd Si alloys. The diffusion couples developed complex interaction regions where phase development was influenced by the alloying additions of the AA6061.

[Influencing factors and mechanism of arsenic removal during the aluminum coagulation process].

PubMed

Chen, Gui-Xia; Hu, Cheng-Zhi; Zhu, Ling-Feng; Tong, Hua-Qing

2013-04-01

Aluminum coagulants are widely used in arsenic (As) removal during the drinking water treatment process. Aluminium chloride (AlCl3) and polyaluminium chloride (PACl) which contains high content of Al13 were used as coagulants. The effects of aluminum species, pH, humic acid (HA) and coexisting anions on arsenic removal were investigated. Results showed that AlCl3 and PACl were almost ineffective in As(II) removal while the As(V) removal efficiency reached almost 100%. pH was an important influencing factor on the arsenic removal efficiency, because pH influenced the distribution of aluminum species during the coagulation process. The efficiency of arsenic removal by aluminum coagulants was positively correlated with the content of Al13 species. HA and some coexisting anions showed negative impact on arsenic removal because of the competitive adsorption. The negative influence of HA was more pronounced at low coagulant dosages. PO4(3-) and F(-) showed marked influence during arsenic removal, but there was no obvious influence when SiO3(2-), CO3(2-) and SO4(2-) coexisted. The present study would be helpful to direct arsenic removal by enhanced coagulation during the drinking water treatment.

Development of a double beam process for joining aluminum and steel

NASA Astrophysics Data System (ADS)

Frank, Sascha

2014-02-01

Multi-material structures pose an attractive option for overcoming some of the central challenges in lightweight design. An exceptionally high potential for creating cost-effective lightweight solutions is attributed to the combination of steel and aluminum. However, these materials are also particularly difficult to join due to their tendency to form intermetallic compounds (IMCs). The growth of these compounds is facilitated by high temperatures and long process times. Due to their high brittleness, IMCs can severely weaken a joint. Thus, it is only possible to create durable steel-aluminum joints when the formation of IMCs can be limited to a non-critical level. To meet this goal, a new joining method has been designed. The method is based on the combination of a continuous wave (pw) and a pulsed laser (pw) source. Laser beams from both sources are superimposed in a common process zone. This makes it possible to apply the advantages of laser brazing to mixed-metal joints without requiring the use of chemical fluxes. The double beam technology was first tested in bead-on-plate experiments using different filler wire materials. Based on the results of these tests, a process for joining steel and aluminum in a double-flanged configuration is now being developed. The double flanged seams are joined using zinc- or aluminum-based filler wires. Microsections of selected seams show that it is possible to achieve good base material wetting while limiting the growth of IMCs to acceptable measures. In addition, the results of tensile tests show that high joint strengths can be achieved.

Impact and residual fatigue behavior of ARALL and AS6/5245 composite materials

NASA Technical Reports Server (NTRS)

Johnson, W. S.

1986-01-01

Aramide fiber reinforced aluminum laminates (ARALL) represent a cross between resin matrix composites and metals. The purpose of this study was to evaluate the impact sensitivity of this concept. Two types of ARALL (7075 aluminum prestrained and 2024 aluminum not prestrained) were tested through static indentation and the results compared to sheet 2024-T3 and 7075-T6 aluminum alloys. A state-of-the-art composite (AS6/5245) was also tested and compared to the ARALL. Further, the two types of ARALL material and the composite were dynamically impacted at two energy levels and fatigue tested to determine residual fatigue strength. Both forms of the ARALL material had worse impact resistance than monolithic sheet aluminum. The ARALL material made with 2024-T3 aluminum had better impact resistance than did the laminates made with 7075-T6 aluminum. The ARALL materials are at least equal to the composite material in impact damage resistance and are better for impact detection. The composite material has higher residual fatigue strength after impact than the ARALL material and is 25 percent lighter. The prestraining of the ARALL greatly reduces the fatigue growth of impact damage.

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...

Nondestructive Evaluation of Friction Stir-Welded Aluminum Alloy to Coated Steel Sheet Lap Joint

NASA Astrophysics Data System (ADS)

Das, H.; Kumar, A.; Rajkumar, K. V.; Saravanan, T.; Jayakumar, T.; Pal, Tapan Kumar

2015-11-01

Dissimilar lap joints of aluminum sheet (AA 6061) of 2 mm thickness and zinc-coated steel sheet of 1 mm thickness were produced by friction stir welding with different combinations of rotational speed and travel speed. Ultrasonic C- and B-scanning, and radiography have been used in a complementary manner for detection of volumetric (cavity and flash) and planar (de bond) defects as the defects are in micron level. Advanced ultrasonic C-scanning did not provide any idea about the defects, whereas B-scanning cross-sectional image showed an exclusive overview of the micron-level defects. A digital x-ray radiography methodology is proposed for quality assessment of the dissimilar welds which provide three-fold increase in signal-to-noise ratio with improved defect detection sensitivity. The present study clearly shows that the weld tool rotational speed and travel speed have a decisive role on the quality of the joints obtained by the friction stir welding process. The suitability of the proposed NDE techniques to evaluate the joint integrity of dissimilar FSW joints is thus established.

The Corrosion Protection of 2219-T87 Aluminum by Organic and Inorganic Zinc-Rich Primers

NASA Technical Reports Server (NTRS)

Danford, M. D.; Mendrek, M. J.; Walsh, D. W.

1995-01-01

The behavior of zinc-rich primer-coated 2219-T87 aluminum in a 3.5-percent Na-Cl was investigated using electrochemical techniques. The alternating current (ac) method of electrochemical impedance spectroscopy (EIS), in the frequency range of 0.001 to 40,000 Hz, and the direct current (dc) method of polarization resistance (PR) were used to evaluate the characteristics of an organic, epoxy zinc-rich primer and an inorganic, ethyl silicate zinc-rich primer. A dc electrochemical galvanic corrosion test was also used to determine the corrosion current of each zinc-rich primer anode coupled to a 2219-T87 aluminum cathode. Duration of the EIS/PR and galvanic testing was 21 days and 24 h, respectively. The galvanic test results demonstrated a very high galvanic current between the aluminum cathode and both zinc-rich primer anodes (37.9 pA/CM2 and 23.7 pA/CM2 for the organic and inorganic primers, respectively). The PR results demonstrated a much higher corrosion rate of the zinc in the inorganic primer than in the organic primer, due primarily to the higher porosity in the former. Based on this investigation, the inorganic zinc-rich primer appears to provide superior galvanic protection and is recommended for additional study for application in the solid rocket booster aft skirt.

The corrosion protection of 2219-T87 aluminum by organic and inorganic zinc-rich primers

NASA Technical Reports Server (NTRS)

Danford, M. D.; Mendrek, M. J.; Walsh, D. W.

1995-01-01

The behavior of zinc-rich primer-coated 2219-T87 aluminum in a 3.5-percent Na-Cl was investigated using electrochemical techniques. The alternating current (ac) method of electro-chemical impedance spectroscopy (EIS), in the frequency range of 0.001 to 40,000 Hz, and the direct current (dc) method of polarization resistance (PR) were used to evaluate the characteristics of an organic, epoxy zinc-rich primer and an inorganic, ethyl silicate zinc-rich primer. A dc electrochemical galvanic corrosion test was also used to determine the corrosion current of each zinc-rich primer anode coupled to a 2219-T87 aluminum cathode. Duration of the EIS/PR and galvanic testing was 21 days and 24 h, respectively. the galvanic test results demonstrated a very high galvanic current between the aluminum cathode and both zinc-rich primer anodes (37.9 micro A/cm(exp 2) and 23.7 micro A/cm(exp 2) for the organic and inorganic primers, respectively). The PR results demonstrated a much higher corrosion rate of the zinc in the inorganic primer than in the organic primer, due primarily to the higher porosity in the former. Based on this investigation, the inorganic zinc-rich primer appears to provide superior galvanic protection and is recommended for additional study for application in the solid rocket booster aft skirt.

Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach

PubMed Central

Su, Zheng-Ming; Qiu, Qi-Hong; Lin, Pai-Chen

2016-01-01

A simple thermal-mechanical model for friction stir spot welding (FSSW) was developed to obtain similar weld performance for different weld tools. Use of the thermal-mechanical model and a combined approach enabled the design of weld tools for various sizes but similar qualities. Three weld tools for weld radii of 4, 5, and 6 mm were made to join 6061-T6 aluminum sheets. Performance evaluations of the three weld tools compared fracture behavior, microstructure, micro-hardness distribution, and welding temperature of welds in lap-shear specimens. For welds made by the three weld tools under identical processing conditions, failure loads were approximately proportional to tool size. Failure modes, microstructures, and micro-hardness distributions were similar. Welding temperatures correlated with frictional heat generation rate densities. Because the three weld tools sufficiently met all design objectives, the proposed approach is considered a simple and feasible guideline for preliminary tool design. PMID:28773800

Determination of design allowable properties. Fracture of 2219-T87 aluminum alloy

NASA Technical Reports Server (NTRS)

Engstrom, W. L.

1972-01-01

A literature survey was conducted to provide a comprehensive report of available valid data on tensile properties, fracture toughness, fatigue crack propagation, and sustained load behavior of 2219-T87 aluminum alloy base metal and weldments, as applicable to manned spacecraft tankage. Most of the data found were from tests conducted at room temperature, -320 F and -423 F. Data are presented in graphical and tabular form, and areas in which data are lacking are established.

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…

Phase Transitions in Aluminum Under Shockless Compression at the Z Machine

NASA Astrophysics Data System (ADS)

Davis, Jean-Paul; Brown, Justin; Shulenburger, Luke; Knudson, Marcus

2017-06-01

Aluminum 6061 alloy has been used extensively as an electrode material in shockless ramp-wave experiments at the Z Machine. Previous theoretical work suggests that the principal quasi-isentrope in aluminum should pass through two phase transitions at multi-megabar pressures, first from the ambient fcc phase to hcp at around 200 GPa, then to bcc at around 320 GPa. Previous static measurements in a diamond-anvil cell have detected the hcp phase above 200 GPa along the room-temperature isentherm. Recent laser-based dynamic compression experiments have observed both the hcp and bcc phases using X-ray diffraction. Here we present high-accuracy velocity waveform data taken on pure and alloy aluminum materials at the Z Machine under shockless compression with 200-ns rise-time to 400 GPa using copper electrodes and lithium-fluoride windows. These are compared to recent EOS tables developed at Los Alamos National Laboratory, to our own results from diffusion quantum Monte-Carlo calculations, and to multi-phase EOS models with phase-transition kinetics. We find clear evidence of a fast transition around 200 GPa as expected, and a possible suggestion of a slower transition at higher pressure. Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy's National Nuclear Security Administration under contract DE AC04-94AL85000.

Dry Sliding Tribological Studies of AA6061-B4C-Gr Hybrid Composites

NASA Astrophysics Data System (ADS)

Monikandan, V. V.; Joseph, M. A.; Rajendrakumar, P. K.

2016-10-01

The dry sliding behavior of stir-cast AA6061-10 wt.% B4C composites containing 2.5, 5 and 7.5 wt.% graphite particles was studied as a function of applied load, sliding speed and sliding distance on a pin-on-disk tribotester. The wear rate and friction coefficient increased with increase in applied load and sliding distance. The increase in graphite addition reduced the increase in wear rate and friction coefficient in the sliding speed range 2-2.5 m/s. Scanning electron microscopy of the worn pin revealed a graphite tribolayer, and transmission electron microscopy revealed overlapping deformation bands under 30 N applied load. Upon increasing the applied load to 40 N, welded region with fine crystalline structure was formed due to dynamic recrystallization of AA6061 alloy matrix.

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. Copyright © 2015. Published by Elsevier B.V.

The Oxidation Products of Aluminum Hydride and Boron Aluminum Hydride Clusters

DTIC Science & Technology

2016-01-04

AFRL-AFOSR-VA-TR-2016-0075 The Oxidation Products of Aluminum Hydride and Boron Aluminum Hydride Clusters KIT BOWEN JOHNS HOPKINS UNIV BALTIMORE MD...Hydride and Boron Aluminum Hydride Clusters 5a.  CONTRACT NUMBER 5b.  GRANT NUMBER FA9550-14-1-0324 5c.  PROGRAM ELEMENT NUMBER 61102F 6. AUTHOR(S) KIT...of both Aluminum Hydride Cluster Anions and Boron Aluminum Hydride Cluster Anions with Oxygen: Anionic Products The anionic products of reactions

Technology for High Pure Aluminum Oxide Production from Aluminum Scrap

NASA Astrophysics Data System (ADS)

Ambaryan, G. N.; Vlaskin, M. S.; Shkolnikov, E. I.; Zhuk, A. Z.

2017-10-01

In this study a simple ecologically benign technology of high purity alumina production is presented. The synthesis process consists of three steps) oxidation of aluminum in water at temperature of 90 °C) calcinations of Al hydroxide in atmosphere at 1100 °C) high temperature vacuum processing of aluminum alpha oxide at 1750 °C. Oxidation of aluminum scrap was carried out under intensive mixing in water with small addition of KOH as a catalyst. It was shown that under implemented experimental conditions alkali was continuously regenerated during oxidation reaction and synergistic effect of low content alkali aqueous solution and intensive mixing worked. The product of oxidation of aluminum scrap is the powder of Al(OH)3. Then it can be preliminary granulated or directly subjected to thermal treatment deleting the impurities from the product (aluminum oxide). It was shown the possibility to produce the high-purity aluminum oxide of 5N grade (99.999 %). Aluminum oxide, synthesized by means of the proposed method, meets the requirements of industrial manufacturers of synthetic sapphire (aluminum oxide monocrystals). Obtained high pure aluminum oxide can be also used for the manufacture of implants, artificial joints, microscalpels, high-purity ceramics and other refractory shapes for manufacture of ultra-pure products.

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.

Test of superplastically formed corrugated aluminum compression specimens with beaded webs

NASA Technical Reports Server (NTRS)

Davis, Randall C.; Royster, Dick M.; Bales, Thomas T.; James, William F.; Shinn, Joseph M., Jr.

1991-01-01

Corrugated wall sections provide a highly efficient structure for carrying compressive loads in aircraft and spacecraft fuselages. The superplastic forming (SPF) process offers a means to produce complex shells and panels with corrugated wall shapes. A study was made to investigate the feasibility of superplastically forming 7475-T6 aluminum sheet into a corrugated wall configuration and to demonstrate the structural integrity of the construction by testing. The corrugated configuration selected has beaded web segments separating curved-cap segments. Eight test specimens were fabricated. Two specimens were simply a single sheet of aluminum superplastically formed to a beaded-web, curved-cap corrugation configuration. Six specimens were single-sheet corrugations modified by adhesive bonding additional sheet material to selectively reinforce the curved-cap portion of the corrugation. The specimens were tested to failure by crippling in end compression at room temperature.

Post-Decontamination Vapor Sampling and Analytical Test Methods

DTIC Science & Technology

2015-08-12

construction materials (e.g., acrylic, stainless steel , glass, etc.) for containing the chemical contaminants, coupons, coupon holders, and decontaminant(s...made of inert materials, e.g., stainless steel , T6061 aluminum, or equivalent. The construction material may be treated to further minimize...include glove ports. The chamber may have certified fume hoods for the containment of toxic chemicals. All exhaust air must be filtered to

Metallurgical characterization of the fracture of several high strength aluminum alloys

NASA Technical Reports Server (NTRS)

Bhandarkar, M. D.; Lisagor, W. B.

1977-01-01

The fracture behavior for structural aluminum alloys (2024, 6061, 7075, and 7178) was examined in selected heat treatments. The investigation included tensile, shear, and precracked notch-bend specimens fractured at ambient temperature under monotonic loading. Specimens were obtained from thin sheets and thick plates and were tested in longitudinal and transverse orientations at different strain rates. Microstructures of alloys were examined using the optical microscope and the scanning electron microscope with associated energy dispersive X ray chemical analysis. Several different types of second phase particles, some not reported by other investigators, were identified in the alloys. Fracture morphology was related to microstructural variables, test variables, and type of commercial product. Specimen orientation examined in the present investigation had little effect on fracture morphology. Test strain rate changes resulted in some change in shear fracture morphology, but not in fracture morphology of tensile specimens.

Hot Press as a Sustainable Direct Recycling Technique of Aluminium: Mechanical Properties and Surface Integrity.

PubMed

Yusuf, Nur Kamilah; Lajis, Mohd Amri; Ahmad, Azlan

2017-08-03

Meltless recycling technique has been utilized to overcome the lack of primary resources, focusing on reducing the usage of energy and materials. Hot press was proposed as a novel direct recycling technique which results in astoundingly low energy usage in contrast with conventional recycling. The aim of this study is to prove the technical feasibility of this approach by characterizing the recycled samples. For this purpose, AA6061 aluminium chips were recycled by utilizing hot press process under various operating temperature (T s = 430, 480, and 530 °C) and holding times (t s = 60, 90, and 120 min). The maximum mechanical properties of recycled chip are Ultimate tensile strength (UTS) = 266.78 MPa, Elongation to failure (ETF) = 16.129%, while, for surface integrity of the chips, the calculated microhardness is 81.744 HV, exhibited at T s = 530 °C and t s = 120 min. It is comparable to theoretical AA6061 T4-temper where maximum UTS and microhardness is increased up to 9.27% and 20.48%, respectively. As the desired mechanical properties of forgings can only be obtained by means of a final heat treatment, T5-temper, aging after forging process was employed. Heat treated recycled billet AA6061 (T5-temper) are considered comparable with as-received AA6061 T6, where the value of microhardness (98.649 HV) at 175 °C and 120 min of aging condition was revealed to be greater than 3.18%. Although it is quite early to put a base mainly on the observations in experimental settings, the potential for significant improvement offered by the direct recycling methods for production aluminium scrap can be clearly demonstrated. This overtures perspectives for industrial development of solid state recycling processes as environmentally benign alternatives of current melting based practices.

Multimaterial lamination as a means of retarding penetration and spallation failures in plates

NASA Technical Reports Server (NTRS)

Dibattista, J. D.; Humes, D. H.

1972-01-01

Experimental data are presented which show that hypervelocity impact spallation and penetration failures of a single solid aluminum plate and of a solid aluminum plate spaced a distance behind a Whipple meteor bumper may be retarded by replacing the solid aluminum plate with a laminated plate. Four sets of experiments were conducted. The first set of experiments was conducted with projectile mass and velocity held constant and with polycarbonate cylinders impacted into single plates of different construction. The second set of experiments was done with single plates of various construction and aluminum spherical projectiles of similar mass but different velocities. These two experiments showed that a laminated plate of aluminum and polycarbonate or aluminum and methyl methacrylate could prevent spallation and penetration failures with a lower areal density than either an all-aluminum laminated plate or a solid aluminum plate. The aluminum laminated plate was in turn superior to the solid aluminum plate in resisting spallation and penetration failures. In addition, through an example of 6061-T6 aluminum and methyl methacrylate, it is shown that a laminated structure ballistically superior to its parent materials may be built. The last two sets of experiments were conducted using bumper-protected main walls of solid aluminum and of laminated aluminum and polycarbonate. Again, under hypervelocity impact conditions, the laminated main walls were superior to the solid aluminum main walls in retarding spallation and penetration failures.

Facile Route to Rare Heterobimetallic Aluminum-Copper and Aluminum-Zinc Selenide Clusters.

PubMed

Li, Bin; Li, Jiancheng; Liu, Rui; Zhu, Hongping; Roesky, Herbert W

2017-03-20

Heterobimetallic aluminum-copper and aluminum-zinc clusters were prepared from the reaction of LAl(SeH) 2 [1; L = HC(CMeNAr) 2 and Ar = 2,6-iPr 2 C 6 H 3 ] with (MesCu) 4 and ZnEt 2 , respectively. The resulting clusters with the core structures of Al 2 Se 4 Cu 4 and Al 2 Se 4 Zn 3 exhibit unique metal-organic frameworks. This is a novel pathway for the synthesis of aluminum-copper and aluminum-zinc selenides. The products have been characterized by spectroscopic methods and single-crystal X-ray structural characterization.

The Corrosion Protection of Metals by Ion Vapor Deposited Aluminum

NASA Technical Reports Server (NTRS)

Danford, M. D.

1993-01-01

A study of the corrosion protection of substrate metals by ion vapor deposited aluminum (IVD Al) coats has been carried out. Corrosion protection by both anodized and unanodized IVD Al coats has been investigated. Base metals included in the study were 2219-T87 Al, 7075-T6 Al, Titanium-6 Al-4 Vanadium (Ti-6Al-4V), 4130 steel, D6AC steel, and 4340 steel. Results reveal that the anodized IVD Al coats provide excellent corrosion protection, but good protection is also achieved by IVD Al coats that have not been anodized.

Minimizing the bimetallic bending for cryogenic metal optics based on electroless nickel

NASA Astrophysics Data System (ADS)

Kinast, Jan; Hilpert, Enrico; Lange, Nicolas; Gebhardt, Andreas; Rohloff, Ralf-Rainer; Risse, Stefan; Eberhardt, Ramona; Tünnermann, Andreas

2014-07-01

Ultra-precise metal optics are key components of sophisticated scientific instruments in astronomy and space applications. Especially for cryogenic applications, a detailed knowledge and the control of the coefficient of thermal expansion (CTE) of the used materials are essential. Reflective optical components in IR- and NIR-instruments primarily consist of the aluminum alloy Al6061. The achievable micro-roughness of diamond machined and directly polished Al6061 does not fulfill the requirements for applications in the visible spectral range. Electroless nickel enables the reduction of the mirror surface roughness to the sub-nm range by polishing. To minimize the associated disadvantageous bimetallic effect, a novel material combination for cryogenic mirrors based on electroless nickel and hypereutectic aluminum-silicon is investigated. An increasing silicon content of the aluminum material decreases the CTE in the temperature range to be considered. This paper shows the CTE for aluminum materials containing about 42 wt% silicon (AlSi42) and for electroless nickel with a phosphorous content ranging from 10.5 to 13 %. The CTE differ to about 0.5 × 10-6 K-1 in a temperature range from -185 °C (LN2) to 100 °C. Besides, the correlations between the chemical compositions of aluminum-silicon materials and electroless nickel are shown. A metrology setup for cryo-interferometry was developed to analyze the remaining and reversible shape deviation at cryogenic temperatures. Changes could be caused by different CTE, mounting forces and residual stress conditions. In the electroless nickel layer, the resulting shape deviation can be preshaped by deterministic correction processes such as magnetorheological finishing (MRF) at room temperature.

Experimental Investigation on the Joining of Aluminum Alloy Sheets Using Improved Clinching Process

PubMed Central

Chen, Chao; Zhao, Shengdun; Han, Xiaolan; Zhao, Xuzhe; Ishida, Tohru

2017-01-01

Aluminum alloy sheets have been widely used to build the thin-walled structures by mechanical clinching technology in recent years. However, there is an exterior protrusion located on the lower sheet and a pit on the upper sheet, which may restrict the application of the clinching technology in visible areas. In the present study, an improved clinched joint used to join aluminum alloy sheets was investigated by experimental method. The improved clinching process used for joining aluminum alloy evolves through four phases: (a) localized deformation; (b) drawing; (c) backward extrusion; and (d) mechanical interlock forming. A flat surface can be produced using the improved clinching process. Shearing strength, tensile strength, material flow, main geometrical parameters, and failure mode of the improved clinched joint were investigated. The sheet material was compressed to flow radially and upward using a punch, which generated a mechanical interlock by producing severe localized plastic deformation. The neck thickness and interlock of the improved clinched joint were increased by increasing the forming force, which also contributed to increase the strength of the clinched joint. The improved clinched joint can get high shearing strength and tensile strength. Three main failure modes were observed in the failure process, which were neck fracture mode, button separation mode, and mixed failure mode. The improved clinched joint has better joining quality to join aluminum alloy sheets on the thin-walled structures. PMID:28763027

Experimental Investigation on the Joining of Aluminum Alloy Sheets Using Improved Clinching Process.

PubMed

Chen, Chao; Zhao, Shengdun; Han, Xiaolan; Zhao, Xuzhe; Ishida, Tohru

2017-08-01

Aluminum alloy sheets have been widely used to build the thin-walled structures by mechanical clinching technology in recent years. However, there is an exterior protrusion located on the lower sheet and a pit on the upper sheet, which may restrict the application of the clinching technology in visible areas. In the present study, an improved clinched joint used to join aluminum alloy sheets was investigated by experimental method. The improved clinching process used for joining aluminum alloy evolves through four phases: (a) localized deformation; (b) drawing; (c) backward extrusion; and (d) mechanical interlock forming. A flat surface can be produced using the improved clinching process. Shearing strength, tensile strength, material flow, main geometrical parameters, and failure mode of the improved clinched joint were investigated. The sheet material was compressed to flow radially and upward using a punch, which generated a mechanical interlock by producing severe localized plastic deformation. The neck thickness and interlock of the improved clinched joint were increased by increasing the forming force, which also contributed to increase the strength of the clinched joint. The improved clinched joint can get high shearing strength and tensile strength. Three main failure modes were observed in the failure process, which were neck fracture mode, button separation mode, and mixed failure mode. The improved clinched joint has better joining quality to join aluminum alloy sheets on the thin-walled structures.

34 CFR 606.1 - What is the Developing Hispanic-Serving Institutions Program?

Code of Federal Regulations, 2011 CFR

2011-07-01

... INSTITUTIONS PROGRAM General § 606.1 What is the Developing Hispanic-Serving Institutions Program? The purpose of the Developing Hispanic-Serving Institutions Program is to provide grants to eligible institutions... 34 Education 3 2011-07-01 2011-07-01 false What is the Developing Hispanic-Serving Institutions...

Effect of Electron Beam Freeform Fabrication (EBF3) Processing Parameters on Composition of Ti-6-4

NASA Technical Reports Server (NTRS)

Lach, Cynthia L.; Taminger, Karen; Schuszler, A. Bud, II; Sankaran, Sankara; Ehlers, Helen; Nasserrafi, Rahbar; Woods, Bryan

2007-01-01

The Electron Beam Freeform Fabrication (EBF3) process developed at NASA Langley Research Center was evaluated using a design of experiments approach to determine the effect of processing parameters on the composition and geometry of Ti-6-4 deposits. The effects of three processing parameters: beam power, translation speed, and wire feed rate, were investigated by varying one while keeping the remaining parameters constant. A three-factorial, three-level, fully balanced mutually orthogonal array (L27) design of experiments approach was used to examine the effects of low, medium, and high settings for the processing parameters on the chemistry, geometry, and quality of the resulting deposits. Single bead high deposits were fabricated and evaluated for 27 experimental conditions. Loss of aluminum in Ti-6-4 was observed in EBF3 processing due to selective vaporization of the aluminum from the sustained molten pool in the vacuum environment; therefore, the chemistries of the deposits were measured and compared with the composition of the initial wire and base plate to determine if the loss of aluminum could be minimized through careful selection of processing parameters. The influence of processing parameters and coupling between these parameters on bulk composition, measured by Direct Current Plasma (DCP), local microchemistries determined by Wavelength Dispersive Spectrometry (WDS), and deposit geometry will also be discussed.

Microstructural development from interdiffusion and reaction between U–Mo and AA6061 alloys annealed at 600° and 550 °C

DOE PAGES

Perez, E.; Keiser, D. D.; Sohn, Y. H.

2016-05-10

The U.S. Material Management and Minimization Reactor Conversion Program is developing low enrichment fuel systems encased in Al-alloy for use in research and test reactors. Monolithic fuel plates have local regions where the Usingle bondMo fuel plate may come into contact with the Al-alloy 6061 (AA6061) cladding. This results in the development of interdiffusion zones with complex microstructures with multiple phases. In this study, the microstructural development of diffusion couples, U–7 wt%Mo, U–10 wt%Mo, and U–12 wt%Mo vs. AA6061, annealed at 600 °C for 24 h and at 550 °C for 1, 5, and 20 h, were analyzed by scanningmore » electron microscopy with x-ray energy dispersive spectroscopy. The microstructural development and kinetics were compared to diffusion couples U–Mo vs. high purity Al and binary Al–Si alloys. As a result, the diffusion couples developed complex interaction regions where phase development was influenced by the alloying additions of the AA6061.« less

Effects of thread interruptions on tool pins in friction stir welding of AA6061

DOE PAGES

Reza-E-Rabby, Md.; Tang, Wei; Reynolds, Anthony P.

2017-06-21

In this paper, effects of pin thread and thread interruptions (flats) on weld quality and process response parameters during friction stir welding (FSW) of 6061 aluminium alloy were quantified. Otherwise, identical smooth and threaded pins with zero to four flats were adopted for FSW. Weldability and process response variables were examined. Results showed that threads with flats significantly improved weld quality and reduced in-plane forces. A three-flat threaded pin led to production of defect-free welds under all examined welding conditions. Spectral analyses of in-plane forces and weld cross-sectional analysis were performed to establish correlation among pin flats, force dynamics andmore » defect formation. Finally, the lowest in-plane force spectra amplitudes were consistently observed for defect-free welds.« less

Effects of thread interruptions on tool pins in friction stir welding of AA6061

DOE Office of Scientific and Technical Information (OSTI.GOV)

Reza-E-Rabby, Md.; Tang, Wei; Reynolds, Anthony P.

In this paper, effects of pin thread and thread interruptions (flats) on weld quality and process response parameters during friction stir welding (FSW) of 6061 aluminium alloy were quantified. Otherwise, identical smooth and threaded pins with zero to four flats were adopted for FSW. Weldability and process response variables were examined. Results showed that threads with flats significantly improved weld quality and reduced in-plane forces. A three-flat threaded pin led to production of defect-free welds under all examined welding conditions. Spectral analyses of in-plane forces and weld cross-sectional analysis were performed to establish correlation among pin flats, force dynamics andmore » defect formation. Finally, the lowest in-plane force spectra amplitudes were consistently observed for defect-free welds.« less

Numerical and experimental validation of a particle Galerkin method for metal grinding simulation

NASA Astrophysics Data System (ADS)

Wu, C. T.; Bui, Tinh Quoc; Wu, Youcai; Luo, Tzui-Liang; Wang, Morris; Liao, Chien-Chih; Chen, Pei-Yin; Lai, Yu-Sheng

2018-03-01

In this paper, a numerical approach with an experimental validation is introduced for modelling high-speed metal grinding processes in 6061-T6 aluminum alloys. The derivation of the present numerical method starts with an establishment of a stabilized particle Galerkin approximation. A non-residual penalty term from strain smoothing is introduced as a means of stabilizing the particle Galerkin method. Additionally, second-order strain gradients are introduced to the penalized functional for the regularization of damage-induced strain localization problem. To handle the severe deformation in metal grinding simulation, an adaptive anisotropic Lagrangian kernel is employed. Finally, the formulation incorporates a bond-based failure criterion to bypass the prospective spurious damage growth issues in material failure and cutting debris simulation. A three-dimensional metal grinding problem is analyzed and compared with the experimental results to demonstrate the effectiveness and accuracy of the proposed numerical approach.

Auger electron spectroscopy and Rutherford backscattering studies of copper in 2024-T3 aluminum following electrochemical anodization in phosphoric acid

NASA Astrophysics Data System (ADS)

Solomon, J. S.

1981-05-01

The effects of the electrochemical anodization of dioxidized 2024-T3 aluminum on copper were characterized by Auger electron spectroscopy and Rutherford backscattering. Anodization was performed in phosphoric acid at constant potential. Data is presented which shows that constant potential anodization of 2024-T3 is more efficient than aluminum in terms of oxide growth rates for short anodization times. However the maximum anodic oxide thickness achievable on the alloy is less than the pure metal. Copper is shown to be enriched at the oxide metal interface because of its diffusion from the bulk during anodization. The presence of copper at the oxide-metal interface is shown to affect oxide morphology.

Charts for the minimum-weight design of 24s-t aluminum-alloy flat compression panels with longitudinal z-section stiffeners

NASA Technical Reports Server (NTRS)

Schuette, Evan H

1945-01-01

Design charts are developed for 24s-t aluminum-alloy flat compression panels with longitudinal z-section stiffeners. These charts make possible the design of the lightest panels of this type for a wide range of design requirements. Examples of the use of the charts are given and it is pointed out on the basis of these examples that, over a wide range of design conditions, the maintenance of buckle-free surfaces does not conflict with the achievement of high structural efficiency. The achievement of the maximum possible structural efficiency with 24s-t aluminum-alloy panels, however, requires closer stiffener spacings than those now in common use.

Electrochemical characterization of cerium-based conversion coatings on aluminum alloy 7075-T6

NASA Astrophysics Data System (ADS)

Joshi, Simon

This research used electrochemical techniques to characterize the deposition and corrosion protection behavior of cerium-based conversion coatings on Al 7075-T6. Alkaline activation decreased native oxide impedance (5.9 kO-cm2) by ˜25% promoting deposition of 250--500 nm coatings. Activation in NaOH solutions deposited coatings with large cracks and craters, whereas Na2CO3 activation resulted in uniform coatings, i.e., fewer cracks and almost no craters. Uniformly deposited coatings exhibited better cathodic inhibition and higher impedance (˜200 kO-cm 2) than on NaOH activated substrates (˜100 kO-cm 2). Subsurface crevices, caused by Cl- and H 2O2 in the deposition solution, were found under large cracks and craters. Thus, Na2CO3 activation produced fewer subsurface crevices. To reduce subsurface crevice formation, Ce(NO3) 3 and CeCl3 were used in different ratios. Coatings made using 100% Ce(NO3)3 solutions were ˜60 nm thick without subsurface crevices, but the coatings offered little corrosion protection. Despite formation of subsurface crevices, Cl- was necessary as impedance increased linearly with Cl- concentration in the deposition solution. To characterize the different non-uniform features of the coatings, microelectrochemical testing was performed and it showed three distinct regions: active, intermediate, and passive. Humidity experiments were performed to understand the effect of moisture during salt spray testing and showed an increase in coating impedance by making the exposed substrate oxide more passive. However, this passive oxide could not provide corrosion resistance in a chloride environment. Dissolution studies showed that cerium migration was only possible at pH ≤2. Overall, deposition of uniform 250--500 nm thick outings was essential to make it an effective barrier to Cl - attach and prevent subsurface crevices on Al 7075-T6.

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.

Numerical simulation study on rolling-chemical milling process of aluminum-lithium alloy skin panel

NASA Astrophysics Data System (ADS)

Huang, Z. B.; Sun, Z. G.; Sun, X. F.; Li, X. Q.

2017-09-01

Single curvature parts such as aircraft fuselage skin panels are usually manufactured by rolling-chemical milling process, which is usually faced with the problem of geometric accuracy caused by springback. In most cases, the methods of manual adjustment and multiple roll bending are used to control or eliminate the springback. However, these methods can cause the increase of product cost and cycle, and lead to material performance degradation. Therefore, it is of significance to precisely control the springback of rolling-chemical milling process. In this paper, using the method of experiment and numerical simulation on rolling-chemical milling process, the simulation model for rolling-chemical milling process of 2060-T8 aluminum-lithium alloy skin was established and testified by the comparison between numerical simulation and experiment results for the validity. Then, based on the numerical simulation model, the relative technological parameters which influence on the curvature of the skin panel were analyzed. Finally, the prediction of springback and the compensation can be realized by controlling the process parameters.

Municipal solid waste processing and separation employing wet torrefaction for alternative fuel production and aluminum reclamation.

PubMed

Mu'min, Gea Fardias; Prawisudha, Pandji; Zaini, Ilman Nuran; Aziz, Muhammad; Pasek, Ari Darmawan

2017-09-01

This study employs wet torrefaction process (also known as hydrothermal) at low temperature. This process simultaneously acts as waste processing and separation of mixed waste, for subsequent utilization as an alternative fuel. The process is also applied for the delamination and separation of non-recyclable laminated aluminum waste into separable aluminum and plastic. A 2.5-L reactor was used to examine the wet torrefaction process at temperatures below 200°C. It was observed that the processed mixed waste was converted into two different products: a mushy organic part and a bulky plastic part. Using mechanical separation, the two products can be separated into a granular organic product and a plastic bulk for further treatment. TGA analysis showed that no changes in the plastic composition and no intrusion from plastic fraction to the organic fraction. It can be proclaimed that both fractions have been completely separated by wet torrefaction. The separated plastic fraction product obtained from the wet torrefaction treatment also contained relatively high calorific value (approximately 44MJ/kg), therefore, justifying its use as an alternative fuel. The non-recyclable plastic fraction of laminated aluminum was observed to be delaminated and separated from its aluminum counterpart at a temperature of 170°C using an additional acetic acid concentration of 3%, leaving less than 25% of the plastic content in the aluminum part. Plastic products from both samples had high calorific values of more than 30MJ/kg, which is sufficient to be converted and used as a fuel. Copyright © 2017 Elsevier Ltd. All rights reserved.

Aluminum acceptor four particle bound exciton complex in 4H, 6H, and 3C SiC

NASA Technical Reports Server (NTRS)

Clemen, L. L.; Devaty, R. P.; Macmillan, M. F.; Yoganathan, M.; Choyke, W. J.; Larkin, D. J.; Powell, J. A.; Edmond, J. A.; Kong, H. S.

1993-01-01

Evidence is presented for a four particle acceptor complex in 3C, 6H, and 4H SiC, obtained in low-temperature photoluminescence and cathodoluminescence experiments. The new lines were observed in p-type films lightly doped with aluminum, of 6H, 4H, and 3C SiC grown on the silicon (0001) face of 6H SiC under special conditions. The lines increase in intensity as more aluminum is added during growth. The multiplicity of observed lines is consistent with symmetry-based models similar to those which have been proposed to describe 4A centers in p-type zincblende semiconductors.

Improvement in Fatigue Performance of Aluminium Alloy Welded Joints by Laser Shock Peening in a Dynamic Strain Aging Temperature Regime.

PubMed

Su, Chun; Zhou, Jianzhong; Meng, Xiankai; Huang, Shu

2016-09-26

As a new treatment process after welding, the process parameters of laser shock peening (LSP) in dynamic strain aging (DSA) temperature regimes can be precisely controlled, and the process is a non-contact one. The effects of LSP at elevated temperatures on the distribution of the surface residual stress of AA6061-T6 welded joints were investigated by using X-ray diffraction technology with the sin² ϕ method and Abaqus software. The fatigue life of the welded joints was estimated by performing tensile fatigue tests. The microstructural evolution in surface and fatigue fractures of the welded joints was presented by means of surface integrity and fracture surface testing. In the DSA temperature regime of AA6061-T6 welded joints, the residual compressive stress was distributed more stably than that of LSP at room temperature. The thermal corrosion resistance and fatigue properties of the welded joints were also improved. The experimental results and numerical analysis were in mutual agreement.

Improvement in Fatigue Performance of Aluminium Alloy Welded Joints by Laser Shock Peening in a Dynamic Strain Aging Temperature Regime

PubMed Central

Su, Chun; Zhou, Jianzhong; Meng, Xiankai; Huang, Shu

2016-01-01

As a new treatment process after welding, the process parameters of laser shock peening (LSP) in dynamic strain aging (DSA) temperature regimes can be precisely controlled, and the process is a non-contact one. The effects of LSP at elevated temperatures on the distribution of the surface residual stress of AA6061-T6 welded joints were investigated by using X-ray diffraction technology with the sin2ϕ method and Abaqus software. The fatigue life of the welded joints was estimated by performing tensile fatigue tests. The microstructural evolution in surface and fatigue fractures of the welded joints was presented by means of surface integrity and fracture surface testing. In the DSA temperature regime of AA6061-T6 welded joints, the residual compressive stress was distributed more stably than that of LSP at room temperature. The thermal corrosion resistance and fatigue properties of the welded joints were also improved. The experimental results and numerical analysis were in mutual agreement. PMID:28773920

Investigations of Effect of Rotary EDM Electrode on Machining Performance of Al6061 Alloy

NASA Astrophysics Data System (ADS)

Robinson Smart, D. S.; Jenish Smart, Joses; Periasamy, C.; Ratna Kumar, P. S. Samuel

2018-04-01

Electric Discharge Machining is an essential process which is being used for machining desired shape using electrical discharges which creates sparks. There will be electrodes subjected to electric voltage and which are separated by a dielectric liquid. Removing of material will be due to the continuous and rapid current discharges between two electrodes.. The spark is very carefully controlled and localized so that it only affects the surface of the material. Usually in order to prevent the defects which are arising due to the conventional machining, the Electric Discharge Machining (EDM) machining is preferred. Also intricate and complicated shapes can be machined effectively by use of Electric Discharge Machining (EDM). The EDM process usually does not affect the heat treat below the surface. This research work focus on the design and fabrication of rotary EDM tool for machining Al6061alloy and investigation of effect of rotary tool on surface finish, material removal rate and tool wear rate. Also the effect of machining parameters of EDM such as pulse on & off time, current on material Removal Rate (MRR), Surface Roughness (SR) and Electrode wear rate (EWR) have studied. Al6061 alloy can be used for marine and offshore applications by reinforcing some other elements. The investigations have revealed that MRR (material removal rate), surface roughness (Ra) have been improved with the reduction in the tool wear rate (TWR) when the tool is rotating instead of stationary. It was clear that as rotary speed of the tool is increasing the material removal rate is increasing with the reduction of surface finish and tool wear rate.

A Numerical Process Control Method for Circular-Tube Hydroforming Prediction

DOE Office of Scientific and Technical Information (OSTI.GOV)

Johnson, Kenneth I.; Nguyen, Ba Nghiep; Davies, Richard W.

2004-03-01

This paper describes the development of a solution control method that tracks the stresses, strains and mechanical behavior of a tube during hydroforming to estimate the proper axial feed (end-feed) and internal pressure loads through time. The analysis uses the deformation theory of plasticity and Hill?s criterion to describe the plastic flow. Before yielding, the pressure and end-feed increments are estimated based on the initial tube geometry, elastic properties and yield stress. After yielding, the pressure increment is calculated based on the tube geometry at the previous solution increment and the current hoop stress increment. The end-feed increment is computedmore » from the increment of the axial plastic strain. Limiting conditions such as column buckling (of long tubes), local axi-symmetric wrinkling of shorter tubes, and bursting due to localized wall thinning are considered. The process control method has been implemented in the Marc finite element code. Hydroforming simulations using this process control method were conducted to predict the load histories for controlled expansion of 6061-T4 aluminum tubes within a conical die shape and under free hydroforming conditions. The predicted loading paths were transferred to the hydroforming equipment to form the conical and free-formed tube shapes. The model predictions and experimental results are compared for deformed shape, strains and the extent of forming at rupture.« less

IADC Vulnerability Report, IT32-21

NASA Technical Reports Server (NTRS)

Christiansen, E. L.; Miller, J. E.; Hyde, J.

2016-01-01

Numerous mission support hardware systems and their spares are maintained outside of the habitable volume of the International Space Station (ISS), and are arranged covered by a multi-layer insulation (MLI) thermal blanket which provides both thermal control and a measure of protection from micrometeoroids and orbital debris (MMOD). The NASA Hypervelocity Impact Technology (HVIT) group at the Johnson Space Center in Houston Texas has assessed the protection provided by MLI in a series of hypervelocity impact tests using a 1 mm thick aluminum 6061-T6 rear wall to simulate the actual hardware behind the MLI. HVIT has also evaluated methods to enhance the protection provided by MLI thermal blankets. The impact study used both aluminum and steel spherical projectiles accelerated to speeds of 7 km/s using a 4.3 mm, two-stage, light-gas gun at the NASA White Sands Test Facility (WSTF).

A new organofunctional ethoxysilane self-assembly monolayer for promoting adhesion of rubber to aluminum.

PubMed

Wang, Fang; Xu, Juan; Luo, Heyi; Wang, Jinggang; Wang, Qian

2009-10-12

Practical adhesion of rubber to aluminum is measured for various aluminum silanization treatments. In this study, 6-(3-triethoxysilylpropylamino)-1,3,5-triazine-2,4-dithiol (TES) was used as the coupling agent for preparing self-assembly monolayers (SAMs) on an aluminum surface. The structure and chemical composition of the SAMs were analyzed using Fourier transform infra-red spectroscopy (FT-IR) and X-ray photoelectron spectroscopy (XPS). The changes in the surface features of the aluminum surface due to TES treatment were investigated by atomic force microscopy (AFM). The adhesive properties of the silanized aluminum surface and EPDM rubber have been evaluated by a T-peel strength test. The results suggested that the Si-O-Al bonding at aluminum TES interface existed and a TES self-assembly monolayer was formed on the aluminum surface. More than 6.0 KN/m adhesion strength is obtained when the aluminum is silanized with 2.5 mmol/dm(3) TES, cured at 160 degrees C and vulcanized with EPDM rubber at 160 degrees C for 30 min. It is suggested that the TES self-assembly monolayer is bound to aluminum through its ethoxysilyl functional group, and the thiol function group is strongly crosslinked to EPDM rubber, respectively.

Evaluation of Aluminum Alloy 2050-T84 Microstructure and Mechanical Properties at Ambient and Cryogenic Temperatures

NASA Technical Reports Server (NTRS)

Hafley, Robert A.; Domack, Marcia S.; Hales, Stephen J.; Shenoy, Ravi N.

2011-01-01

Aluminum alloy 2050 is being considered for the fabrication of cryogenic propellant tanks to reduce the mass of future heavy-lift launch vehicles. The alloy is available in section thicknesses greater than that of the incumbent aluminum alloy, 2195, which will enable designs with greater structural efficiency. While ambient temperature design allowable properties are available for alloy 2050, cryogenic properties are not available. To determine its suitability for use in cryogenic propellant tanks, tensile, compression and fracture tests were conducted on 4 inch thick 2050-T84 plate at ambient temperature and at -320degF. Various metallurgical analyses were also performed in order to provide an understanding of the compositional homogeneity and microstructure of 2050.

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

Mechanical Properties and Microstructural Evolution of Friction-Stir-Welded Thin Sheet Aluminum Alloys

NASA Astrophysics Data System (ADS)

Cerri, Emanuela; Leo, Paola; Wang, Xiang; Embury, J. D.

2011-05-01

Friction stir welding of thin aluminum sheets represents a potential goal for aircraft and automotive industries because of the advantages of using this new technological process. In the current work, the microstructural evolution and mechanical behavior of 6082T6-6082T6, 2024T3-2024T3, and 6082T6-2024T3 thin friction-stir-welded joints were investigated. Uniaxial tensile testing at room temperature, 443 K, 473 K, and 503 K (170 °C, 200 °C, and 230 °C) was used to determine the extent to which these ultra-thin joints can be used and deformed. The tensile stress-strain curves showed a decrease of the flow stress with increasing temperature and decreasing strain rate. The ductility of 6082T6-6082T6 joints generally improved when deformed at warm temperatures. It was almost constant for the 6082T6-2024T3 and reached the higher value in the 2024T3-2024T3 when deformed at 443 K and 473 K (170 °C and 200 °C) when compared with the room temperature value. Tensile specimens fractured in the middle of the weld zone in a ductile mode. The precipitation and growth of S' type phases strengthens 2024T3-2024T3 joints during deformation. In the 6082T6-6082T6, β″ precipitates show some increase in size but give a lower contribution to strength. At 503 K (230 °C), recovery mechanisms (dislocation reorganization inside the deformed grains) are initiated but the temperature was not enough high to produce a homogeneous subgrain structure.

Organosilane self-assembled layers (SAMs) and hybrid silicate magnesium-rich primers for the corrosion protection of aluminum alloy 2024 T3

NASA Astrophysics Data System (ADS)

Wang, Duhua

Although current chromate coatings function very well in corrosion protection for aircraft alloys, such as aluminum alloy 2024 T3, the U.S. Environmental Protection Agency is planning to totally ban the use of chromates as coating materials in the next decade or so because of their extremely toxic effect. For this purpose, both self-assembled layers and silicate magnesium-rich primers were tested to provide the corrosion protection for aluminum alloy. The long-term goal of this research is to develop a coating system to replace the current chromate coating for aircraft corrosion protection. Aluminum alloy 2024 T3 substrates were modified with self-assembled monolayer or multilayer thin films from different alkylsilane compounds. Mono-functional silanes, such as octadecyltrichlorosilane (C18SiCl3), can form a mixed hydrophobic monolayer or multilayer thin film on the aluminum oxide surface to provide a barrier to water and other electrolytes, so the corrosion resistance of the SAMs modified surface was increased significantly. On the other hand, the bi-functional silane self-assembly could attach the aluminum surface through the silicon headgroup while using its functional tailgroup to chemically bond the polymer coating, thus improving the adhesion between the aluminum substrate and coating substantially, and seems to contribute more to corrosion protection of aluminum substrate. Organosilanes were also combined with tetraethyl orthosilicate (TEOS) in propel ratios to form a sol-gel binder to make silicate magnesium-rich primers. Analogue to the inorganic zinc-rich coatings, the silicate magnesium-rich primers also showed excellent adhesion and solvent resistance. The sacrificial magnesium pigments and the chemically inert silicate binder both contribute to the anti-corrosion properties. Future studies will be focused on the formula optimization for better toughness, chemical resistance and anticorrosion performance.

First wall design of aluminum alloy R-tokamak

NASA Astrophysics Data System (ADS)

Hamada, Y.; Matsuoka, K.; Ogawa, Y.; Kitagawa, S.; Toi, K.; Yamazaki, K.; Abe, Y.; Amano, T.; Fujita, J.; Kaneko, O.; Kawahata, K.; Kuroda, T.; Matsuura, K.; Midzuno, Y.; Naitou, H.; Noda, N.; Ohkubo, K.; Oka, Y.; Sakurai, K.; Tanahashi, S.; Watari, T.

1984-05-01

A design study of a low-activation D-T tokamak Reacting Plasma Project In Nagoya has been finished. The study emphasizes the vacuum vessel and the bumper limiter. Our choice of materials (aluminum vacuum vessel, copper conductors, aluminum TF coil case and lead shield) results in a radiation level of about 1 × 10 -3 times that of a TFTR type design, and 1 × 10 -4 times that of JET type design, at 2 weeks after one D-T shot. Thick graphite tiles will be fixed directly on the aluminum vacuum vessel using aluminum spring washers and bolts. With this simplified structure of the bumper limiter, the inner surface temperature of the thick aluminum vacuum vessel will be less than 120°C which is required to reduce the overaging effect of the aluminum alloy.

Influence of particle size on Cutting Forces and Surface Roughness in Machining of B4Cp - 6061 Aluminium Matrix Composites

NASA Astrophysics Data System (ADS)

Hiremath, Vijaykumar; Badiger, Pradeep; Auradi, V.; Dundur, S. T.; Kori, S. A.

2016-02-01

Amongst advanced materials, metal matrix composites (MMC) are gaining importance as materials for structural applications in particular, particulate reinforced aluminium MMCs have received considerable attention due to their superior properties such as high strength to weight ratio, excellent low-temperature performance, high wear resistance, high thermal conductivity. The present study aims at studying and comparing the machinability aspects of B4Cp reinforced 6061Al alloy metal matrix composites reinforced with 37μm and 88μm particulates produced by stir casting method. The micro structural characterization of the prepared composites is done using Scanning Electron Microscopy equipped with EDX analysis (Hitachi Su-1500 model) to identify morphology and distribution of B4C particles in the 6061Al matrix. The specimens are turned on a conventional lathe machine using a Polly crystalline Diamond (PCD) tool to study the effect of particle size on the cutting forces and the surface roughness under varying machinability parameters viz., Cutting speed (29-45 m/min.), Feed rate (0.11-0.33 mm/rev.) and depth of cut (0.5-1mm). Results of micro structural characterization revealed fairly uniform distribution of B4C particles (in both cases i.e., 37μm and 88μm) in 6061Al matrix. The surface roughness of the composite is influenced by cutting speed. The feed rate and depth of cut have a negative influence on surface roughness. The cutting forces decreased with increase in cutting speed whereas cutting forces increased with increase in feed and depth of cut. Higher cutting forces are noticed while machining Al6061 base alloy compared to reinforced composites. Surface finish is high during turning of the 6061Al base alloy and surface roughness is high with 88μm size particle reinforced composites. As the particle size increases Surface roughness also increases.

An electrochemical study of the corrosion behavior of primer coated 2219-T87 aluminum

NASA Technical Reports Server (NTRS)

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

1985-01-01

The corrosion behavior for 2219-T87 aluminum coated with various primers, including those used for the external tank and solid rocket boosters of the Space Shuttle Transportation System, were investigated using electrochemical techniques. Corrosion potential time, polarization resistance time, electrical resistance time, and corrosion rate time measurements were all investigated. It was found that electrical resistance time and corrosion rate time measurement were most useful for studying the corrosion behavior of painted aluminum. Electrical resistance time determination give useful information concerning the porosity of paint films, while corrosion rate time curves give important information concerning overall corrosion rates and corrosion mechanisms. In general, the corrosion rate time curves all exhibited at least one peak during the 30 day test period, which was attributed, according to the proposed mechanisms, to the onset of the hydrogen evolution reaction and the beginning of destruction of the protective properties of the paint film.

Interfacial Interaction in Anodic Aluminum Oxide Templates Modifies Morphology, Surface Area, and Crystallization of Polyamide-6 Nanofibers.

PubMed

Xue, Junhui; Xu, Yizhuang; Jin, Zhaoxia

2016-03-08

Here, we demonstrated that, when the precipitation process of polyamide-6 (PA6) solution happens in cylindrical channels of an anodized aluminum oxide membrane (AAO), interface interactions between a solid surface, solvent, non-solvent, and PA6 will influence the obtained polymer nanostructures, resulting in complex morphologies, increased surface area, and crystallization changes. With the enhancing interaction of PA6 and the AAO surface, the morphology of PA6 nanostructures changes from solid nanofibers, mesoporous, to bamboo-like, while at the same time, metastable γ-phase domains increase in these PA6 nanostructures. Brunauer-Emmett-Teller (BET) surface areas of solid, bamboo-like, and mesoporous PA6 nanofibers rise from 16, 20.9, to 25 m(2)/g. This study shows that interfacial interaction in AAO template fabrication can be used in manipulating the morphology and crystallization of one-dimensional polymer nanostructures. It also provides us a simple and novel method to create porous PA6 nanofibers with a large surface area.

Improvement of Strength and Energy Absorption Properties of Porous Aluminum Alloy with Aligned Unidirectional Pores Using Equal-Channel Angular Extrusion

NASA Astrophysics Data System (ADS)

Yoshida, Tomonori; Muto, Daiki; Tamai, Tomoya; Suzuki, Shinsuke

2018-04-01

Porous aluminum alloy with aligned unidirectional pores was fabricated by dipping A1050 tubes into A6061 semi-solid slurry. The porous aluminum alloy was processed through Equal-channel Angular Extrusion (ECAE) while preventing cracking and maintaining both the pore size and porosity by setting the insert material and loading back pressure. The specific compressive yield strength of the sample aged after 13 passes of ECAE was approximately 2.5 times higher than that of the solid-solutionized sample without ECAE. Both the energy absorption E V and energy absorption efficiency η V after four passes of ECAE were approximately 1.2 times higher than that of the solid-solutionized sample without ECAE. The specific yield strength was improved via work hardening and precipitation following dynamic aging during ECAE. E V was improved by the application of high compressive stress at the beginning of the compression owing to work hardening via ECAE. η V was improved by a steep increase of stress at low compressive strain and by a gradual increase of stress in the range up to 50 pct of compressive strain. The gradual increase of stress was caused by continuous shear fracture in the metallic part, which was due to the high dislocation density and existence of unidirectional pores parallel to the compressive direction in the structure.

Improvement of Strength and Energy Absorption Properties of Porous Aluminum Alloy with Aligned Unidirectional Pores Using Equal-Channel Angular Extrusion

NASA Astrophysics Data System (ADS)

Yoshida, Tomonori; Muto, Daiki; Tamai, Tomoya; Suzuki, Shinsuke

2018-06-01

Porous aluminum alloy with aligned unidirectional pores was fabricated by dipping A1050 tubes into A6061 semi-solid slurry. The porous aluminum alloy was processed through Equal-channel Angular Extrusion (ECAE) while preventing cracking and maintaining both the pore size and porosity by setting the insert material and loading back pressure. The specific compressive yield strength of the sample aged after 13 passes of ECAE was approximately 2.5 times higher than that of the solid-solutionized sample without ECAE. Both the energy absorption E V and energy absorption efficiency η V after four passes of ECAE were approximately 1.2 times higher than that of the solid-solutionized sample without ECAE. The specific yield strength was improved via work hardening and precipitation following dynamic aging during ECAE. E V was improved by the application of high compressive stress at the beginning of the compression owing to work hardening via ECAE. η V was improved by a steep increase of stress at low compressive strain and by a gradual increase of stress in the range up to 50 pct of compressive strain. The gradual increase of stress was caused by continuous shear fracture in the metallic part, which was due to the high dislocation density and existence of unidirectional pores parallel to the compressive direction in the structure.

Monitoring the Softening of Aluminum-Alloy V95ochT2 Shapes by a Nondestructive Method

NASA Astrophysics Data System (ADS)

Shigapov, A. I.; Klimova, T. A.; Il'inkova, T. A.

2015-09-01

Correlation relations between the strength and the electrical conductivity of aluminum shapes are determined. The properties of alloy V95ochT2 are studied after different temperature-and-time actions. It is shown that the "dark spots" appearing on the surface of such shapes can be evaluated by a nondestructive eddy-current method.

Achieving Carbon Neutrality in the Global Aluminum Industry

NASA Astrophysics Data System (ADS)

Das, Subodh

2012-02-01

In the 21st century, sustainability is widely regarded as the new corporate culture, and leading manufacturing companies (Toyota, GE, and Alcoa) and service companies (Google and Federal Express) are striving towards carbon neutrality. The current carbon footprint of the global aluminum industry is estimated at 500 million metric tonnes carbon dioxide equivalent (CO2eq), representing about 1.7% of global emissions from all sources. For the global aluminum industry, carbon neutrality is defined as a state where the total "in-use" CO2eq saved from all products in current use, including incremental process efficiency improvements, recycling, and urban mining activities, equals the CO2eq expended to produce the global output of aluminum. This paper outlines an integrated and quantifiable plan for achieving "carbon neutrality" in the global aluminum industry by advocating five actionable steps: (1) increase use of "green" electrical energy grid by 8%, (2) reduce process energy needs by 16%, (3) deploy 35% of products in "in-use" energy saving applications, (4) divert 6.1 million metric tonnes/year from landfills, and (5) mine 4.5 million metric tonnes/year from aluminum-rich "urban mines." Since it takes 20 times more energy to make aluminum from bauxite ore than to recycle it from scrap, the global aluminum industry could set a reasonable, self-imposed energy/carbon neutrality goal to incrementally increase the supply of recycled aluminum by at least 1.05 metric tonnes for every tonne of incremental production via primary aluminum smelter capacity. Furthermore, the aluminum industry can and should take a global leadership position by actively developing internationally accepted and approved carbon footprint credit protocols.

Neurobehavioral, autonomic nervous function and lymphocyte subsets among aluminum electrolytic workers.

PubMed

He, S C; Qiao, N; Sheng, W

2003-01-01

The purpose of our study is to determine the alteration of neurobehavioral parameters, autonomic nervous function and lymphocyte subsets in aluminum electrolytic workers of long-term aluminum exposure. 33 men who were 35.16 +/- 2.95 (mean +/- S.D) years old occupationally exposed to aluminum for 14.91 +/- 6.31 (mean +/- S.D) years. Air Al level and urinary aluminum concentration was measured by means of graphite furnace atomic absorption spectrophotometer. Normal reference group were selected from a flour plant. Neurobehavioral core test battery (NCTB) recommended by WHO was utilized. Autonomic nervous function test battery recommended by Ewing DJ was conducted on subjects. FAC SCAN was used to measure the lymphocyte subsets of peripheral blood. The mean air aluminum level in the workshop was 6.36 mg/m3, ranged from 2.90 to 11.38 mg/m3. Urinary aluminum of the Al electrolytic workers (40.08 +/- 9.36 microgram/mg.cre) was obviously higher than that of control group (26.84 +/- 8.93 m/mg.cre). Neurobehavioral results showed that the scores of DSY, PAC and PA in Al electrolytic workers were significantly lower than those of control group, The score of POMSC, POMSF and SRT among Al exposed workers were significantly augmented in relation to those of control group. Autonomic nervous function test results showed that R-R interval variability of maximum ratio of immediately standing up in Al electrolytic workers were decreased compare with the control group, while the BP-IS, HR-V, HR-DB, R30:15 had no significant change. Peripheral blood lymphocyte subsets test showed that CD4-CD8+ T lymphocyte in Al electrolytic workers increased. This study suggests that Al exposure exerts adverse effects on neurobehavioral performance, especially movement coordination and negative mood, and parasympathetic nervous function; moreover it increase CD4-CD8+ T lymphocyte subsets.

Investigation of Fatigue Crack-Growth Resistance of Aluminum Alloys under Spectrum Loading.

DTIC Science & Technology

1983-04-01

Effects on Fatigue Crack Progation in 2024 -T3 Aluminum Alloy ," Eng. Frac. Mech, Vol...results ("a" from 6 to 13 mm) can be made (Figure 20a): 1. The 2XXX alloys 2020-T651, 2324-T39, and 2024 - T351 had longer spectrum fatigue lives than the...strength and spectrum life exists at all three maximum peak stress levels for the 2024 alloy , with the lower yield strength T351 condition having

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.

ICALEO '91 - Laser materials processing; Proceedings of the Meeting, San Jose, CA, Nov. 3-8, 1991

NASA Astrophysics Data System (ADS)

Metzbower, Edward A.; Beyer, Eckhard; Matsunawa, Akira

Consideration is given to new developments in LASERCAV technology, modeling of deep penetration laser welding, the theory of radiative transfer in the plasma of the keyhole in penetration laser welding, a synchronized laser-video camera system study of high power laser material interactions, laser process monitoring with dual wavelength optical sensors, new devices for on-line process diagnostics during laser machining, and the process development for a portable Nd:YAG laser materials processing system. Attention is also given to laser welding of alumina-reinforced 6061 aluminum alloy composite, the new trend of laser materials processing, optimization of the laser cutting process for thin section stainless steels, a new nozzle concept for cutting with high power lasers, rapid solidification effects during laser welding, laser surface modification of a low carbon steel with tungsten carbide and carbon, absorptivity of a polarized beam during laser hardening, and laser surface melting of 440 C tool steel. (No individual items are abstracted in this volume)

The Effect of Artificial Aging on the Tensile Properties of Alclad 24S-T and 24S-T Aluminum Alloy

NASA Technical Reports Server (NTRS)

Kotanchik, Joseph N.; Woods, Walter; Zender, George W.

1943-01-01

An experimental study was made to determine the effect of artificial aging on the tensile properties of alclad 24S-T and 24S-T aluminum-alloy sheet material. The results of the tests show that certain combinations of aging time and temperature cause a marked increase in the yield strength and a small increase in the ultimate strength; these increases are accompanied by a very large decrease in elongation. A curve is presented that shows the maximum yield strengths that can be obtained by aging this material at various combinations of time and temperature. The higher values of yield stress are obtained in material aged at relatively longer times and lower temperatures.

Methodology for Evaluation of Fatigue Crack-Growth Resistance of Aluminum Alloys under Spectrum Loading.

DTIC Science & Technology

1982-04-01

fatigue life , except for the 2024 - T351 alloy which had a significantly longer spectrum fatigue life than the other alloys and 2) for...OF FATIGUE CRACK GROWTH OF ALUMINUM ALLOYS UNDER SPECTRUM LOADING MATERIALS PRESENT EFFORT FUTURE EFFORT 2024 - T351 2020-T651 2024 -T851 TMT2020-T6X51...the same spectrum fatigue life . The 2024 - T351 alloy had a significantly longer spectrum

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

Impact verification of space suit design for space station

NASA Technical Reports Server (NTRS)

Fish, Richard H.

1987-01-01

The ballistic limits of single sheet and double sheet structures made of 6061 T6 Aluminum of 1.8 mm and larger nominal thickness were investigated for projectiles of 1.5 mm diameter fired in the Vertical Gun Range Test Facility and NASA Ames Research Center. The hole diameters and sheet deformation behavior were studied for various ratios of sheet spacing to projectile diameter. The results indicate that for projectiles of less than 1.5 mm diameter the ballistic limit exceeds the nominal 10 km/sec orbital debris encounter velocity, if a single-sheet suit of 1.8 mm thickness is behind a single bumper sheet of 1 mm thickness spaced 12.5 mm apart.

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.

Strength and Formability Improvement of Al-Cu-Mn Aluminum Alloy Complex Parts by Thermomechanical Treatment with Sheet Hydroforming

NASA Astrophysics Data System (ADS)

Chen, Yi-Zhe; Liu, Wei; Yuan, Shi-Jian

2015-05-01

Normally, the strength and formability of aluminum alloys can be increased largely by severe plastic deformation and heat treatment. However, many plastic deformation processes are more suitable for making raw material, not for formed parts. In this article, an experimental study of the thermomechanical treatment by using the sheet hydroforming process was developed to improve both mechanical strength and formability for aluminum alloys in forming complex parts. The limiting drawing ratio, thickness, and strain distribution of complex parts formed by sheet hydroforming were investigated to study the formability and sheet-deformation behavior. Based on the optimal formed parts, the tensile strength, microhardness, grain structure, and strengthening precipitates were analyzed to identify the strengthening effect of thermomechanical treatment. The results show that in the solution state, the limiting drawing ratio of cylindrical parts could be increased for 10.9% compared with traditional deep drawing process. The peak values of tensile stress and microhardness of formed parts are 18.0% and 12.5% higher than that in T6 state. This investigation shows that the thermomechanical treatment by sheet hydroforming is a potential method for the products manufacturing of aluminum alloy with high strength and good formability.

Study on Finite Element Method of Stress Field in Aluminum Alloy High-Speed Milling Process

NASA Astrophysics Data System (ADS)

Zhang, Wei; Li, Shunming; Wu, Qijun; An, Zenghui

2017-11-01

Three-dimensional numerical simulation model has been built by means of Advantage FEM. Perform simulation the stress fields of 7050-T7451 aluminum alloy in high speed milling process at the speed range of 628 m/min∼5946 m/min. The dynamic change and speed’s influence of stress fields and residual stress in machined layer is systematically analyzed. Some conclusions were drawn. With the cutting process development, the stress field converts to the stress state that crushing stress occupies a leading position. The magnitudes of crushing stress in all directions reduce with milling processes as the effect of Thermal-Mechanical-Coupled weakens; With the cutting speed increasing the magnitudes of crushing stress in all directions fluctuate near -950Mpa first, and then increase at the speed of 3000m/min; The residual pulling stress beneath the surface 0.03mm has been found and the magnitude increases with the cutting speed. A good agreement was obtained between predictions and experiments.

Homogeneity of Mechanical Properties of Underwater Friction Stir Welded 2219-T6 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Liu, H. J.; Zhang, H. J.; Yu, L.

2011-11-01

Underwater friction stir welding (FSW) has been demonstrated to be available for the improvement in tensile strength of normal FSW joints. In order to illuminate the intrinsic reason for strength improvement through underwater FSW, a 2219 aluminum alloy was underwater friction stir welded and the homogeneity of mechanical properties of the joint was investigated by dividing the joint into three layers. The results indicate that the tensile strength of the three layers of the joint is all improved by underwater FSW, furthermore, the middle and lower layers have larger extent of strength improvement than the upper layer, leading to an increase in the homogeneity of mechanical properties of the joint. The minimum hardness value of each layer, especially the middle and lower layers, is improved under the integral water cooling effect, which is the intrinsic reason for the strength improvement of underwater joint.

Mechanical properties of friction stir welded Al alloys with different hardening mechanisms

NASA Astrophysics Data System (ADS)

Lim, Sunggon; Kim, Sangshik; Lee, Chang-Gil; Kim, Sung Joon

2005-04-01

The mechanical properties of precipitation hardened Al 6061-T651 and Al 7075-T6 and strain hardened Al 5083-H32, friction stir welded with various welding parameters, were examined in the present study. 4 mm thick Al 6061-T651, Al 7075-T6, and Al 5083-H32 alloy plates were used for friction stir welding (FSW) with rotating speed varied from 1000 to 2500 rpm (rotation per minute) and welding speed ranging from 0.1 to 0.4 mpm (m/min). Each alloy displayed slightly different trends with respect to the effect of different welding parameters on the tensile properties of the FSWed Al alloys. The tensile elongation of FSWed Al 6061-T651 and Al 7075-T6 tended to increase greatly, while the tensile strength decreased marginally, with increasing welding speed and/or decreasing rotating speed. The tensile strength and the tensile elongation of Al 6061-T651 decreased from 135 to 154 MPa and 10.6 to 17.0%, respectively, with increasing welding speed from 0.1 to 0.4 mpm at a rotating speed of 1,600 rpm. Unlike the age-hardened Al 6061-T651 and Al 7075-T6, the strain-hardened Al 5083-H32 showed no notable change in tensile property with varying welding parameters. The change in the strength level with different welding parameters for each alloy was not as significant as the variation in tensile elongation. It was believed that the tensile elongation of FSWed Al alloys with varying welding parameters was mainly determined by the coarse particle clustering. With respect to the change in tensile strength during friction stir welding, it is hypothesized that two competing mechanisms, recovery by friction and heat and strain hardening by plastic flow in the weld zone offset the effects of different welding parameters on the tensile strength level of FSWed Al alloys.

Long-term thermal degradation and alloying constituent effects on five boron/aluminum composites

NASA Technical Reports Server (NTRS)

Olsen, G. C.

1982-01-01

Thermal exposure effects on the properties of five boron/aluminum composite systems were experimentally investigated. The composite systems were 49 volume percent boron fibers (203 micron diameter) in aluminum-alloy matrices 1100 Al, 2024 Al, 3003 Al, 5052 Al, and 6061 Al. Specimens were thermally exposed up to 10,000 hours at 500 K and 590 K, up to 500 hours at 730 K, and up to 10,000 hours at 500 K and 590 K, up to 500 hours at 730 K, and up to 2000 thermal cycles between 200 K and 590 K. Composite longitudinal and transverse tensile strengths, longitudinal compression strength, and in-plane shear strength were determined. None of the systems was severely degraded by exposure at 590 K. The best performing system was B-2024 Al. Effects of matrix alloys on degradation mechanisms were experimentally investigated. Composite specimens and individual fibers were metallurgically analyzed with a scanning electron microscope and an electron microprobe to determine failure characteristics, chemical element distribution, and reaction layer morphology. Alloying constituents were found to be affect the composite degradation mechanisms as follows: alloys containing iron, but without manganese as a stabilizer, caused increased low-temperature degradation; alloys containing magnesium, iron, or manganese caused increased degradation; and alloys containing copper caused increased fiber strength.

Solution processed aluminum paper for flexible electronics.

PubMed

Lee, Hye Moon; Lee, Ha Beom; Jung, Dae Soo; Yun, Jung-Yeul; Ko, Seung Hwan; Park, Seung Bin

2012-09-11

As an alternative to vacuum deposition, preparation of highly conductive papers with aluminum (Al) features is successfully achieved by the solution process consisting of Al precursor ink (AlH(3){O(C(4)H(9))(2)}) and low temperature stamping process performed at 110 °C without any serious hydroxylation and oxidation problems. Al features formed on several kinds of paper substrates (calendar, magazine, and inkjet printing paper substrates) are less than ~60 nm thick, and their electrical conductivities were found to be as good as thermally evaporated Al film or even better (≤2 Ω/□). Strong adhesion of Al features to paper substrates and their excellent flexibility are also experimentally confirmed by TEM observation and mechanical tests, such as tape and bending tests. The solution processed Al features on paper substrates show different electrical and mechanical performance depending on the paper type, and inkjet printing paper is found to be the best substrate with high and stable electrical and mechanical properties. The Al conductive papers produced by the solution process may be applicable in disposal paper electronics.

Transient Liquid-Phase Diffusion Bonding of Aluminum Metal Matrix Composite Using a Mixed Cu-Ni Powder Interlayer

NASA Astrophysics Data System (ADS)

Maity, Joydeep; Pal, Tapan Kumar

2012-07-01

In the present study, the transient liquid-phase diffusion bonding of an aluminum metal matrix composite (6061-15 wt.% SiCp) has been investigated for the first time using a mixed Cu-Ni powder interlayer at 560 °C, 0.2 MPa, for different holding times up to 6 h. The microstructure of the isothermally solidified zone contains equilibrium precipitate CuAl2, metastable precipitate Al9Ni2 in the matrix of α-solid solution along with the reinforcement particles (SiC). On the other hand, the microstructure of the central bond zone consists of equilibrium phases such as NiAl3, Al7Cu4Ni and α-solid solution along with SiC particles (without any segregation) and the presence of microporosities. During shear test, the crack originates from microporosities and propagates along the interphase interfaces resulting in poor bond strength for lower holding times. As the bonding time increases, with continual diffusion, the structural heterogeneity is diminished, and the microporosities are eliminated at the central bond zone. Accordingly, after 6-h holding, the microstructure of the central bond zone mainly consists of NiAl3 without any visible microporosity. This provides a joint efficiency of 84% with failure primarily occurring through decohesion at the SiC particle/matrix interface.

[Atmospheric emission of PCDD/Fs from secondary aluminum metallurgy industry in the southwest area, China].

PubMed

Lu, Yi; Zhang, Xiao-Ling; Guo, Zhi-Shun; Jian, Chuan; Zhu, Ming-Ji; Deng, Li; Sun, Jing; Zhang, Qin

2014-01-01

Five secondary aluminum metallurgy enterprises in the southwest area of China were measured for emissions of PCDD/Fs. The results indicated that the emission levels of PCDD/Fs (as TEQ) were 0.015-0.16 ng x m(-3), and the average was 0.093 ng x m(-3) from secondary aluminum metallurgy enterprises. Emission factors of PCDD/Fs (as TEQ) from the five secondary aluminum metallurgy enterprises varied between 0.041 and 4.68 microg x t(-1) aluminum, and the average was 2.01 microg x t(-1) aluminum; among them, PCDD/Fs emission factors from the crucible smelting furnace was the highest. Congener distribution of PCDD/F in stack gas from the five secondary aluminum metallurgies was very different from each other. Moreover, the R(PCDF/PCDD) was the lowest in the enterprise which was installed only with bag filters; the R(PCDF/PCDD) were 3.8-12.6 (the average, 7.7) in the others which were installed with water scrubbers. The results above indicated that the mechanism of PCDD/Fs formation was related to the types of exhaust gas treatment device. The results of this study can provide technical support for the formulation of PCDD/Fs emission standards and the best available techniques in the secondary aluminum metallurgy industry.

Separation and Recycling of Spent Carbon Cathode Blocks in the Aluminum Industry by the Vacuum Distillation Process

NASA Astrophysics Data System (ADS)

Yaowu, Wang; Jianping, Peng; Yuezhong, Di

2018-04-01

Aluminum is the second most produced metal after iron. China is the top producer of primary aluminum with a production capacity of 41,000 kt and an output in 2016 of 32,000 kt. A large amount of spent carbon cathode block (SCCB) is produced after electrolytic pot failure. SCCB consists of carbon, fluorides, alkali metals, carbides, nitrides, cyanides, and oxides, and is considered to be a hazardous material because it contains significant concentrations of toxic and soluble cyanides and fluorides. There is no economical and efficient process for the treatment of SCCB and is most commonly disposed in landfill. In this study, the vacuum distillation process (VDP) has been used to separate and recycle SCCB. The results show that Na3AlF6, NaF, and sodium metal can be effectively separated from SCCB by VDP, and the distillation ratio is above 80% at a distillation temperature of 1200°C. The carbon content in the distilled SCCB is above 91% and the impurities are mainly CaF2 and Al2O3.

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)

Analysis of thermal stresses and metal movement during welding

NASA Technical Reports Server (NTRS)

Muraki, T.; Pattee, F. M.; Masubuchi, K.

1974-01-01

Finite element computer programs were developed to determine thermal stresses and metal movement during butt welding of flat plates and bead-on-plate welding along the girth of a cylindrical shell. Circular cylindrical shells of 6061 aluminum alloy were used for the tests. Measurements were made of changes in temperature and thermal strains during the welding process.

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.

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

NASA Astrophysics Data System (ADS)

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

2018-02-01

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

Processing, structure, property and performance relationships for the thermal spray of the internal surface of aluminum cylinders

NASA Astrophysics Data System (ADS)

Cook, David James

The increased need for automotive weight reduction has necessitated the use of aluminum for engine blocks. Conventional aluminum alloys cannot survive the constant wear from a piston ring reciprocating on the surface. However, a wear resistant thermal spray coating can be applied on the internal surface of the cylinder bore, which has significant advantages over other available options. Thermal spray is a well-established process for depositing molten, semi-molten, or solid particles onto a substrate to form a protective coating. For this application, the two main challenges were obtaining good wear resistance, and achieving good adhesion. To design a system capable of producing a well-adhered, wear resistant coating for this high volume application it is necessary to identify the overall processing, structure, properties, and performance relationships. The results will demonstrate that very important relationships exist among particle characteristics, substrate conditions, and the properties of the final coating. However, it is the scientific studies to understand some of the process physics in these relationships that allow recognition of the critical processing conditions that need to be controlled to ensure a consistent, reliable thermal spray coating. In this investigation, it will be shown that the critical microstructural aspect of the coating that produced the required tribological properties was the presence of wuestite (FeO). It was found that by using a low carbon steel material with compressed air atomizing gas, it was possible to create an Fe/FeO structure that exhibited excellent tribological properties. This study will also show that traditional thermal spray surface preparation techniques were not ideal for this application, therefore a novel alternative approach was developed. The application of a flux to the aluminum surface prior to thermal spray promotes excellent bond strengths to non-roughened aluminum. Analysis will show that this flux strips

An Experimental Investigation of the Effects of Vacuum Environment on the Fatigue Life, Fatigue-Crack-Growth Behavior, and Fracture Toughness of 7075-T6 Aluminum Alloy. Ph.D. Thesis - North Carolina State Univ.

NASA Technical Reports Server (NTRS)

Hudson, C. M.

1972-01-01

Axial load fatigue life, fatigue-crack propagation, and fracture toughness tests were conducted on 0.090-inch thick specimens made of 7075-T6 aluminum alloy. The fatigue life and fatigue-crack propagation experiments were conducted at a stress ratio of 0.02. Maximum stresses ranged from 33 to 60 ksi in the fatigue life experiments, and from 10 to 40 ksi in the fatigue-crack propagation experiments, and fatigue life experiments were conducted at gas pressures of 760, 0.5, 0.05, and 0.00000005 torr. Fatigue-crack-growth and fracture toughness experiments were conducted at gas pressures of 760 and 5 x 10 to the minus 8th power torr. Residual stress measurements were made on selected fatigue life specimens to determine the effect of such stresses on fatigue life. Analysis of the results from the fatigue life experiments indicated that fatigue life progressively increased as the gas pressure decreased. Analysis of the results from the fatigue-crack-growth experiments indicates that at low values of stress-intensity range, the fatigue crack growth rates were approximately twice as high in air as in vacuum. Fracture toughness data showed there was essentially no difference in the fracture toughness of 7075-T6 in vacuum and in air.

High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History

NASA Astrophysics Data System (ADS)

Zhang, Jingyi; Upadhyay, Piyush; Hovanski, Yuri; Field, David P.

2018-01-01

Friction stir welding (FSW) is a cost-effective and high-quality joining process for aluminum alloys (especially heat-treatable alloys) that is historically operated at lower joining speeds (up to hundreds of millimeters per minute). In this study, we present a microstructural analysis of friction stir welded AA7075-T6 blanks with high welding speeds up to 3 M/min. Textures, microstructures, mechanical properties, and weld quality are analyzed using TEM, EBSD, metallographic imaging, and Vickers hardness. The higher welding speed results in narrower, stronger heat-affected zones (HAZs) and also higher hardness in the nugget zones. The material flow direction in the nugget zone is found to be leaning towards the welding direction as the welding speed increases. Results are coupled with welding parameters and thermal history to aid in the understanding of the complex material flow and texture gradients within the welds in an effort to optimize welding parameters for high-speed processing.

Effect of Traverse and Rotational Speeds on the Tensile Behavior of the Underwater Dissimilar Friction Stir Welded Aluminum Alloys

NASA Astrophysics Data System (ADS)

Bijanrostami, Kh.; Barenji, R. Vatankhah; Hashemipour, M.

2017-02-01

The tensile behavior of the underwater dissimilar friction stir welded AA6061 and AA7075 aluminum alloy joints was investigated for the first time. For this aim, the joints were welded at different conditions and tensile test was conducted for measuring the strength and elongation of them. In addition, the microstructure of the joints was characterized by means of optical and transmission electron microscopes. Scanning electron microscope was used for fractography of the joints. Furthermore, the process parameters and tensile properties of the joints were correlated and optimized. The results revealed that the maximum tensile strength of 237.3 MPa and elongation of 41.2% could be obtained at a rotational speed 1853 rpm and a traverse speed of 50 mm/min. In comparison with the optimum condition, higher heat inputs caused grain growth and reduction in dislocation density and hence led to lower strength. The higher elongations for the joints welded at higher heat inputs were due to lower dislocation density inside the grains, which was consistent with a more ductile fracture of them.

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.

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.

Detailed examination of LDEF's frame and the A0178 thermal blankets by the meteoroid and debris special investigations group

NASA Astrophysics Data System (ADS)

See, Thomas H.; Warren, Jack L.; Mack, Kimberly S.; Zolensky, Michael E.

1992-06-01

A responsibility of the group is to define the hypervelocity particle environment encountered by LDEF during its stay in low Earth orbit. LDEF's 6061-T6 aluminum frame and the 'Teflon silver-inconel paint' thermal blankets represent large surface areas that were widely distributed around the spacecraft. The results are reported of high resolution scans of approx. 0.36 and approx. 0.31 sq m for the intercostals and thermal blankets, respectively. The findings are in qualitative agreement with existing model predictions that suggest high differential bombardment histories for surfaces pointing into specific directions relative to the velocity vector of a non-spinning platform in LEO. The production rate for craters greater than or = 50 microns in diameter in aluminum and penetration holes greater than or = 100 microns in diameter in thin foil materials differ by more than a factor of 10 between forward and rearward facing surfaces. These are substantial differences that must be considered during the design of future long duration space platforms in LEO.

Detailed examination of LDEF's frame and the A0178 thermal blankets by the meteoroid and debris special investigations group

NASA Technical Reports Server (NTRS)

See, Thomas H.; Warren, Jack L.; Mack, Kimberly S.; Zolensky, Michael E.

1992-01-01

A responsibility of the group is to define the hypervelocity particle environment encountered by LDEF during its stay in low Earth orbit. LDEF's 6061-T6 aluminum frame and the 'Teflon silver-inconel paint' thermal blankets represent large surface areas that were widely distributed around the spacecraft. The results are reported of high resolution scans of approx. 0.36 and approx. 0.31 sq m for the intercostals and thermal blankets, respectively. The findings are in qualitative agreement with existing model predictions that suggest high differential bombardment histories for surfaces pointing into specific directions relative to the velocity vector of a non-spinning platform in LEO. The production rate for craters greater than or = 50 microns in diameter in aluminum and penetration holes greater than or = 100 microns in diameter in thin foil materials differ by more than a factor of 10 between forward and rearward facing surfaces. These are substantial differences that must be considered during the design of future long duration space platforms in LEO.