Corrosion behavior of aluminum-alumina composites in aerated 3.5 percent chloride solution

NASA Astrophysics Data System (ADS)

Acevedo Hurtado, Paul Omar

Aluminum based metal matrix composites are finding many applications in engineering. Of these Al-Al2O3 composites appear to have promise in a number of defense applications because of their mechanical properties. However, their corrosion behavior remains suspect, especially in marine environments. While efforts are being made to improve the corrosion resistance of Al-Al2O3 composites, the mechanism of corrosion is not well known. In this study, the corrosion behavior of powder metallurgy processed Al-Cu alloy reinforced with 10, 15, 20 and 25 vol. % Al2O3 particles (XT 1129, XT 2009, XT 2048, XT 2031) was evaluated in aerated 3.5% NaCl solution using microstructural and electrochemical measurements. AA1100-O and AA2024T4 monolithic alloys were also studied for comparison purposes. The composites and unreinforced alloys were subjected to potentiodynamic polarization and Electrochemical Impedance Spectroscopy (EIS) testing. Addition of 25 vol. % Al2O 3 to the base alloys was found to increase its corrosion resistance considerably. Microstructural studies revealed the presence of intermetallic Al2Cu particles in these composites that appeared to play an important role in the observations. Pitting potential for these composites was near corrosion potential values, and repassivation potential was below the corresponding corrosion potential, indicating that these materials begin to corrode spontaneously as soon as they come in contact with the 3.5 % NaCl solution. EIS measurements indicate the occurrence of adsorption/diffusion phenomena at the interface of the composites which ultimately initiate localized or pitting corrosion. Polarization resistance values were extracted from the EIS data for all the materials tested. Electrically equivalent circuits are proposed to describe and substantiate the corrosive processes occurring in these Al-Al2O 3 composite materials.

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.

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.

Stress Corrosion Cracking Study of Aluminum Alloys Using Electrochemical Noise Analysis

NASA Astrophysics Data System (ADS)

Rathod, R. C.; Sapate, S. G.; Raman, R.; Rathod, W. S.

2013-12-01

Stress corrosion cracking studies of aluminum alloys AA2219, AA8090, and AA5456 in heat-treated and non heat-treated condition were carried out using electrochemical noise technique with various applied stresses. Electrochemical noise time series data (corrosion potential vs. time) was obtained for the stressed tensile specimens in 3.5% NaCl aqueous solution at room temperature (27 °C). The values of drop in corrosion potential, total corrosion potential, mean corrosion potential, and hydrogen overpotential were evaluated from corrosion potential versus time series data. The electrochemical noise time series data was further analyzed with rescaled range ( R/ S) analysis proposed by Hurst to obtain the Hurst exponent. According to the results, higher values of the Hurst exponents with increased applied stresses showed more susceptibility to stress corrosion cracking as confirmed in case of alloy AA 2219 and AA8090.

A Positron Annihilation Study of Corrosion of Aluminum and Aluminum Alloy by NaOH

NASA Astrophysics Data System (ADS)

Wu, Y. C.; Zhai, T.; Coleman, P. G.

2012-08-01

Corrosion of fully-annealed pure aluminum and a continuous-cast AA2037 aluminum alloy (solutionized and water quenched) in a 1M NaOH solution for various periods of time were analyzed with positron beam-based Doppler broadening spectroscopy. By varying the energy of the incident positron beam, corrosion-induced defects at different depths from the surface were detected. It was found that the Doppler-broadened annihilation line-width parameter was significantly increased near the surface of pure aluminum after corrosion, probably due to the interaction between positrons and nanometer-sized voids formed near the aluminum surface during corrosion. Examination by atomic force microscopy indicated that many pits were formed on the aluminum surface after corrosion. In contrast, a significant decrease in the line-width parameter was observed in AA2037 alloy after corrosion and interpreted as being caused by copper enrichment at the metal-oxide interface during corrosion; such enrichment at large cavity sites was confirmed by energy dispersion spectrometry.

Effect of Interfacial Reaction on the Mechanical Performance of Steel to Aluminum Dissimilar Ultrasonic Spot Welds

NASA Astrophysics Data System (ADS)

Xu, Lei; Wang, Li; Chen, Ying-Chun; Robson, Joe D.; Prangnell, Philip B.

2016-01-01

The early stages of formation of intermetallic compounds (IMC) have been investigated in dissimilar aluminum to steel welds, manufactured by high power (2.5 kW) ultrasonic spot welding (USW). To better understand the influence of alloy composition, welds were produced between a low-carbon steel (DC04) and two different aluminum alloys (6111 and 7055). The joint strengths were measured in lap shear tests and the formation and growth behavior of IMCs at the weld interface were characterized by electron microscopy, for welding times from 0.2 to 2.4 seconds. With the material combinations studied, the η (Fe2Al5) intermetallic phase was found to form first, very rapidly in the initial stage of welding, with a discontinuous island morphology. Continuous layers of η and then θ (FeAl3) phase were subsequently seen to develop on extending the welding time to greater than 0.7 second. The IMC layer formed in the DC04-AA7055 combination grew thicker than for the DC04-AA6111 welds, despite both weld sets having near identical thermal histories. Zinc was also found to be dissolved in the IMC phases when welding with the AA7055 alloy. After post-weld aging of the aluminum alloy, fracture in the lap shear tests always occurred along the joint interface; however, the DC04-AA6111 welds had higher fracture energy than the DC04-AA7055 combination.

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.

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.

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.

Materials Research in Support of Superconducting Machinery V

DTIC Science & Technology

1976-04-01

GTAW , EB, GMAW), brazing, and soldering from 4-300 K. Properties include tensile, notched tensile, fracture toughness, and fatigue crack growth...include: aluminum alloys 1100, 2014, 2219; a nicke1- chromium -iron alloy; iron-47.5 nickel; and the composite materials boron/aluminum, boron/epoxy, S...nickel" by H. M. Ledbetter and D. T. Read. (3) N. jkel- chromium -iron-molybdenum alloy. There is an accompanying reprint of our previously described

Several braze filler metals for joining an oxide-dispersion-strengthened nickel-chromium-aluminum alloy

NASA Technical Reports Server (NTRS)

Gyorgak, C. A.

1975-01-01

An evaluation was made of five braze filler metals for joining an aluminum-containing oxide dispersion-strengthened (ODS) alloy, TD-NiCrAl. All five braze filler metals evaluated are considered suitable for joining TD-NiCrAl in terms of wettability and flow. Also, the braze alloys appear to be tolerant of slight variations in brazing procedures since joints prepared by three sources using three of the braze filler metals exhibited similar brazing characteristics and essentially equivalent 1100 C stress-rupture properties in a brazed butt-joint configuration. Recommendations are provided for brazing the aluminum-containing ODS alloys.

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.

Frictional conditions between alloy AA6060 aluminium and tool steel

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

Wideroee, Fredrik; Welo, Torgeir

The frictional conditions in the new process of screw extrusion of aluminium have been investigated. The contact behaviour between the aluminum alloy and the tool steel in the extruder is vital for understanding the extrusion process. Using a compressive-rotational method for frictional measurements the conditions for unlubricated sticking friction between aluminum alloy AA6060 and tool steel at different combinations of temperatures and pressures have been investigated. In this method the samples in the form of disks are put under hydrostatic pressure while simultaneously being rotated at one end. Pins made from contrast material have been inserted into the samples tomore » measure the deformation introduced. This approach along with 3D simulations form a method for determining the frictional conditions. The paper describes the test method and the results. It was found that the necessary pressure for sticking to occur between the aluminum AA6060 and the different parts of the extruder is heavily influenced by the temperature.« less

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.

Hot corrosion resistance of nickel-chromium-aluminum alloys

NASA Technical Reports Server (NTRS)

Santoro, G. J.; Barret, C. A.

1977-01-01

The hot corrosion resistance of nickel-chromium-aluminum alloys was examined by cyclically oxidizing sodium sulfate-coated specimens in still air at 900, 1000, and 1100 C. The compositions tested were within the ternary region: Ni, Ni-50 at.% Cr, and Ni-50 at.% Al. At each temperature the corrosion data were statistically fitted to a third order regression equation as a function of chromium and aluminum contents. From these equations corrosion isopleths were prepared. Compositional regions with the best hot corrosion resistance were identified.

Hot corrosion resistance of nickel-chromium-aluminum alloys

NASA Technical Reports Server (NTRS)

Santoro, G. J.; Barrett, C. A.

1977-01-01

The hot corrosion resistance of nickel-chromium-aluminum alloy was examined by cyclically oxidizing sodium sulfate coated specimens in still air at 900, 1000 and 1100 C. The compositions tested were within the ternary region: Ni; Ni-50 at.% Cr; and Ni-50 at.% Al. At each temperature the corrosion data were statistically fitted to a third order regression equation as a function of chromium and aluminum contents. Corrosion isopleths were prepared from these equations. Compositional regions with the best hot corrosion resistance were identified.

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.

Chromium-free conversion coatings based on inorganic salts (Zr/Ti/Mn/Mo) for aluminum alloys used in aircraft applications

NASA Astrophysics Data System (ADS)

Santa Coloma, P.; Izagirre, U.; Belaustegi, Y.; Jorcin, J. B.; Cano, F. J.; Lapeña, N.

2015-08-01

Novel chromium-free conversion coatings based on Zr/Ti/Mn/Mo compounds were developed at a pilot scale to improve the corrosion resistance of the AA2024-T3 and AA7075-T6 aluminum alloys for aircraft applications. The influence of the presence of Zr and Ti in the Zr/Ti/Mn/Mo conversion bath's formulation on the corrosion resistance of the coated alloys was investigated. The corrosion resistance provided by the conversion coatings was evaluated by salt spray exposure and potentiodynamic sweeps. Optical and scanning electron microscopy coupled with energy dispersive spectroscopy (SEM/EDS) and atomic force microscopy (AFM) operating in the Kelvin Probe mode (SKPFM) were used to provide microstructural information of the coated samples that achieved the best results in the corrosion tests. The salt spray test evidenced the higher corrosion resistance of the coated samples compared to the bare surfaces for both alloys. The potentiodynamic tests showed that the corrosion current density decreased for coated AA7075-T6 and AA2024-T3 alloys, which indicated an obvious improvement of the corrosion resistance with all the processes for both alloys. Although the corrosion resistance of the coated samples appeared to be higher for the alloy AA7075-T6 than for the alloy AA2024-T3, both alloys achieved the best corrosion protection with the coatings deposited from conversion bath formulations containing no titanium salts. The microscopy analysis on the coated AA7075-T6 samples revealed that a local deposition of Zr compounds and, possibly, an oxidation process occurred in the vicinity of the alloy's intermetallic particles. The amount of the Zr deposits at these locations increased with coating's formulations without Ti, which provided the best corrosion resistance. The Cr-free conversion coatings developed in this study for the AA7075-T6 and AA2024-T3 alloys do not meet yet the strict requirements of the aircraft industry. However, they significantly improved the corrosion performance with respect to the bare alloys and could be a good starting point for further studies and optimization.

Recycling of Aluminum Alloy with Dimox and Rheocasting Functionalize High Performance Structural Foam Composite

NASA Astrophysics Data System (ADS)

Rabeeh, Bakr Mohamed

Great efforts aiming towards the synthesis and the development of structural composite materials. Direct metal oxidation, DIMOX introduced for hybrid composite processing. However, oxidation temperatures around 1100°C lead to the formation of porous ceramic materials. To utilize this porosity intentionally for foam production, a new approach based on synergetic effect of alloying elements, DIMOX and semisolid (rheocsting) processing is developed. A semisolid reaction, rheocasting is introduced to control porosity shape and size. Aluminum alloy 6xxx (automobile scrap pistons) is recycled for this objective and DIMOX at 1100°C for 30 min, then rheocasting, at 750°C for 30 minutes. The effect of α-Fe powder, Mg powder, and Boric acid powder established for the objective of a hybrid structural metal matrix composite in bulk foam matrix. The kinetic of formation of hybrid metal matrix foam composite is introduced. Microstructural and mechanical characterization established for high performance Aluminum foam hybrid composite materials.

Iron-aluminum alloys having high room-temperature and method for making same

DOEpatents

Sikka, Vinod K.; McKamey, Claudette G.

1993-01-01

Iron-aluminum alloys having selectable room-temperature ductilities of greater than 20%, high resistance to oxidation and sulfidation, resistant pitting and corrosion in aqueous solutions, and possessing relatively high yield and ultimate tensile strengths are described. These alloys comprise 8 to 9.5% aluminum, up to 7% chromium, up to 4% molybdenum, up to 0.05% carbon, up to 0.5% of a carbide former such as zirconium, up to 0.1 yttrium, and the balance iron. These alloys in wrought form are annealed at a selected temperature in the range of 700.degree. C. to about 1100.degree. C. for providing the alloys with selected room-temperature ductilities in the range of 20 to about 29%.

Acceptable aluminum additions for minimal environmental effect in iron-aluminum alloys

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

Sikka, V.K.; Viswanathan, S.; Vyas, S.

A systematic study of iron-aluminum alloys has shown that Fe-16 at. % Al alloys are not very sensitive to environmental embrittlement. The Fe-22 and -28 at. % Al alloys are sensitive to environmental embrittlement, and the effect can be reduced by the addition of chromium and through the control of grain size by additions of zirconium and carbon. The Fe-16 at. % Al binary, and alloys based on it, yielded over 20% room-temperature (RT) elongation even after high-temperature annealing treatments at 1100[degree]C. The best values for the Fe-22 and -28 at. % Al-base alloys after similar annealing treatments were 5more » and 10%, respectively. A multicomponent alloy, FAP, based on Fe- 16 at. % Al was designed, which gave an RT ductility of over 25%.« less

Acceptable aluminum additions for minimal environmental effect in iron-aluminum alloys

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

Sikka, V.K.; Viswanathan, S.; Vyas, S.

A systematic study of iron-aluminum alloys has shown that Fe-16 at. % Al alloys are not very sensitive to environmental embrittlement. The Fe-22 and -28 at. % Al alloys are sensitive to environmental embrittlement, and the effect can be reduced by the addition of chromium and through the control of grain size by additions of zirconium and carbon. The Fe-16 at. % Al binary, and alloys based on it, yielded over 20% room-temperature (RT) elongation even after high-temperature annealing treatments at 1100{degree}C. The best values for the Fe-22 and -28 at. % Al-base alloys after similar annealing treatments were 5more » and 10%, respectively. A multicomponent alloy, FAP, based on Fe- 16 at. % Al was designed, which gave an RT ductility of over 25%.« less

Gas tungsten arc welding of aluminum alloys 1XXX and 3003 to 3004, 5052 and 5X54. 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-2201 is qualified under Section IX of the ASME Boiler and Pressure Vessel for gas tungsten arc welding of aluminum alloys 1060, 1100, and 3003 (P-21) to 3004, 5052, 5154, and 5454 (P-22), in thickness range 0.062 to 0.5 in.; filler metal is ER5356 (F-22); shielding gas is argon.

Intergranular corrosion in AA5XXX aluminum alloys with discontinuous precipitation at the grain boundaries

NASA Astrophysics Data System (ADS)

Bumiller, Elissa

The US Navy currently uses AA5xxx aluminum alloys for structures exposed to a marine environment. These alloys demonstrate excellent corrosion resistance over other aluminum alloys (e.g., AA2xxx or AA7xxx) in this environment, filling a niche in the marine structures market when requiring a light-weight alternative to steel. However, these alloys are susceptible to localized corrosion; more specifically, intergranular corrosion (IGC) is of concern. IGC of AA5xxx alloys due to the precipitation of beta phase on the grain boundaries is a well-established phenomenon referred to as sensitization. At high degrees of sensitization, the IGC path is a continuous anodic path of beta phase particles. At lower degrees of sensitization, the beta phase coverage at the grain boundaries is not continuous. The traditional ranges of susceptibility to IGC as defined by ASTM B928 are in question due to recent studies. These studies showed that even at mid range degrees of sensitization where the beta phase is no longer continuous, IGC may still occur. Previous thoughts on IGC of these alloy systems were founded on the idea that once the grain boundary precipitate became discontinuous the susceptibility to IGC was greatly reduced. Additionally, IGC susceptibility has been defined metallurgically by compositional gradients at the grain boundaries. However, AA5xxx alloys show no compositional gradients at the grain boundaries, yet are still susceptible to IGC. The goal of this work is to establish criteria necessary for IGC to occur given no continuous beta phase path and no compositional gradient at the grain boundaries. IGC performance of the bulk alloy system AA5083 has been studied along with the primary phases present in the IGC system: alpha and beta phases using electrochemistry and modeling as the primary tools. Numerical modeling supports that at steady-state the fissure tip is likely saturated with Mg in excess of the 4% dissolved in the matrix. By combining these results, quantitative insights into the IGC susceptibility of AA5xxx alloys is gained. As the aspect ratio increases, the concentration of metal ions in the fissure solution increases, thus driving up the ability to form corrosion product, whether precipitate or gelatinous product. As the theta beta increases, the IGC rates increase for a constant potential. By a combination of aspect ratio, φp, thetabeta, and likely fissure chemistry, the potential drop within the fissure is fully described and the IGC penetration rate can be predicted.

Eutectic structures in friction spot welding joint of aluminum alloy to copper

NASA Astrophysics Data System (ADS)

Shen, Junjun; Suhuddin, Uceu F. H.; Cardillo, Maria E. B.; dos Santos, Jorge F.

2014-05-01

A dissimilar joint of AA5083 Al alloy and copper was produced by friction spot welding. The Al-MgCuAl2 eutectic in both coupled and divorced manners were found in the weld. At a relatively high temperature, mass transport of Cu due to plastic deformation, material flow, and atomic diffusion, combined with the alloy system of AA5083 are responsible for the ternary eutectic melting.

Effect of Fe- and Si-Enriched Secondary Precipitates and Surface Roughness on Pore Formation on Aluminum Plate Surfaces During Anodizing

NASA Astrophysics Data System (ADS)

Zhu, Yuanzhi; Wang, Shizhi; Yang, Qingda; Zhou, Feng

2014-09-01

Two twin roll casts (TRCs) and one hot rolled (HR) AA 1235 aluminum alloy plates with different microstructures are prepared. The plates were electrolyzed in a 1.2 wt% HCl solution with a voltage of 21 V and a current of 1.9 mA. The shape, size, and number of pores formed on the surfaces of these plates were analyzed and correlated with the microstructures of the plates. It is found that pores are easier to form on the alloy plates containing subgrains with a lower dislocation density inside the subgrains, rather than along the grain boundaries. Furthermore, Fe- and Si-enriched particles in the AA1235 aluminum alloys lead to the formation of pores on the surface during electrolyzing; the average precipitate sizes of 4, 3.5, and 2 μm in Alloy 1#, Alloy 2# and Alloy 3# result in the average pore sizes of 3.78, 2.76, and 1.9 μm on the surfaces of the three alloys, respectively; The G.P zone in the alloy also facilitates the surface pore formation. High-surface roughness enhances the possibility of entrapping more lubricants into the plate surface, which eventually blocks the formation of the pores on the surface of the aluminum plates in the following electrolyzing process.

NASA-UVA Light Aerospace Alloy and Structures Technology program (LA2ST)

NASA Technical Reports Server (NTRS)

Starke, Edgar A., Jr.; Gangloff, Richard P.; Herakovich, Carl T.; Scully, John R.; Shiflet, Gary J.; Stoner, Glenn E.; Wert, John A.

1995-01-01

The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light-weight aerospace alloys, composites, and thermal gradient structures in collaboration with NASA-Langley researchers. The general aim is to produce relevant data and basic understanding of material mechanical response, environment/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement and modeling advances; and a pool of educated students for aerospace technologies. Specific technical objectives are presented for each of the following research projects: time-temperature dependent fracture in advanced wrought ingot metallurgy, and spray deposited aluminum alloys; cryogenic temperature effects on the deformation and fracture of Al-Li-Cu-In alloys; effects of aging and temperature on the ductile fracture of AA2095 and AA2195; mechanisms of localized corrosion in alloys 2090 and 2095; hydrogen interactions in aluminum-lithium alloys 2090 and selected model alloys; mechanisms of deformation and fracture in high strength titanium alloys (effects of temperature and hydrogen and effects of temperature and microstructure); evaluations of wide-panel aluminum alloy extrusions; Al-Si-Ge alloy development; effects of texture and precipitates on mechanical property anisotropy of Al-Cu-Mg-X alloys; damage evolution in polymeric composites; and environmental effects in fatigue life prediction - modeling crack propagation in light aerospace alloys.

Eutectic structures in friction spot welding joint of aluminum alloy to copper

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

Shen, Junjun, E-mail: junjun.shen@hzg.de; Suhuddin, Uceu F. H.; Cardillo, Maria E. B.

2014-05-12

A dissimilar joint of AA5083 Al alloy and copper was produced by friction spot welding. The Al-MgCuAl{sub 2} eutectic in both coupled and divorced manners were found in the weld. At a relatively high temperature, mass transport of Cu due to plastic deformation, material flow, and atomic diffusion, combined with the alloy system of AA5083 are responsible for the ternary eutectic melting.

Double-pulse femtosecond laser peening of aluminum alloy AA5038: Effect of inter-pulse delay on transient optical plume emission and final surface micro-hardness

NASA Astrophysics Data System (ADS)

Ageev, E. I.; Bychenkov, V. Yu.; Ionin, A. A.; Kudryashov, S. I.; Petrov, A. A.; Samokhvalov, A. A.; Veiko, V. P.

2016-11-01

Double-pulse ablative femtosecond laser peening of the AA5038 aluminum alloy surface in the phase explosion regime results in its enhanced microhardness, which monotonously decreases till the initial value versus inter-pulse delay, increasing on a sub-nanosecond timescale. Optical emission spectroscopy of the double-pulse ablative plume reveals the same trend in the yield of the corresponding atomic and ion emission versus inter-pulse delay, enlightening the interaction of the second femtosecond laser pump pulse with the surface and the resulting plume.

Static Recovery Modeling of Dislocation Density in a Cold Rolled Clad Aluminum Alloy

NASA Astrophysics Data System (ADS)

Penlington, Alex

Clad alloys feature one or more different alloys bonded to the outside of a core alloy, with non-equilibrium, interalloy interfaces. There is limited understanding of the recovery and recrystallization behaviour of cold rolled clad aluminum alloys. In order to optimize the properties of such alloys, new heat treatment processes may be required that differ from what is used for the monolithic alloys. This study examines the recovery behaviour of a cold rolled Novelis Fusion(TM) alloy containing an AA6XXX core with an AA3003 cladding on one side. The bond between alloys appears microscopically discrete and continuous, but has a 30 microm wide chemical gradient. The as-deformed structure at the interalloy region consists of pancaked sub-grains with dislocations at the misorientation boundaries and a lower density organized within the more open interiors. X-ray line broadening was used to extract the dislocation density from the interalloy region and an equivalently deformed AA6XXX following static annealing using a modified Williamson-Hall analysis. This analysis assumed that Gaussian broadening contributions in a pseudo-Voigt function corresponded only to strain from dislocations. The kinetics of the dislocation density evolution to recrystallization were studied isothermally at 2 minute intervals, and isochronally at 175 and 205°C. The data fit the Nes model, in which the interalloy region recovered faster than AA6XXX at 175°C, but was slower at 205°C. This was most likely caused by change in texture and chemistry within this region such as over-aging of AA6XXX . Simulation of a continuous annealing and self homogenization process both with and without pre-recovery indicates a detectable, though small change in the texture and grain size in the interalloy region.

Effect of Scandium on the Interaction of Concurrent Precipitation and Recrystallization in Commercial AA3003 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Tu, Yiyou; Qian, Huan; Zhou, Xuefeng; Jiang, Jianqing

2014-04-01

In the current study, the effect of Sc addition on the interaction of concurrent precipitation and recrystallization in commercial AA3003 aluminum alloy was investigated using optical microscopy, scanning electron microscopy, and transmission electron microscopy. In case of AA3003 alloy, which was cold rolled to a true strain of 2.20 and heated at a heating rate of 150 K/s, the onset of precipitation and ending of recrystallization are signified by the critical temperature, T C ~740 K (467 °C). There is a change in the shape of the recrystallized grains from pancake-like to equiaxed shape, as the annealing temperature increases greater than T C. In case of AA3003 alloy microalloyed with 0.4 wt pct of Sc, the high no. density precipitation of coherent Al3Sc precipitates always occurs before recrystallization because of the small nucleation barrier and high rate of decomposition. This leads to extremely coarse pancake-like recrystallization grains with high fraction of low-angle grain boundaries in the entire annealing temperature range, even at a high brazing temperature of 883 K (610 °C).

Change of Hot Cracking Susceptibility in Welding of High Strength Aluminum Alloy AA 7075

NASA Astrophysics Data System (ADS)

Holzer, M.; Hofmann, K.; Mann, V.; Hugger, F.; Roth, S.; Schmidt, M.

High strength aluminum alloys are known as hard to weld alloys due to their high hot crack susceptibility. However, they have high potential for applications in light weight constructions of automotive industry and therefore it is needed to increase weldability. One major issue is the high hot cracking susceptibility. Vaporization during laser beam welding leads to a change of concentration of the volatile elements magnesium and zinc. Hence, solidification range of the weld and therefore hot cracking susceptibility changes. Additionally, different welding velocities lead to changed solidification conditions with certain influence on hot cracking. This paper discusses the influence of energy per unit length during laser beam welding of AA 7075 on the change of element concentration in the weld seam and the resulting influence on hot cracking susceptibility. Therefore EDS-measurements of weld seams generated with different velocities are performed to determine the change of element concentration. These quantitative data is used to numerically calculate the solidification range in order to evaluate its influence on the hot cracking susceptibility. Besides that, relative hot crack length and mechanical properties are measured. The results increase knowledge about welding of high strength aluminum alloy AA 7075 and hence support further developing of the welding process.

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.

Measurements of degree of sensitization (DoS) in aluminum alloys using EMAT ultrasound.

PubMed

Li, Fang; Xiang, Dan; Qin, Yexian; Pond, Robert B; Slusarski, Kyle

2011-07-01

Sensitization in 5XXX aluminum alloys is an insidious problem characterized by the gradual formation and growth of beta phase (Mg(2)Al(3)) at grain boundaries, which increases the susceptibility of alloys to intergranular corrosion (IGC) and intergranular stress-corrosion cracking (IGSCC). The degree of sensitization (DoS) is currently quantified by the ASTM G67 Nitric Acid Mass Loss Test, which is destructive and time consuming. A fast, reliable, and non-destructive method for rapid detection and the assessment of the condition of DoS in AA5XXX aluminum alloys in the field is highly desirable. In this paper, we describe a non-destructive method for measurements of DoS in aluminum alloys with an electromagnetic acoustic transducer (EMAT). AA5083 aluminum alloy samples were sensitized at 100°C with processing times varying from 7days to 30days. The DoS of sensitized samples was first quantified with the ASTM 67 test in the laboratory. Both ultrasonic velocity and attenuation in sensitized specimens were then measured using EMAT and the results were correlated with the DoS data. We found that the longitudinal wave velocity was almost a constant, independent of the sensitization, which suggests that the longitudinal wave can be used to determine the sample thickness. The shear wave velocity and especially the shear wave attenuation are sensitive to DoS. Relationships between DoS and the shear velocity, as well as the shear attenuation have been established. Finally, we performed the data mining to evaluate and improve the accuracy in the measurements of DoS in aluminum alloys with EMAT. Copyright © 2010 Elsevier B.V. All rights reserved.

The Examination of the Aluminum Alloy 7017 as a Replacement for the Aluminum Alloy 7039 in Lightweight Armor Systems

DTIC Science & Technology

2016-07-01

ORGANIZATION REPORT NUMBER ARL-TR-7727 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10 . SPONSOR/MONITOR’S ACRONYM(S) 11. SPONSOR/MONITOR’S...of 0.50-cal. FSP vs. AA7017 plate at 0° .......................................................................................................... 10 ... 10 List of Tables Table 1 Chemical composition, weight percent

Resistance of nickel-chromium-aluminum alloys to cyclic oxidation at 1100 C and 1200 C

NASA Technical Reports Server (NTRS)

Barrett, C. A.; Lowell, C. E.

1976-01-01

Nickel-rich alloys in the Ni-Cr-Al system were evaluated for cyclic oxidation resistance in still air at 1,100 and 1,200 C. A first approximation oxidation attack parameter Ka was derived from specific weight change data involving both a scaling growth constant and a spalling constant. An estimating equation was derived with Ka as a function of the Cr and Al content by multiple linear regression and translated into countour ternary diagrams showing regions of minimum attack. An additional factor inferred from the regression analysis was that alloys melted in zirconia crucibles had significantly greater oxidation resistance than comparable alloys melted otherwise.

Heat Treatment of Gas-Atomized Powders for Cold Spray Deposition

NASA Astrophysics Data System (ADS)

Story, William A.; Brewer, Luke N.

2018-02-01

This communication demonstrates the efficacy of heat treatment on the improved deposition characteristics of aluminum alloy powders. A novel furnace was constructed for solutionizing of feedstock powders in an inert atmosphere while avoiding sintering. This furnace design achieved sufficiently high cooling rates to limit re-precipitation during powder cooling. Microscopy showed homogenization of the powder particle microstructures after heat treatment. Cold spray deposition efficiency with heat-treated powders substantially increased for the alloys AA2024, AA6061, and AA7075.

Morphology and Mechanism of Benign Inhibitors

DTIC Science & Technology

2012-07-01

AAO resulting in much lower SLD. ....... 84 xiv List of Acronyms AA: Aluminum alloy; AAO : Anodic aluminum oxide ; AMCC: Advanced Materials...shown, we achieved excellent vanadate, trivalent chromium process (TCP) and anodic aluminum oxide ( AAO ) films. We also tried Ce but Ce did not form a...we also initiated the study of anodizing of aluminum . According to the literature anodic aluminum oxide

Effect of current and speed on porosity in autogenous Tungsten Inert Gas (TIG) welding of aluminum alloys A1100 butt joint

NASA Astrophysics Data System (ADS)

Milyardi, Indra; Sunar Baskoro, Ario

2018-04-01

Autogenous Tungsten Inert Gas (TIG) welding has been conducted on aluminum alloy A1100. The purpose of this research is to determine the proper current and speed of autogenous TIG welding with butt joint pattern. Variations on welding current are 150 A, 155 A, and 160 A with the variations on welding speed are 1 mm/seconds, 1.1 mm/seconds, 1.2 mm/seconds. The welded results were tested using non-destructive test (NDT) method using X-Ray radiography. After the test, it is found that the appropriate current for the best result without porosity can be achieved using the welding parameter of welding current of 160 A and the welding speed of 1.1 mm seconds.

General Corrosion Resistance Assessments of AA7085, AA7129, and Other High-Performance Aluminum Alloys for Department of Defense (DOD) Systems UsingLaboratory Based Accelerated Corrosion Methods and Electrochemistry

DTIC Science & Technology

2013-09-01

laboratory should play a role in the final design decision process. Integration factors such as conversion coatings , primers, topcoats, and their...Cyclic Accelerated Corrosion Analysis of Nonchromate Conversion Coatings on Aluminum Alloys 2024, 2219, 5083, and 7075 Using DoD Paint Systems; ARL...Titanium 0.08 0.10 max 0.10 max 0.15 max 0.08 max 0.05 max Zirconium 0.05 – 0.15 0.05 – 0.15 - 0.10 – 0.25 0.05 – 0.15 - Vanadium - - - - - 0.05 max

Modeling the Controlled Recrystallization of Particle-Containing Aluminum Alloys

NASA Astrophysics Data System (ADS)

Adam, Khaled; Root, Jameson M.; Long, Zhengdong; Field, David P.

2017-01-01

The recrystallized fraction for AA7050 during the solution heat treatment is highly dependent upon the history of deformation during thermomechanical processing. In this work, a state variable model was developed to predict the recrystallization volume fraction as a function of processing parameters. Particle stimulated nucleation (PSN) was observed as a dominant mechanism of recrystallization in AA7050. The mesoscale Monte Carlo Potts model was used to simulate the evolved microstructure during static recrystallization with the given recrystallization fraction determined already by the state variable model for AA7050 alloy. The spatial inhomogeneity of nucleation is obtained from the measurement of the actual second-phase particle distribution in the matrix identified using backscattered electron (BSE) imaging. The state variable model showed good fit with the experimental results, and the simulated microstructures were quantitatively comparable to the experimental results for the PSN recrystallized microstructure of 7050 aluminum alloy. It was also found that the volume fraction of recrystallization did not proceed as dictated by the Avrami equation in this alloy because of the presence of the growth inhibitors.

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

NASA Astrophysics Data System (ADS)

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

2009-04-01

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

Statistical Analysis of High-Cycle Fatigue Behavior of Friction Stir Welded AA5083-H321

DTIC Science & Technology

2011-01-01

durable structures are: (a) FSW is 111being used in a serial production of aluminum alloy -based 112ferryboat deck structures in Finland; (b) Al-Mg- Si -based...and strain-hardened/stabilized Al-Mg-Mn alloy ) are characterized by a relatively large statistical scatter. This scatter is closely related to the...associated with friction stir-welded (FSW) joints of AA5083-H321 (a solid-solution-strengthened and strain-hardened/stabilized Al-Mg-Mn alloy ) are

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

Comparative study on Ti/Zr/V and chromate conversion treated aluminum alloys: Anti-corrosion performance and epoxy coating adhesion properties

NASA Astrophysics Data System (ADS)

Zhu, Wen; Li, Wenfang; Mu, Songlin; Fu, Nianqing; Liao, Zhongmiao

2017-05-01

In this study, a Ti/Zr/V conversion coating (TZVCC) was deposited on the surface of aluminum alloy 6063 (AA6063) as an alternative of the chromate conversion coating (CCC). Both the TZVCC treated AA6063 (TZVCC/AA6063) and CCC treated AA6063 (CCC/AA6063) were characterized by scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), atomic force microscope (AFM) and contact angle measuring device. The anti-corrosion performance of the TZVCC/AA6063 and CCC/AA6063 was evaluated by electrochemical measurements and neutral salt spray tests. It showed that both the surface roughness and surface free energy of the AA6063 were significantly increased after TZVCC treatment. The anti-corrosion performance of TZVCC/AA6063 was superior to that of CCC/AA6063. In addition, the effects of the TZVCC and CCC on the adhesion properties and anti-corrosion performance of epoxy coating applied on samples were examined by pull-off tests and electrochemical impedance spectroscopy (EIS). The dry, wet and recovery adhesive strengths of the epoxy coating on TZVCC treated samples (epoxy coated TZVCC/AA6063) were very close to those of epoxy coating on CCC treated ones (epoxy coated CCC/AA6063). The epoxy coated TZVCC/AA6063 showed better corrosion resistance than the epoxy coated CCC/AA6063 and epoxy coated AA6063.

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

Craters in aluminum 1100 targets using glass projectiles at 1-7 km/s

NASA Technical Reports Server (NTRS)

Bernhard, R. P.; See, T. H.; Hoerz, F.; Cintala, M. J.

1994-01-01

We report on impact experiments using soda-lime glass spheres of 3.2 mm diameter and aluminum targets (1100 series). The purpose is to assist in the interpretation of LDEF instruments and in the development of future cosmic-dust collectors in low-Earth orbit. Because such instruments demand understanding of both the cratering and penetration process, we typically employ targets with thicknesses that range from massive, infinite half-space targets, to ultrathin films. This report addresses a subset of cratering experiments that were conducted to fine-tune our understanding of crater morphology as a function of impact velocity. Also, little empirical insight exists about the physical distribution and shock-metamorphism of the impactor residues as a function of encounter speed, despite their recognized significance in the analysis of space-exposed surfaces. Soda-lime glass spheres were chosen as a reasonable analog to extraterrestrial silicates, and aluminum 1100 was chosen for targets, which among the common Al-alloys, best represents the physical properties of high-purity aluminum. These materials complement existing impact studies that typically employed metallic impactors and less ductile Al-alloys. We have completed dimensional analyses of the resulting craters and are in the process of investigating the detailed distribution of the unmelted and melted impactor residues via SEM methods, as well as potential compositional modifications of the projectile melts via electron microprobe.

The Role of Second Phase Hard Particles on Hole Stretchability of two AA6xxx Alloys

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

Hu, Xiaohua; Sun, Xin; Golovashchenko, Sergey F.

The hole stretchability of two Aluminum Alloys (AA6111 and AA6022) are studied by using a two stages integrated finite element framework where the edge geometry and edge damages from the hole piercing processes were considered in the subsequent hole expansion processes. Experimentally it has been found that AA6022 has higher hole expansion ratios than those of AA6111. This observation has been nicely captured by finite element simulations. The main cause of differences have been identified to the volume fractions of the random distributed second phase hard particles which play a critical role in determining the fracture strains of the materials.

Aluminum alloy AA-6061 and RSA-6061 heat treatment for large mirror applications

NASA Astrophysics Data System (ADS)

Newswander, T.; Crowther, B.; Gubbels, G.; Senden, R.

2013-09-01

Aluminum mirrors and telescopes can be built to perform well if the material is processed correctly and can be relatively low cost and short schedule. However, the difficulty of making high quality aluminum telescopes increases as the size increases, starting with uniform heat treatment through the thickness of large mirror substrates. A risk reduction effort was started to build and test a ½ meter diameter super polished aluminum mirror. Material selection, the heat treatment process and stabilization are the first critical steps to building a successful mirror. In this study, large aluminum blanks of both conventional AA-6061 per AMS-A-22771 and RSA AA-6061 were built, heat treated and stress relieved. Both blanks were destructively tested with a cut through the thickness. Hardness measurements and tensile tests were completed. We present our results in this paper and make suggestions for modification of procedures and future work.

Heat-Affected Zone Liquation Cracking Resistance of Friction Stir Processed Aluminum-Copper Alloy AA 2219

NASA Astrophysics Data System (ADS)

Karthik, G. M.; Janaki Ram, G. D.; Kottada, Ravi Sankar

2017-04-01

In the current work, the effect of friction stir processing on heat-affected zone (HAZ) liquation cracking resistance of aluminum-copper alloy AA 2219 was evaluated. In Gleeble hot-ductility tests and longitudinal Varestraint tests, the FSPed material, despite its very fine dynamically recrystallized equiaxed grain structure, showed considerably higher susceptibility to HAZ liquation cracking when compared to the base material. Detailed microstructural studies showed that the increased cracking susceptibility of the FSPed material is due to (i) increase in the amount of liquating θ phase (equilibrium Al2Cu) and (ii) increase in the population of grain boundary θ particles. An important learning from the current work is that, in certain materials like alloy 2219, the use of FSP as a pretreatment to fusion welding can be counterproductive.

Damage percolation during stretch flange forming of aluminum alloy sheet

NASA Astrophysics Data System (ADS)

Chen, Zengtao; Worswick, Michael J.; Keith Pilkey, A.; Lloyd, David J.

2005-12-01

A multi-scale finite element (FE)-damage percolation model was employed to simulate stretch flange forming of aluminum alloys AA5182 and AA5754. Material softening and strain gradients were captured using a Gurson-based FE model. FE results were then fed into the so-called damage percolation code, from which the damage development was modelled within measured microstructures. The formability of the stretch flange samples was predicted based upon the onset of catastrophic failure triggered by profuse void coalescence within the measured second-phase particle field. Damage development is quantified in terms of crack and void areal fractions, and compared to metallographic results obtained from interrupted stretch flange specimens. Parametric study is conducted on the effect of void nucleation strain in the prediction of formability of stretch flanges to "calibrate" proper nucleation strains for both alloys.

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Effect of Chromate and Chromate-Free Organic Coatings on Corrosion Fatigue of an Aluminum Alloy

DTIC Science & Technology

2012-02-20

Investigations of alloy AA7075 corrosion in acid rain solution, inhibited by chromate-free blends of zinc phosphate with bentonite, zeolite and calcium...with solution components. Single use of zinc phosphate and these ion exchanged pigments for corrosion inhibition do not provide desired effect...primer performance against corrosion fatigue cracking under a commercial polyurethane topcoat. As a control , they used samples of chromated AA2024

Anodization Mechanism on SiC Nanoparticle Reinforced Al Matrix Composites Produced by Power Metallurgy.

PubMed

Ferreira, Sonia C; Conde, Ana; Arenas, María A; Rocha, Luis A; Velhinho, Alexandre

2014-12-19

Specimens of aluminum-based composites reinforced by silicon carbide nanoparticles (Al/SiC np ) produced by powder metallurgy (PM) were anodized under voltage control in tartaric-sulfuric acid (TSA). In this work, the influence of the amount of SiC np on the film growth during anodizing was investigated. The current density versus time response and the morphology of the porous alumina film formed at the composite surface are compared to those concerning a commercial aluminum alloy (AA1050) anodized under the same conditions. The processing method of the aluminum alloys influences the efficiency of the anodizing process, leading to a lower thicknesses for the unreinforced Al-PM alloy regarding the AA1050. The current density versus time response is strongly dependent on the amount of SiC np . The current peaks and the steady-state current density recorded at each voltage step increases with the SiC np volume fraction due to the oxidation of the SiC np . The formation mechanism of the anodic film on Al/SiC np composites is different from that occurring in AA1050, partly due the heterogeneous distribution of the reinforcement particles in the metallic matrix, but also to the entrapment of SiC np in the anodic film.

Anodization Mechanism on SiC Nanoparticle Reinforced Al Matrix Composites Produced by Power Metallurgy

PubMed Central

Ferreira, Sonia C.; Conde, Ana; Arenas, María A.; Rocha, Luis A.; Velhinho, Alexandre

2014-01-01

Specimens of aluminum-based composites reinforced by silicon carbide nanoparticles (Al/SiCnp) produced by powder metallurgy (PM) were anodized under voltage control in tartaric-sulfuric acid (TSA). In this work, the influence of the amount of SiCnp on the film growth during anodizing was investigated. The current density versus time response and the morphology of the porous alumina film formed at the composite surface are compared to those concerning a commercial aluminum alloy (AA1050) anodized under the same conditions. The processing method of the aluminum alloys influences the efficiency of the anodizing process, leading to a lower thicknesses for the unreinforced Al-PM alloy regarding the AA1050. The current density versus time response is strongly dependent on the amount of SiCnp. The current peaks and the steady-state current density recorded at each voltage step increases with the SiCnp volume fraction due to the oxidation of the SiCnp. The formation mechanism of the anodic film on Al/SiCnp composites is different from that occurring in AA1050, partly due the heterogeneous distribution of the reinforcement particles in the metallic matrix, but also to the entrapment of SiCnp in the anodic film. PMID:28788295

Dynamic oxidation behavior at 1000 and 1100 C of four nickel-base cast alloys, NASA-TRW VIA, B-1900, 713C, and 738X

NASA Technical Reports Server (NTRS)

Sanders, W. A.

1974-01-01

The superalloys NASA-TRW VIA, B-1900, 713C, and 738X were tested cyclically and isothermally for resistance to oxidation in high velocity gas streams for 100 hours at specimen temperatures of 1000 C and 1100 C. Alloys VIA and B-1900, which were the most oxidation resistant, displayed slight and very similar weight changes and metal losses. Alloy 713C also sustained only slight metal losses, but it exhibited some tendency to spall. Alloy 738X was found to be the most susceptible to cyclic oxidation; this resulted in heavy spalling, which in turn caused high weight losses and high metal losses. Oxidation test results are related to the amounts of chromium aluminum, and the refractory metals in the alloys investigated.

Microstructure-sensitive plasticity and fatigue modeling of extruded 6061 aluminum alloys

NASA Astrophysics Data System (ADS)

McCullough, Robert Ross

In this study, the development of fatigue failure and stress anisotropy in light weight ductile metal alloys, specifically Al-Mg-Si aluminum alloys, was investigated. The experiments were carried out on an extruded 6061 aluminum alloy. Reverse loading experiments were performed up to a prestrain of 5% in both tension-followed-by-compression and compression-followed-by-tension. The development of isotropic and kinematic hardening and subsequent anisotropy was indicated by the observation of the Bauschinger effect phenomenon. Experimental results show that 6061 aluminum alloy exhibited a slight increase in the kinematic hardening versus applied prestrain. However, the ratio of kinematic-to-isotropic hardening remained near unity. An internal state variable (ISV) plasticity and damage model was used to capture the evolution of the anisotropy for the as-received T6 and partially annealed conditions. Following the stress anisotropy experiments, the same extruded 6061 aluminum alloy was tested under fully reversing, strain-controlled low cycle fatigue at up to 2.5% strain amplitudes and two heat treatment conditions. Observations were made of the development of striation fields up to the point of nucleation at cracked and clustered precipitants and free surfaces through localized precipitant slip band development. A finite element enabled micro-mechanics study of fatigue damage development of local strain field in the presence of hard phases was conducted. Both the FEA and experimental data sets were utilized in the implementation of a multi-stage fatigue model in order to predict the microstructure response, including fatigue nucleation and propagation contributions on the total fatigue life in AA6061. Good correlation between experimental and predicted results in the number of cycles to final failure was observed. The AA6061 material maintained relatively consistent low cycle fatigue performance despite two different heat treatments.

Structure-composition-property relationships in 5xxx series aluminum alloys

NASA Astrophysics Data System (ADS)

Unocic, Kinga A.

Al-Mg alloys are well suited for marine applications due to their low density, ease of fabrication, structural durability, and most notably resistance to corrosion. The purpose of this study is to investigate the effects of alloying additions, mechanical processing and heat treatments on the development of grain boundary phases that have an effect on intergranular corrosion (IGC). Cu, Zn, and Si modified compositions of AA5083 were produced that were subjected to a low and high degree of cold work and various heat treatments. ASTM G67 (NAMLT) intergranular corrosion testing and detailed microstructural characterization for various alloys was carried out. An optimal composition and processing condition that yielded the best intergranular corrosion resistant material was identified based on the ASTM G67 test screening. Further, the outstanding modified AA5083 was selected for further microstructural analysis. This particular alloy with has a magnesium level high enough to make it susceptible to intergranular corrosion is very resistant to IGC. It was found that development of the appropriate sub-structure with some Cu, Si and Zn resulted in a material very resistant to IGC. Formation of many sinks, provided by sub-boundaries, within microstructure is very beneficial since it produces a relatively uniform distribution of Mg in the grain interiors, and this can suppress sensitization of this alloy very successfully. This is a very promising rote for the production of high-strength, and corrosion resistant aluminum alloys. Additionally in this study, TEM sample preparation become very crucial step in grain boundary phase investigation. Focus Ion Beam (FIB) milling was used as a primary TEM sample preparation technique because it enables to extract the samples from desired and very specific locations without dissolving grain boundary phases as it was in conventional electropolishing method. However, other issues specifically relevant to FIB milling of aluminum alloys related to Ga accumulation were discovered, that produce significant microstructural artifacts. It is well known that liquid gallium can cause Liquid Metal Embitterment (LME) aluminum alloys, and gallium readily penetrates aluminum grain boundaries. Low energy Ar ion nanomilling is potentially quite effective at removing gallium from the external and internal surfaces of aluminum thin foils, but can still leave persistent artifacts. Al-Mg alloys can be also susceptible to localized corrosion such as pitting corrosion in the presence of chloride ions. In this study the phases responsible for this type of corrosion were identified. ASSET (ASTM G66) test was used to determine the influence of heat-treatment on pitting corrosion on various modified AA5083 alloys. Additionally, potentiodynamic polarization as well as potentiostatic measurements in conjunction with SEM analysis were carried out to obtain pitting potential (Epit) and to determine the location of metastable pit initiation, respectively.

An Improvement of the Anisotropy and Formability Predictions of Aluminum Alloy Sheets

NASA Astrophysics Data System (ADS)

Banabic, D.; Comsa, D. S.; Jurco, P.; Wagner, S.; Vos, M.

2004-06-01

The paper presents an yield criterion for orthotropic sheet metals and its implementation in a theoretical model in order to calculate the Forming Limit Curves. The proposed yield criterion has been validated for two aluminum alloys: AA3103-0 and AA5182-0, respectively. The biaxial tensile test of cross specimens has been used for the determination of the experimental yield locus. The new yield criterion has been implemented in the Marciniak-Kuczynski model for the calculus of limit strains. The calculated Forming Limit Curves have been compared with the experimental ones, determined by frictionless test: bulge test, plane strain test and uniaxial tensile test. The predicted Forming Limit Curves using the new yield criterion are in good agreement with the experimental ones.

In-Situ Neutron Diffraction Studies of Micromechanical Behavior in a Friction Stir Welded AA7475-T761

NASA Astrophysics Data System (ADS)

Liu, X. P.; Lin Peng, R.; Hofmann, M.; Johansson, S.; Wang, Y. D.

2011-01-01

An in-situ neutron diffraction technique was used to investigate the lattice strain distributions and micromechanical behavior in a friction stir welded (FSW) sheet of AA7475-T761. The neutron diffraction experiments were performed on the spectrometer for material research, STRESS-SPEC, at FRM II (Garching, Germany). The lattice strain profiles around the weld center were measured as a function of the applied strain during the tensile loading and unloading. The anisotropic elastic and plastic properties of the FSW aluminum alloy were simulated by elasto-plastic self-consistent (EPSC) model to predict the anisotropic deformation behaviors involving the grain-to-grain interactions. Material parameters used for describing the constitutive laws of each test position were determined from the measured lattice strain distributions for different diffraction hkl planes as well as the macroscopic stress-strain curve of the FSW aluminum alloy. A good agreement between experimental results and numerical simulations was obtained. The present investigations provided a reliable prediction of the anisotropic micromechanical behavior of the FSW aluminum alloy during tensile deformation.

The Ballistic and Corrosion Evaluation of Magnesium Elektron E675 vs. Baseline Magnesium Alloy AZ31B and Aluminum Alloy 5083 for Armor Applications

DTIC Science & Technology

2011-06-01

critical property in reducing the plastic failure of the material. The ductility is marginally better than Mg AZ31B. 2 Table 1. Chemical...composition (%) of metal alloys. Element (%)/Alloy CPMg 9980B AZ31B-H24 AA5083-H131 Aluminum — 2.5–3.5 REM Manganese 0.10 max 0.2–1.0 0.40‒1.0 Zinc — 0.6...This trend was attributed to the lack of ductility in E675 compared to 5083, which reduced energy dissipation. Visual analysis of the Mg E675

Rapid Solidification of a New Generation Aluminum-Lithium Alloy via Electrospark Deposition

NASA Astrophysics Data System (ADS)

Heard, David W.; Boselli, Julien; Gauvin, Raynald; Brochu, Mathieu

Electrospark deposition (ESD) is a rapid solidification processing technique capable of depositing a metal onto a conductive substrate. The short pulse duration and high pulse frequency, combined with the small amount of material transferred during each pulse, results in high cooling rates being realized, on the order of 105-106 C/sec. This study investigates the ability to induce solute trapping behavior, for a new generation aluminum-lithium alloy, AA2199, using ESD.

Four-point-bend fatigue of AA 2026 aluminum alloys

NASA Astrophysics Data System (ADS)

Li, J. X.; Zhai, T.; Garratt, M. D.; Bray, G. H.

2005-09-01

High-cycle fatigue tests were carried out on a newly developed high-strength AA 2026 Al alloy, which was in the form of extrusion bars with square and rectangular cross sections, using a self-aligning four-point-bend rig at room temperature, 15 Hz, and R = 0.1, in lab air. The fatigue strength of the square and rectangular bars was measured to be 85 and 90 pct of their yield strength, respectively, more than twice that of the predecessor to the 2026 alloy (the AA 2024 Al alloy). Fatigue cracks were found to be always initiated at large Θ' (Al7Cu2(Fe,Mn)) particles and to propagate predominantly in a crystallographic mode in the AA 2026 alloy. The fatigue fractographies of the square and rectangular extrusion bars were found to be markedly different, due to their different grain structures (fibril and layered, respectively). Fracture steps on the crack face were found in both of these extrusion bars. Since the 2026 alloy was purer in terms of Fe and Si content, it contained much less coarse particles than in a 2024 alloy. This partially accounted for the superior fatigue strength of the 2026 alloy.

Dynamic Response of AA2519 Aluminum Alloy under High Strain Rates

NASA Astrophysics Data System (ADS)

Olasumboye, Adewale Taiwo

Like others in the AA2000 series, AA2519 is a heat-treatable Al-Cu alloy. Its excellent ballistic properties and stress corrosion cracking resistance, combined with other properties, qualify it as a prime candidate for armored vehicle and aircraft applications. However, available data on its high strain-rate response remains limited. In this study, AA2519 aluminum alloy was investigated in three different temper conditions: T4, T6, and T8, to determine the effects of heat treatment on the microstructure and dynamic deformation behavior of the material at high strain rates ranging within 1000 ≤ epsilon ≤ 4000 s-1. Split Hopkinson pressure bar integrated with digital image correlation system was used for mechanical response characterization. Optical microscopy and scanning electron microscopy were used to assess the microstructure of the material after following standard metallographic specimen preparation techniques. Results showed heterogeneous deformation in the three temper conditions. It was observed that dynamic behavior in each condition was dependent on strength properties due to the aging type controlling the strengthening precipitates produced and initial microstructure. At 1500 s -1, AA2519-T6 exhibited peak dynamic yield strength and flow stress of 509 and 667 MPa respectively, which are comparable with what were observed in T8 condition at higher rate of 3500 s-1 but AA2519-T4 showed the least strength and flow stress properties. Early stress collapse, dynamic strain aging, and higher susceptibility to shear band formation and fracture were observed in the T6 condition within the selected range of high strain rates. The alloy's general mode of damage evolution was by dispersoid particle nucleation, shearing and cracking.

Study of issues in difficult-to-weld thick materials by hybrid laser arc welding

NASA Astrophysics Data System (ADS)

Mazar Atabaki, Mehdi

There is a high interest for the high strength-to-weight ratio with good ductility for the welds of advanced alloys. The concern about the welding of thick materials (Advanced high strength steels (AHSS) and 5xxx and 6xxx series of aluminum alloys) has stimulated the development of manufacturing processes to overcome the associated issues. The need to weld the dissimilar materials (AHSS and aluminum alloys) is also required for some specific applications in different industries. Hence, the requirement in the development of a state-of-the-art welding procedure can be helpful to fulfill the constraints. Among the welding methods hybrid laser/arc welding (HLAW) has shown to be an effective method to join thick and difficult-to-weld materials. This process benefits from both advantages of the gas metal arc welding (GMAW) and laser welding processes. The interaction of the arc and laser can help to have enough penetration of weld in thick plates. However, as the welding of dissimilar aluminum alloys and steels is very difficult because of the formation of brittle intermetallics the present work proposed a procedure to effectively join the alloys. The reports showed that the explosively welded aluminum alloys to steels have the highest toughness, and that could be used as an "insert" (TRICLAD) for welding the thick plates of AHSS to aluminum alloys. Therefore, the HLAW of the TRICLAD-Flange side (Aluminum alloy (AA 5456)) to the Web side (Aluminum alloys (AA 6061 and AA 5456)) and the TRICLAD-Flange side (ASTM A516) to the Web side (AHSS) was studied in the present work. However, there are many issues related to HLAW of the dissimilar steels as well as dissimilar aluminum alloys that have to be resolved in order to obtain sound welds. To address the challenges, the most recent welding methods for joining aluminum alloys to steels were studied and the microstructural development, mechanical properties, and on-line monitoring of the welding processes were discussed as well. The heat and mass transfer and the issues in joining of dissimilar alloys by the hybrid laser/arc welding process (HLAW) were explicitly explained in details. A finite element model was developed to simulate the heat transfer in HLAW of the aluminum alloys. Two double-ellipsoidal heat source models were considered to describe the heat input of the gas metal arc welding and laser welding processes. An experimental procedure was also developed for joining thick advanced high strength steel plates by using the HLAW, by taking into consideration different butt joint configurations. The geometry of the weld groove was optimized according to the requirements of ballistic test, where the length of the softened heat affected zone should be less than 15.9 mm measured from the weld centerline. Since the main issue in HLAW of the AHSS was the formation of the pores, the possible mechanisms of the pores formation and their mitigation methods during the welding process were investigated. Mitigation methods were proposed to reduce the pores inside in the weld area and the influence of each method on the process stability was investigated by an on-line monitoring system of the HLAW process. The groove angle was optimized for the welding process based on the allowed amount of heat input along the TRICLADRTM interface generated by an explosive welding. The weld was fractured in the heat affected zone of the aluminum side in the tensile test. The microharness was shown that the temperature variation caused minor softening in the heat affected zone satisfying the requirement that the width of the softened heat affected zone in the steel side falls within 15.9 mm far away from the weld centerline. The microstructure analysis showed the presence of tempered martensite at the vicinity of the weld area, which it was a cause of softening in the heat affected zone.

High-temperature oxidation of aluminum electroplated Fe-Mn alloys

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

Bernabai, U.; Felli, F.; Capuano, G.A.

1990-04-01

Austenitic Mn-Al alloys (20-32 W/O Mn, 7-10 Al, 2-3 Si, 1C) were found to have satisfactory oxidation resistance up to 950{degree}C under isothermal conditions in air. Surface enrichment of aluminum is a necessary condition for obtaining an almost pure alumina scale for uses at higher temperatures. Four different Mn-steels were Al-coated by the Capuano electroplating process. In all the steels there was an increase in the hot-oxidation resistance. The best results were obtained with steels containing both Al and Si, and this for temperatures up to 1,100{degree}C.

Friction Stir Weld Failure Mechanisms in Aluminum-Armor Structures Under Ballistic Impact Loading Conditions

DTIC Science & Technology

2013-01-01

REPORT Friction Stir Weld Failure Mechanisms in Aluminum -Armor Structures Under Ballistic Impact Loading Conditions 14. ABSTRACT 16. SECURITY...Stir Weld Failure Mechanisms in Aluminum -Armor Structures Under Ballistic Impact Loading Conditions M. Grujicic, B. Pandurangan, A. Arakere, C-F. Yen...K.O. Pedersen, Fracture Mechanisms of Aluminum Alloy AA7075-T651 Under Various Loading Conditions , Int. J. Impact Eng., 2010, 37, p 537–551 24. T

Constitutive Behavior and Deep Drawability of Three Aluminum Alloys Under Different Temperatures and Deformation Speeds

NASA Astrophysics Data System (ADS)

Panicker, Sudhy S.; Prasad, K. Sajun; Basak, Shamik; Panda, Sushanta Kumar

2017-08-01

In the present work, uniaxial tensile tests were carried out to evaluate the stress-strain response of AA2014, AA5052 and AA6082 aluminum alloys at four temperatures: 303, 423, 523 and 623 K, and three strain rates: 0.0022, 0.022 and 0.22 s-1. It was found that the Cowper-Symonds model was not a robust constitutive model, and it failed to predict the flow behavior, particularly the thermal softening at higher temperatures. Subsequently, a comparative study was made on the capability of Johnson-Cook (JC), modified Zerilli-Armstrong (m-ZA), modified Arrhenius (m-ARR) and artificial neural network (ANN) for modeling the constitutive behavior of all the three aluminum alloys under the mentioned strain rates and temperatures. Also, the improvement in formability of the materials was evaluated at an elevated temperature of 623 K in terms of cup height and maximum safe strains by conducting cylindrical cup deep drawing experiments under two different punch speeds of 4 and 400 mm/min. The cup heights increased during warm deep drawing due to thermal softening and increase in failure strains. Also, a small reduction in cup height was observed when the punch speed increased from 4 to 400 mm/min at 623 K. Hence, it was suggested to use high-speed deformation at elevated temperature to reduce both punch load and cycle time during the deep drawing process.

Modeling the microstructural changes during hot tandem rolling of AA5 XXX aluminum alloys: Part I. Microstructural evolution

NASA Astrophysics Data System (ADS)

Wells, M. A.; Samarasekera, I. V.; Brimacombe, J. K.; Hawbolt, E. B.; Lloyd, D. J.

1998-06-01

A comprehensive mathematical model of the hot tandem rolling process for aluminum alloys has been developed. Reflecting the complex thermomechanical and microstructural changes effected in the alloys during rolling, the model incorporated heat flow, plastic deformation, kinetics of static recrystallization, final recrystallized grain size, and texture evolution. The results of this microstructural engineering study, combining computer modeling, laboratory tests, and industrial measurements, are presented in three parts. In this Part I, laboratory measurements of static recrystallization kinetics and final recrystallized grain size are described for AA5182 and AA5052 aluminum alloys and expressed quantitatively by semiempirical equations. In Part II, laboratory measurements of the texture evolution during static recrystallization are described for each of the alloys and expressed mathematically using a modified form of the Avrami equation. Finally, Part III of this article describes the development of an overall mathematical model for an industrial aluminum hot tandem rolling process which incorporates the microstructure and texture equations developed and the model validation using industrial data. The laboratory measurements for the microstructural evolution were carried out using industrially rolled material and a state-of-the-art plane strain compression tester at Alcan International. Each sample was given a single deformation and heat treated in a salt bath at 400 °C for various lengths of time to effect different levels of recrystallization in the samples. The range of hot-working conditions used for the laboratory study was chosen to represent conditions typically seen in industrial aluminum hot tandem rolling processes, i.e., deformation temperatures of 350 °C to 500 °C, strain rates of 0.5 to 100 seconds and total strains of 0.5 to 2.0. The semiempirical equations developed indicated that both the recrystallization kinetics and the final recrystallized grain size were dependent on the deformation history of the material i.e., total strain and Zener-Hollomon parameter ( Z), where Z = dot \\varepsilon exp left( {{Q_{def} }/{RT_{def }}} right) and time at the recrystallization temperature.

Properties of Free-Machining Aluminum Alloys at Elevated Temperatures

NASA Astrophysics Data System (ADS)

Faltus, Jiří; Karlík, Miroslav; Haušild, Petr

In areas close to the cutting tool the workpieces being dry machined could be heated up to 350°C and they may be impact loaded. Therefore it is of interest to study mechanical properties of corresponding materials at elevated temperatures. Free-machining alloys of Al-Cu and Al-Mg-Si systems containing Pb, Bi and Sn additions (AA2011, AA2111B, AA6262, and AA6023) were subjected to Charpy U notch impact test at the temperatures ranging from 20 to 350°C. The tested alloys show a sharp drop in notch impact strength KU at different temperatures. This drop of KU is caused by liquid metal embrittlement due to the melting of low-melting point dispersed phases which is documented by differential scanning calorimetry. Fracture surfaces of the specimens were observed using a scanning electron microscope. At room temperature, the fractures of all studied alloys exhibited similar ductile dimple fracture micromorphology, at elevated temperatures, numerous secondary intergranular cracks were observed.

The Solidification Behavior of AA2618 Aluminum Alloy and the Influence of Cooling Rate

PubMed Central

Liu, Yulin; Liu, Ming; Luo, Lei; Wang, Jijie; Liu, Chunzhong

2014-01-01

In AA2618 aluminum alloy, the iron- and nickel-rich intermetallics formed during solidification are of great effect on the mechanical properties of the alloy at both room temperature and elevated temperatures. However, the solidification behavior of the alloy and the formation mechanism of the intermetallics during solidification of the alloy are not clear. This research fills the gap and contributes to understanding the intermetallic of the alloy. The results showed that cooling rate was of great influence on the formation of the intermetallics. Under the condition of slow cooling, the as-cast microstructures of the alloy were complex with many coarse eutectic compounds including Al9FeNi, Al7(CuNi)5, Si, Al2Cu and Al2CuMg. The phase Al9FeNi was the dominant intermetallic compound, which precipitated at the earlier stage of the solidification by eutectic reaction L → α-Al + Al9FeNi. Increasing the cooling rate would suppress the formation of the coarse eutectic intermetallics. Under the condition of near-rapid cooling, the as-cast microstructures of the alloy consisted of metastable intermetallics Al9FeNi and Al2Cu; the equilibrium eutectic compounds were suppressed. This research concluded that intermetallics could be refined to a great extent by near-rapid cooling. PMID:28788281

The Mechanical Behavior of Friction-Stir Spot Welded Aluminum Alloys

NASA Astrophysics Data System (ADS)

Güler, Hande

2014-10-01

Aluminum and alloys are widely used in the automotive industry due to the light weight, good formability, and malleability. Spot welding is the most commonly used joining method of these materials, but the high current requirements and the inconsistent quality of the final welds make this process unsuitable. An alternative welding technique, the friction-stir spot welding process, can also be successfully used in joining of aluminum and alloys. In this study, 1-mm-thick AA5754 Al-alloy plates in the H-111 temper conditions were joined by friction-stir spot welding using two different weld parameters such as tool rotational speed and dwell time. Mechanical properties of the joints were obtained with extensive hardness measurements and tensile shear tests. The effect of these parameters on the failure modes of welded joints was also determined.

Dissimilar Impact Welding of 6111-T4, 5052-H32 Aluminum Alloys to 22MnB5, DP980 Steels and the Structure-Property Relationship of a Strongly Bonded Interface

NASA Astrophysics Data System (ADS)

Liu, Bert; Vivek, Anupam; Presley, Michael; Daehn, Glenn S.

2018-03-01

The ability to weld high-strength aluminum to high-strength steel is highly desired for vehicle lightweighting but difficult to attain by conventional means. In this work, vaporizing foil actuator welding was used to successfully weld four Al/Fe combinations consisting of high-strength alloys: AA5052-H32, AA6111-T4, DP980, and 22MnB5. Flyer velocities up to 727 m/s were reached using 10 kJ input energy. In lap-shear testing, samples primarily failed in base aluminum near the aluminum's native strength, showing that the welds were stronger than a base metal and that the base metal was not significantly weakened by the welding process. A particularly strong weld area was studied by transmission electron microscopy to shed light on the microstructural features of strong impact welds. It was found to be characterized by a continuously bonded, fully crystalline interface, extremely fine (nanoscale) grains, mesoscopic as well as microscopic wavy features, and lack of large continuous intermetallic compounds.

A Directionally Solidified Iron-chromium-aluminum-tantalum Carbide Eutectic Alloy

NASA Technical Reports Server (NTRS)

Harf, F. H.

1977-01-01

A eutectic alloy, Fe-13.6CR-3.7Al+9TaC, was directionally solidified in a high gradient furnace, producing a microstructure of alined TaC fibers in an oxidation resistant alpha-iron matrix. Tensile and stress rupture properties, thermal cycling resistance, and microstructures were evaluated. The alloy displays at 1000 C an ultimate tensile strength of 58 MPa and a 100-hour rupture life at a stress of 21 MPa. Thermal cycling to 1100 C induces faceting in the TaC fibers.

Corrosion behavior of ultrafine-grained AA2024 aluminum alloy produced by cryorolling

NASA Astrophysics Data System (ADS)

Laxman Mani Kanta, P.; Srivastava, V. C.; Venkateswarlu, K.; Paswan, Sharma; Mahato, B.; Das, Goutam; Sivaprasad, K.; Krishna, K. Gopala

2017-11-01

The objectives of this study were to produce ultrafine-grained (UFG) AA2024 aluminum alloy by cryorolling followed by aging and to evaluate its corrosion behavior. Solutionized samples were cryorolled to 85% reduction in thickness. Subsequent aging resulted in a UFG structure with finer precipitates of Al2CuMg in the cryorolled alloy. The (1) solutionized and (2) solutionized and cryorolled samples were uniformly aged at 160°C/24 h and were designated as CGPA and CRPA, respectively; these samples were subsequently subjected to corrosion studies. Potentiodynamic polarization studies in 3.5wt% NaCl solution indicated an increase in corrosion potential and a decrease in corrosion current density for CRPA compared to CGPA. In the case of CRPA, electrochemical impedance spectroscopic studies indicated the presence of two complex passive oxide layers with a higher charge transfer resistance and lower mass loss during intergranular corrosion tests. The improved corrosion resistance of CRPA was mainly attributed to its UFG structure, uniform distribution of fine precipitates, and absence of coarse grain-boundary precipitation and associated precipitate-free zones as compared with the CGPA alloy.

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

NASA Technical Reports Server (NTRS)

Gangloff, Richard P.; Scully, John R.; Stoner, Glenn E.; Thornton, Earl A.; Wawner, Franklin E., Jr.; Wert, John A.

1993-01-01

The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program continues a high level of activity. Progress achieved between 1 Jan. and 30 Jun. 1993 is reported. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, light weight aerospace alloys, composites, and thermal gradient structures in collaboration with NASA-Langley researchers. The following projects are addressed: environmental fatigue of Al-Li-Cu alloys; mechanisms of localized corrosion and environmental fracture in Al-Cu-Li-Mg-Ag alloy X2095 and compositional variations; the effect of zinc additions on the precipitation and stress corrosion cracking behavior of alloy 8090; hydrogen interactions with Al-Li-Cu alloy 2090 and model alloys; metastable pitting of aluminum alloys; cryogenic fracture toughness of Al-Cu-Li + In alloys; the fracture toughness of Weldalite (TM); elevated temperature cracking of advanced I/M aluminum alloys; response of Ti-1100/SCS-6 composites to thermal exposure; superplastic forming of Weldalite (TM); research to incorporate environmental effects into fracture mechanics fatigue life prediction codes such as NASA FLAGRO; and thermoviscoplastic behavior.

A computational study of low-head direct chill slab casting of aluminum alloy AA2024

NASA Astrophysics Data System (ADS)

Hasan, Mainul; Begum, Latifa

2016-04-01

The steady state casting of an industrial-sized AA2024 slab has been modeled for a vertical low-head direct chill caster. The previously verified 3-D CFD code is used to investigate the solidification phenomena of the said long-range alloy by varying the pouring temperature, casting speed and the metal-mold contact heat transfer coefficient from 654 to 702 °C, 60-180 mm/min, and 1.0-4.0 kW/(m2 K), respectively. The important predicted results are presented and thoroughly discussed.

Effect of Post Weld Heat Treatment on Corrosion Behavior of AA2014 Aluminum – Copper Alloy Electron Beam Welds

NASA Astrophysics Data System (ADS)

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

2018-03-01

The present work pertains to the study of corrosion behavior of aluminum alloy electron beam welds. The aluminium alloy used in the present study is copper containing AA2014 alloy. Electron Beam Welding (EBW) was used to weld the alloys in annealed (O) condition. Microstructural changes across the welds were recorded and the effect of post weld heat treatment (PWHT) in T4 (Solutionized and naturally aged) condition on pitting corrosion resistance was studied. A software based PAR basic electrochemical system was used for potentio-dynamic polarization tests. From the study it is observed that weld in O condition is prone to more liquation than that of PWHT condition. This may be attributed to re-melting and solidification of excess eutectic present in the O condition of the base metal. It was also observed that slightly higher hardness values are recorded in O condition than that of PWHT condition. The pitting corrosion resistance of the PMZ/HAZ in PWHT condition is better than that of O condition. This is attributed to copper segregation at the grain boundaries of PMZ in O condition.

Prognostic investigation of galvanic corrosion precursors in aircraft structures and their detection strategy

NASA Astrophysics Data System (ADS)

James, Robin; Kim, Tae Hee; Narayanan, Ram M.

2017-04-01

Aluminum alloys have been the dominant materials for aerospace construction in the past fifty years due to their light weight, forming and alloying, and relative low cost in comparison to titanium and composites. However, in recent years, carbon fiber reinforced polymers (CFRPs) and honeycomb materials have been used in aircrafts in the quest to attain lower weight, high temperature resistance, and better fuel efficiency. When these two materials are coupled together, the structural strength of the aircraft is unparalleled, but this comes at a price, namely galvanic corrosion. Previous experimental results have shown that when CFRP composite materials are joined with high strength aluminum alloys (AA7075-T6 or AA2024-T3), galvanic corrosion occurs at the material interfaces, and the aluminum is in greater danger of corroding, particularly since carbon and aluminum are on the opposite ends of the galvanic series. In this paper, we explore the occurrence of the recognizable precursors of galvanic corrosion when CFRP plate is coupled to an aluminum alloy using SS-304 bolts and exposed to environmental degradation, which creates significant concerns for aircraft structural reliability. The galvanic corrosion software package, BEASY, is used to simulate the growth of corrosion in the designed specimen after which a microwave non-destructive testing (NDT) technique is explored to detect corrosion defects that appear at the interface of this galvanic couple. This paper also explores a loaded waveguide technique to determine the dielectric constant of the final corrosion product at the Q-band millimeter-wave frequency range (33-50 GHz), as this can be an invaluable asset in developing early detection strategies.

Computational Investigation of Hardness Evolution During Friction-Stir Welding of AA5083 and AA2139 Aluminum Alloys

DTIC Science & Technology

2011-01-01

expensive post-weld machining; and (g) low 102 environmental impact . However, some disadvantages of the 103 FSW process have also been identified such as (a...material. Its 443 density and thermal properties are next set to that of AISI- H13 , 444 a hot-worked tool steel, frequently used as the FSW-tool 445

Friction stir welding process and material microstructure evolution modeling in 2000 and 5000 series of aluminum alloy

NASA Astrophysics Data System (ADS)

Yalavarthy, Harshavardhan

Interactions between the rotating and advancing pin-shaped tool (terminated at one end with a circular-cylindrical shoulder) with the clamped welding-plates and the associated material and heat transport during a Friction Stir Welding (FSW) process are studied computationally using a fully-coupled thermo-mechanical finite-element analysis. To surmount potential numerical problems associated with extensive mesh distortions/entanglement, an Arbitrary Lagrangian Eulerian (ALE) formulation was used which enabled adaptive re-meshing (to ensure the continuing presence of a high-quality mesh) while allowing full tracking of the material free surfaces. To demonstrate the utility of the present computational approach, the analysis is applied to the cases of same-alloy FSW of two Aluminum-alloy grades: (a) AA5083 (a solid-solution strengthened and strain-hardened/stabilized Al-Mg-Mn alloy); and (b) AA2139 (a precipitation hardened quaternary Al-Cu-Mg-Ag alloy). Both of these alloys are currently being used in military-vehicle hull structural and armor systems. In the case of non-age-hardenable AA5083, the dominant microstructure evolution processes taking place during FSW are extensive plastic deformation and dynamic recrystallization of highly-deformed material subjected to elevated temperatures approaching the melting temperature. To account for the competition between plastic-deformation controlled strengthening and dynamic-recrystallization induced softening phenomena during the FSW process, the original Johnson-Cook strain- and strain-rate hardening and temperature-softening material strength model is modified in the present work using the available recrystallization-kinetics experimental data. In the case of AA2139, in addition to plastic deformation and dynamic recrystallization, precipitates coarsening, over-aging, dissolution and re-precipitation had to be also considered. Limited data available in the open literature pertaining to the kinetics of the aforementioned microstructure-evolution processes are used to predict variation in the material hardness and the residual stresses throughout the various FSW zones of the two alloys. The results showed that with proper modeling of the material behavior under high-temperature/severe-plastic-deformation conditions, significantly improved agreement can be attained between the computed and measured post-FSW residual-stress and material-strength distribution results. Keywords: Friction Stir Welding; AA5083; AA2139; Johnson-Cook Strength Model; Finite Element Analysis; Hardness Prediction.

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.

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.

The effect of oxide film properties on the corrosion behavior of SiC/Al metal-matrix composites

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

Golledge, S.L.

1991-01-01

Oxide growth on pure aluminum, aluminum alloy 6061, and the aluminum-based metal matrix composite SiC/AA6061 was studied, and the properties of the oxides related to the pit-initiation behavior of the materials. The objectives of the work were to identify the effect of alloying elements and SiC reinforcement on the oxide film, and to better understand how the oxide properties control pit initiation behavior. To this end, electrochemical and optical studies of the materials were carried out in a buffered sodium/boric acid solution at pH values of 8.4 and 7.2. The alloy and metal-matrix composite showed a slightly lesser tendency tomore » pit than pure aluminum, as measured by the pitting potential. The oxide on the composite was less resistant to pit initiation, and was found to exhibit slower repassivation rates than the other materials. The repassivation behavior and resistance to pit initiation were quite similar in the case of the alloy and the pure aluminum. Induction times for pit initiation were consistent with the predictions of Heusler's model for the breakdown of passivity.« less

Studies on post weld heat treatment of dissimilar aluminum alloys by laser beam welding technique

NASA Astrophysics Data System (ADS)

Srinivas, B.; Krishna, N. Murali; Cheepu, Muralimohan; Sivaprasad, K.; Muthupandi, V.

2018-03-01

The present study mainly focuses on post weld heat treatment (PWHT) of AA5083 and AA6061 alloys by joining these using laser beam welding at three different laser power and two different beam spot sizes and three different welding speeds. Effects of these parameters on microstructural and mechanical properties like hardness, tensile strength were studied at PWHT condition and significant changes had been observed. The PWHT used was artificial aging technique. The microstructural observations revealed that there was a appreciable changes were taken place in the grain size. The microhardness observations proven that the change in the hardness profile in AA6061 was appreciable than in the AA5083. The tensile strength of 246 MPa was recorded as highest. The fractured surfaces observed are predominantly ductile in nature.

Structural Phase Evolution in Ultrasonic-Assisted Friction Stir Welded 2195 Aluminum Alloy Joints

NASA Astrophysics Data System (ADS)

Eliseev, A. A.; Fortuna, S. V.; Kalashnikova, T. A.; Chumaevskii, A. V.; Kolubaev, E. A.

2017-10-01

The authors examined the structural and phase state of fixed joints produced by method of friction stir welding (FSW) and ultrasonic-assisted friction stir welding (UAFSW) from extruded profile of aluminum alloy AA2195. In order to identify the role of ultrasonic application in the course of welding, such characteristics, as volume fraction and average size of secondary particles are compared in the base material and stir zones of FSW and UAFSW joints. By applying the methods of SEM and TEM analysis, researchers established the complex character of phase transitions as a result of ultrasonic application.

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.

Protection by Thermal and Chemical Activation with Cerium Salts of the Alloy AA2017 in Aqueous Solutions of NaCl

NASA Astrophysics Data System (ADS)

Bethencourt, Manuel; Botana, Francisco Javier; Cano, María José; González-Rovira, Leandro; Marcos, Mariano; Sánchez-Amaya, José María

2012-01-01

A wide variety of anticorrosive treatments for aluminum alloys that can be employed as "green" alternatives to those based on Cr(VI) are currently under development. This article reports a study of the morphological and anticorrosive characteristics of surface layers formed on the Al-Cu alloy AA2017 by immersion treatment in baths of cerium salt, accelerated by increased temperature and the employment of hydrogen peroxide. Scanning electron microscopy (SEM)/X-ray energy dispersive spectroscopy (XEDS) studies of the samples treated have demonstrated the existence of a heterogeneous layer formed by a film of aluminum oxide/hydroxide on the matrix, and a series of dispersed islands of cerium over the cathodic intermetallics. The protective efficacy has been evaluated using electrochemical techniques, linear polarizations (LP) and electrochemical impedance spectroscopy (EIS), and salt spray tests. The results obtained indicate that the layer provided good resistance to corrosion in media with chlorides, and the method gives a considerable reduction of the time required for the immersion treatments.

Microstructure Stability During Creep of Friction Stir Welded AA2024-T3 Alloy

NASA Astrophysics Data System (ADS)

Regev, Michael; Rashkovsky, Tal; Cabibbo, Marcello; Spigarelli, Stefano

2018-01-01

The poor weldability of the AA2024 aluminum alloy limits its use in industrial applications. Because friction stir welding (FSW) is a non-fusion welding process, it seems to be a promising solution for welding this alloy. In the current study, FSW was applied to butt weld AA2024-T3 aluminum alloy plates. Creep tests were conducted at 250 and at 315 °C on both the parent material and the friction stir welded specimens. The microstructures of the welded and non-welded AA2024-T3 specimens before and after the creep tests were studied and compared. A comprehensive transmission electron microscopy study together with a high-resolution scanning electron microscopy study and energy-dispersive x-ray spectroscopy analysis was conducted to investigate the microstructure stability. The parent material seems to contain two kinds of Cu-rich precipitates—coarse precipitates of a few microns each and uniformly dispersed fine nanosized precipitates. Unlike the parent material, the crept specimens were found to contain the two kinds of precipitates mentioned above together with platelet-like precipitates. In addition, extensive decoration of the grain boundaries with precipitates was clearly observed in the crept specimens. Controlled aging experiments for up to 280 h at the relevant temperatures were conducted on both the parent material and the welded specimens in order to isolate the contribution of exposure to high temperatures to the microstructure changes. TEM study showed the development of dislocation networks into a cellular dislocation structure in the case of the parent metal. Changes in the dislocation structure as a function of the creep strain and the FSW process were recorded. A detailed creep data analysis was conducted, taking into account the instability of the microstructure.

Experimental and numerical investigation of strain rate effect on low cycle fatigue behaviour of AA 5754 alloy

NASA Astrophysics Data System (ADS)

Kumar, P.; Singh, A.

2018-04-01

The present study deals with evaluation of low cycle fatigue (LCF) behavior of aluminum alloy 5754 (AA 5754) at different strain rates. This alloy has magnesium (Mg) as main alloying element (Al-Mg alloy) which makes this alloy suitable for Marines and Cryogenics applications. The testing procedure and specimen preparation are guided by ASTM E606 standard. The tests are performed at 0.5% strain amplitude with three different strain rates i.e. 0.5×10-3 sec-1, 1×10-3 sec-1 and 2×10-3 sec-1 thus the frequency of tests vary accordingly. The experimental results show that there is significant decrease in the fatigue life with the increase in strain rate. LCF behavior of AA 5754 is also simulated at different strain rates by finite element method. Chaboche kinematic hardening cyclic plasticity model is used for simulating the hardening behavior of the material. Axisymmetric finite element model is created to reduce the computational cost of the simulation. The material coefficients used for “Chaboche Model” are determined by experimentally obtained stabilized hysteresis loop. The results obtained from finite element simulation are compared with those obtained through LCF experiments.

Investigations on Laser Beam Welding of Different Dissimilar Joints of Steel and Aluminum Alloys for Automotive Lightweight Construction

NASA Astrophysics Data System (ADS)

Seffer, Oliver; Pfeifer, Ronny; Springer, André; Kaierle, Stefan

Due to the enormous potential of weight saving, and the consequential reduction of pollutant emissions, the use of hybrid components made of steel and aluminum alloys is increasing steadily, especially concerning automotive lightweight construction. However, thermal joining of steel and aluminum is still being researched, due to a limited solubility of the binary system of iron and aluminum causing the formation of hard and brittle intermetallic phases, which decrease the strength and the formability of the dissimilar seam. The presented results show the investigation of laser beam welding for joining different dissimilar hybrid components of the steel materials HX220LAD+Z100, 22MnB5+AS150 and 1.4301, as well as the aluminum alloy AA6016-T4 as a lap joint. Among other things, the influences of the energy per unit length, the material grade, the sheet thickness t, the weld type (lap weld, fillet weld) and the arrangement of the base materials in a lap joint (aluminum-sided irradiation, steel-sided irradiation) on the achievable strengths are analyzed. The characterization of the dissimilar joints includes tensile shear tests and metallographic analyses, depending on the energy per unit length.

A Study on Infrared Local Heat Treatment for AA5083 to Improve Formability and Automotive Part Forming

NASA Astrophysics Data System (ADS)

Lee, Eun-Ho; Yang, Dong-Yol; Ko, SeJin

2017-10-01

Automotive industries are increasingly employing aluminum alloys for auto parts to reduce vehicle weight. However, the low formability of aluminum alloys has been an obstacle to their application. To resolve the formability problem, some studies involving heat treatments under laboratory conditions have been reported. However, for industrial applications, the heat treatment sequence, heating energy efficiency, and a commercial part test should be studied. This work shows an infrared (IR) local heat treatment, heating only small areas where the heat treatment is required, for an aluminum alloy to improve the formability with a reduction of heating energy. The experiment shows that the formability drastically increases when the aluminum alloy is heat treated between two forming stages, referred to as intermediate heat treatment. The microstructures of the test pieces are evaluated to identify the cause of the increase in the formability. For an industrial application, an aluminum tailgate, which cannot be manufactured without heat treatment, was successfully manufactured by the IR local heat treatment with a reduction of energy. A simulation was also conducted with a stress-based forming limit diagram, which is not affected by the strain path and heat treatment histories. The simulation gives a good prediction of the formability improvement.

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

NASA Astrophysics Data System (ADS)

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

2002-07-01

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

Effects of various Mg/Si ratios on microstructure and performance property of Al-Mg-Si alloy cables

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

Xu, Xuexuan

2016-09-15

High quality AA6101 aluminum cables are critical to electrical industry to meet the energy consumption requests. In the present work, the influence of Mg/Si ratios on the electrical conductivity and mechanical properties of AA6101 aluminum alloy was investigated. Wheatstone Bridge method and tensile test were employed to characterize the mechanical properties. X-ray Diffraction (XRD), Scanning Electron Microscope (SEM) and Transmission Electron Microscope (TEM) were used to understand the morphology of the precipitation and the mechanism of age hardening. It is found that excessive Si benefits high strength and high conductivity while excessive Mg plays a negative role in the strengthmore » and the conductivity of AA6101 cables. Excessive Si elements promote both the precipitating rate and quantity of β″ phase therefore increase the tensile strength. Excessive Si elements also help with decreasing the lattice distortion, which contributes to the enhancement of the conductivity. Excessive Mg elements lead to more dissolved Mg after aging treatment, therefore increase lattice distortion of the matrix and promote the deposit of coarse Mg-enriched secondary phase. - Highlights: •A new available method to improve the mechanical and electrical properties of Al-Mg-Si alloy •Investigation on the role of various Mg/Si ratios in the changes of comprehensive performances •Discussions on the morphology of the precipitation phases and the mechanism of hardening.« less

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.

Corrosion of aluminum alloy 2024 by microorganisms isolated from aircraft fuel tanks.

PubMed

McNamara, Christopher J; Perry, Thomas D; Leard, Ryan; Bearce, Ktisten; Dante, James; Mitchell, Ralph

2005-01-01

Microorganisms frequently contaminate jet fuel and cause corrosion of fuel tank metals. In the past, jet fuel contaminants included a diverse group of bacteria and fungi. The most common contaminant was the fungus Hormoconis resinae. However, the jet fuel community has been altered by changes in the composition of the fuel and is now dominated by bacterial contaminants. The purpose of this research was to determine the composition of the microbial community found in fuel tanks containing jet propellant-8 (JP-8) and to determine the potential of this community to cause corrosion of aluminum alloy 2024 (AA2024). Isolates cultured from fuel tanks containing JP-8 were closely related to the genus Bacillus and the fungi Aureobasidium and Penicillium. Biocidal activity of the fuel system icing inhibitor diethylene glycol monomethyl ether is the most likely cause of the prevalence of endospore forming bacteria. Electrochemical impedance spectroscopy and metallographic analysis of AA2024 exposed to the fuel tank environment indicated that the isolates caused corrosion of AA2024. Despite the limited taxonomic diversity of microorganisms recovered from jet fuel, the community has the potential to corrode fuel tanks.

Microstructure Evolution during Dissimilar Friction Stir Welding of AA7003-T4 and AA6060-T4.

PubMed

Dong, Jialiang; Zhang, Datong; Zhang, Weiwen; Zhang, Wen; Qiu, Cheng

2018-02-27

In this work, the dissimilar joint of AA7003-T4 and 6060-T4 alloy has been produced by friction stir welding (FSW). The microstructure was examined by optical microscope (OM), electron back scattered diffraction (EBSD), transmission electron microscopy (TEM), and the mechanical properties of the joint were investigated. It is demonstrated that sound dissimilar joint can be produced through FSW. In the nugget; precipitations dissolve into the matrix and η' reprecipitate subsequently; and the elongated aluminum grains are replaced by fine and equiaxed grains due to dynamic recrystallization (DRX). In the heat affected zone (HAZ), coarse β' and η precipitates are formed and the aluminum grains are coarser as compared to the base materials. In the thermo-mechanical affected zone (TMAZ), equiaxed and elongated grains coexist due to incomplete DRX. The ultimate tensile strength of the dissimilar joint is 159.2 MPa and its elongation is 10.4%. The weak area exists in the HAZ of 6060 alloy, which is placed in the retreating side during FSW. The correlations between the microstucture and mechanical properties of the dissimilar joint are discussed.

Microstructure Evolution during Dissimilar Friction Stir Welding of AA7003-T4 and AA6060-T4

PubMed Central

Dong, Jialiang; Zhang, Datong; Zhang, Weiwen; Zhang, Wen; Qiu, Cheng

2018-01-01

In this work, the dissimilar joint of AA7003-T4 and 6060-T4 alloy has been produced by friction stir welding (FSW). The microstructure was examined by optical microscope (OM), electron back scattered diffraction (EBSD), transmission electron microscopy (TEM), and the mechanical properties of the joint were investigated. It is demonstrated that sound dissimilar joint can be produced through FSW. In the nugget; precipitations dissolve into the matrix and η′ reprecipitate subsequently; and the elongated aluminum grains are replaced by fine and equiaxed grains due to dynamic recrystallization (DRX). In the heat affected zone (HAZ), coarse β′ and η precipitates are formed and the aluminum grains are coarser as compared to the base materials. In the thermo-mechanical affected zone (TMAZ), equiaxed and elongated grains coexist due to incomplete DRX. The ultimate tensile strength of the dissimilar joint is 159.2 MPa and its elongation is 10.4%. The weak area exists in the HAZ of 6060 alloy, which is placed in the retreating side during FSW. The correlations between the microstucture and mechanical properties of the dissimilar joint are discussed. PMID:29495463

The effect of laser surface melting on microstructure and corrosion behavior of friction stir welded aluminum alloy 2219

NASA Astrophysics Data System (ADS)

Ma, Shengchong; Zhao, Yong; Zou, Jiasheng; Yan, Keng; Liu, Chuan

2017-11-01

This study aimed to explore the electrochemical properties and microstructure of friction stir welds to understand the correlation between their properties and processing. Friction stir welding is a promising solid-state joining process for high-strength aluminum alloys (AA). Although friction stir welding (FSW) eliminates the problems of fusion welding due to the fact that it is performed below Tm, it causes severe plastic deformation in the material. Some AA welded by FSW exhibit relatively poor corrosion resistance. In this research, the corrosion resistance of such welds was enhanced through laser surface melting. A friction stir weld of AA 2219 was laser melted. The melt depth and microstructure were observed using optical and scanning electron microscopy. The melt zone exhibited epitaxially grown columnar grains. The redistribution of elemental composition was analyzed using energy-dispersive spectroscopy. The anticorrosion properties of both laser-melted and original welds were studied in aqueous 3.5% NaCl solution using cyclic potentiodynamic polarization. The results indicated a noticeable increase in the pitting corrosion resistance after the laser treatment on the surface. The repassivation potential was nobler than the corrosion potential after the laser treatment, confirming that the resistance to pitting growth improved.

Effect of MWCNT reinforcement on the precipitation-hardening behavior of AA2219

NASA Astrophysics Data System (ADS)

Thomas, Shijo; Umasankar, V.

2018-01-01

Aluminum alloy matrix composites have found a predominant place in research, and their applications are explored in almost all industries. The aerospace industry has been using precipitation-hardenable alloys in structural applications. However, insufficient literature is available on the influence of multiwalled carbon nanotubes (MWCNTs) on precipitation-hardenable alloy composite materials; thus, this work was designed to elucidate the effect on MWCNT reinforcement on AA2219 with and without precipitation hardening. Reinforcement with MWCNTs has been reported to accelerate precipitation and to achieve greater hardness within a much shorter time. The addition of 0.75wt% MWCNTs resulted in maximal hardness at 90 min, which is approximately 27% of improvement over the maximum hardness achieved by the corresponding monolithic alloy after 10 h of aging. The sample reinforced with 0.75wt% MWCNTs showed an improvement of 82% in hardness by solutionizing and aging compared to that achieved by sintering.

Tailored Welding Technique for High Strength Al-Cu Alloy for Higher Mechanical Properties

NASA Astrophysics Data System (ADS)

Biradar, N. S.; Raman, R.

AA2014 aluminum alloy, with 4.5% Cu as major alloying element, offers highest strength and hardness values in T6 temper and finds extensive use in aircraft primary structures. However, this alloy is difficult to weld by fusion welding because the dendritic structure formed can affect weld properties seriously. Among the welding processes, AC-TIG technique is largely used for welding. As welded yield strength was in the range of 190-195 MPa, using conventional TIG technique. Welding metallurgy of AA2014 was critically reviewed and factors responsible for lower properties were identified. Square-wave AC TIG with Transverse mechanical arc oscillation (TMAO) was postulated to improve the weld strength. A systematic experimentation using 4 mm thick plates produced YS in the range of 230-240 MPa, has been achieved. Through characterization including optical and SEM/EDX was conducted to validate the metallurgical phenomena attributable to improvement in weld properties.

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

The effect of precipitation on the evolution of recrystallization textures in an AA 8011 aluminum alloy sheet

NASA Astrophysics Data System (ADS)

Ryu, Jong-Ho; Lee, Yoon-Soo; Lee, Dong Nyung

2001-06-01

The texture of an AA 8011 aluminum alloy sheet cold rolled by 95% showed a typical β-fiber, which runs from the copper orientation [C={112}<111>] over S [{123}<634>] to brass [B={011}<112>]. The development of annealing textures depended on annealing temperatures due to the interaction between precipitation and recrystallization. Upon annealing at a low temperature of 275°C, precipitation took place before recrystallization. This led to a weak recrystallization texture consisting of {011}<122>, {001˜<100>, and {hk0}<001>, among which the {011}<122> orientation developed near large FeAl3 particles as the main orientation and the cube [{001}<100>] orientation originating from the matrix was relatively weak. After annealing at 350 and 500°C, a strong cube texture developed along with a weak {011}<122> orientation. When the cube orientation developed, the copper orientation disappeared most rapidly. These results were discussed based on the interaction between precipitation and recrystallization.

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

NASA Astrophysics Data System (ADS)

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

2012-07-01

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

3D microstructural evolution of primary recrystallization and grain growth in cold rolled single-phase aluminum alloys

NASA Astrophysics Data System (ADS)

Adam, Khaled; Zöllner, Dana; Field, David P.

2018-04-01

Modeling the microstructural evolution during recrystallization is a powerful tool for the profound understanding of alloy behavior and for use in optimizing engineering properties through annealing. In particular, the mechanical properties of metallic alloys are highly dependent upon evolved microstructure and texture from the softening process. In the present work, a Monte Carlo (MC) Potts model was used to model the primary recrystallization and grain growth in cold rolled single-phase Al alloy. The microstructural representation of two kinds of dislocation densities, statistically stored dislocations and geometrically necessary dislocations were quantified based on the ViscoPlastic Fast Fourier transform method. This representation was then introduced into the MC Potts model to identify the favorable sites for nucleation where orientation gradients and entanglements of dislocations are high. Additionally, in situ observations of non-isothermal microstructure evolution for single-phase aluminum alloy 1100 were made to validate the simulation. The influence of the texture inhomogeneity is analyzed from a theoretical point of view using an orientation distribution function for deformed and evolved texture.

Effect of thermomechanical treatment on the microstructure, phase composition, and mechanical properties of Al-Cu-Mn-Mg-Zr alloy

NASA Astrophysics Data System (ADS)

Zuiko, I. S.; Gazizov, M. R.; Kaibyshev, R. O.

2016-09-01

The effect of the thermomechanical treatment on the microstructure, phase composition, and mechanical properties of heat-treatable AA2519 aluminum alloy (according to the classification of the Aluminum Association) has been considered. After solid-solution treatment, quenching, and artificial aging (T6 treatment) at 180°C for the peak strength, the yield stress, ultimate tensile strength, and elongation to failure are ~300 MPa, 435 MPa, and 21.7%, respectively. It has been shown that treatments that include intermediate plastic deformations with degrees of 7 and 15% (T87 and T815 treatments, respectively) have a significant effect on the phase composition and morphology of strengthening particles precipitated during peak aging T8X type, where X is pre-strain percent, treatments initiate the precipitation of significant amounts of particles of the θ'- and Ω-phases. After T6 treatment, predominantly homogeneously distributed particles of θ″-phase have been observed. Changes in the microstructure and phase composition of the AA2519 alloy, which are caused by intermediate deformation, lead to a significant increase in the yield stress and ultimate tensile strength (by ~40 and ~8%, respectively), whereas the plasticity decreases by 40-50%.

A parametric study of surface roughness and bonding mechanisms of aluminum alloys with epoxies: a molecular dynamics simulation

NASA Astrophysics Data System (ADS)

Timilsina, Rajendra; Termaath, Stephanie

The marine environment is highly aggressive towards most materials. However, aluminium-magnesium alloys (Al-Mg, specifically, 5xxx series) have exceptionally long service life in such aggressive marine environments. For instance, an Al-Mg alloy, AA5083, is extensively used in naval structures because of its good mechanical strength, formability, seawater corrosion resistance and weldability. However, bonding mechanisms of these alloys with epoxies in a rough surface environment are not fully understood yet. It requires a rigorous investigation at molecular or atomic levels. We performed a molecular dynamics simulation to study an adherend surface preparation and surface bonding mechanisms of Al-Mg alloy (AA5083) with different epoxies by developing several computer models. Various distributions of surface roughness are introduced in the models and performed molecular dynamics simulations. Formation of a beta phase (Al3Mg2) , microstructures, bonding energies at the interface, bonding strengths and durability are investigated. Office of Naval Research.

Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Jain, Rahul; Pal, Surjya Kanta; Singh, Shiv Brat

2017-02-01

Friction Stir Welding (FSW) is a solid state joining process and is handy for welding aluminum alloys. Finite Element Method (FEM) is an important tool to predict state variables of the process but numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and work piece and interdependency of displacement and temperature. In the present work, a three dimensional coupled thermo-mechanical method based on Lagrangian implicit method is proposed to study the thermal history, strain distribution and thermo-mechanical process in butt welding of Aluminum alloy 2024 using DEFORM-3D software. Workpiece is defined as rigid-visco plastic material and sticking condition between tool and work piece is defined. Adaptive re-meshing is used to tackle high mesh distortion. Effect of tool rotational and welding speed on plastic strain is studied and insight is given on asymmetric nature of FSW process. Temperature distribution on the workpiece and tool is predicted and maximum temperature is found in workpiece top surface.

Investigation of Mechanical Properties and Fracture Simulation of Solution-Treated AA 5754

NASA Astrophysics Data System (ADS)

Kumar, Pankaj; Singh, Akhilendra

2017-10-01

In this work, mechanical properties and fracture toughness of as-received and solution-treated aluminum alloy 5754 (AA 5754) are experimentally evaluated. Solution heat treatment of the alloy is performed at 530 °C for 2 h, and then, quenching is done in water. Yield strength, ultimate tensile strength, impact toughness, hardness, fatigue life, brittle fracture toughness (K_{Ic} ) and ductile fracture toughness (J_{Ic} ) are evaluated for as-received and solution-treated alloy. Extended finite element method has been used for the simulation of tensile and fracture behavior of material. Heaviside function and asymptotic crack tip enrichment functions are used for modelling of the crack in the geometry. Ramberg-Osgood material model coupled with fracture energy is used to simulate the crack propagation. Fracture surfaces obtained from various mechanical tests are characterized by scanning electron microscopy.

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.

Evaluation of laminated aluminum plate for shuttle applications

NASA Technical Reports Server (NTRS)

Martin, M. J.

1973-01-01

Flaw growth behavior in roll diffusion bonded and adhesive bonded 2219-T87 aluminum alloy was compared to that in monolothic 2219-T87. Based on tests at 40 KSI cyclic stress, for equivalent cyclic life, a .004 interlayer laminate can tolerate a surface flaw twice as wide as in monolithic material, or provide an 8% weight saving by operating at higher stress for the same initial flaw. Roll diffusion bonded material with three structural plies of 2219-T87 and two interlayers of 1100 aluminum was prepared with interlayer thicknesses of .004, .007 and .010 in. Total laminate thickness was .130 in. The .004 interlayer laminate was most effective and gave better results than monolithic material at 40 and 48 ksi. Adhesive bonded specimens were fabricated of three sheets of 2219-T87 aluminum alloy bonded with METLBOND 329 adhesive. Adhesive bonded specimens gave longer lives to failure than diffusion bonded specimens at 40 ksi the diffusion bonded material was superior. Flaws initiated in one ply of the laminate grew to the edges of the specimen in that ply but did not propagate into adjacent plies.

Electrochemical studies of corrosion inhibitors

NASA Technical Reports Server (NTRS)

Danford, M. D.

1990-01-01

The effect of single salts, as well as multicomponent mixtures, on corrosion inhibition was studied for type 1010 steel; for 5052, 1100, and 2219-T87 aluminum alloys; and for copper. Molybdate-containing inhibitors exhibit an immediate, positive effect for steel corrosion, but an incubation period may be required for aluminum before the effect of a given inhibitor can be determined. The absence of oxygen was found to provide a positive effect (smaller corrosion rate) for steel and copper, but a negative effect for aluminum. This is attributed to the two possible mechanisms by which aluminum can oxidize. Corrosion inhibition is generally similar for oxygen-rich and oxygen-free environments. The results show that the electrochemical method is an effective means of screening inhibitors for the corrosion of single metals, with caution to be exercised in the case of aluminum.

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

NASA Astrophysics Data System (ADS)

Theohari, S.; Kontogeorgou, Ch.

2013-11-01

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

Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys

DTIC Science & Technology

2011-01-01

tool material (AISI H13 tool steel ) is modeled as an isotropic linear-elastic material. Within the analysis, the effects of some of the FSW key process...threads/m; (b) tool 598 material = AISI H13 tool steel ; (c) workpiece material = 599 AA5059; (d) tool rotation speed = 500 rpm; (e) tool travel 600 speed...the strain-hardening term is augmented to take into account for the effect of dynamic recrystallization) while the FSW tool material (AISI H13

Hot granules medium pressure forming process of AA7075 conical parts

NASA Astrophysics Data System (ADS)

Dong, Guojiang; Zhao, Changcai; Peng, Yaxin; Li, Ying

2015-05-01

High strength aluminum alloy plate has a low elongation at room temperature, which leads to the forming of its components need a high temperature. Liquid or gas is used as the pressure-transfer medium in the existing flexible mould forming process, the heat resistance of the medium and pressurizing device makes the application of aluminum alloy plate thermoforming restricted. To solve this problem, the existing medium is replaced by the heat-resisting solid granules and the general pressure equipments are applied. Based on the pressure-transfer performance test of the solid granules medium, the feasibility that the assumption of the extended Drucker-Prager linear model can be used in the finite element analysis is proved. The constitutive equation, the yield function and the theoretical forming limit diagram(FLD) of AA7075 sheet are established. Through the finite element numerical simulation of hot granules medium pressure forming(HGMF) process, not only the influence laws of the process parameters, such as forming temperature, the blank-holder gap and the diameter of the slab, on sheet metal forming performance are discussed, but also the broken area of the forming process is analyzed and predicted, which are coincided with the technological test. The conical part whose half cone angle is 15° and relative height H/d 0 is 0.57, is formed in one process at 250°C. The HGMF process solves the problems of loading and seal in the existing flexible mould forming process and provides a novel technology for thermoforming of light alloy plate, such as magnesium alloy, aluminium alloy and titanium alloy.

Friction stir processing of an aluminum-magnesium alloy with pre-placing elemental titanium powder: In-situ formation of an Al{sub 3}Ti-reinforced nanocomposite and materials characterization

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

Khodabakhshi, F., E-mail: farzadkhodabakhshi83@gmail.com; Simchi, A.; Institute for Nanoscience and Nanotechnology, Sharif University of Technology, P.O. Box 11365-9466, Azadi Avenue, 14588 Tehran

A fine-grained Al–Mg/Al{sub 3}Ti nanocomposite was fabricated by friction stir processing (FSP) of an aluminum-magnesium (AA5052) alloy with pre-placed titanium powder in the stirred zone. Microstructural evolutions and formation of intermetallic phases were analyzed by optical and electron microscopic techniques across the thickness section of the processed sheets. The microstructure of the nanocomposite consisted of a fine-grained aluminum matrix (1.5 µm), un-reacted titanium particles (<40 µm) and reinforcement particles of Al{sub 3}Ti (<100 nm) and Mg{sub 2}Si (<100 nm). Detailed microstructural analysis indicated solid-state interfacial reactions between the aluminum matrix and micro-sized titanium particles to form Al{sub 3}Ti intermetallic phase.more » The hard inclusions were then fractured and re-distributed in the metal matrix by the severe thermo-mechanical conditions imposed by FSP. Evaluation of mechanical properties by hardness measurement and uniaxial tensile test determined significant enhancement in the mechanical strength (by 2.5 order of magnetite) with a high ductility (~22%). Based on a dislocation-based model analysis, it was suggested that the strength enhancement was governed by grain refinement and the presence of hard inclusions (4 vol%) in the metal matrix. Fractographic studies also showed a ductile-brittle fracture mode for the nanocomposite compared with fully ductile rupture of the annealed alloy as well as the FSPed specimen without pre-placing titanium particles. - Highlights: • FSP was employed to fabricate in situ nanocomposite. • The AA5052 Al alloy with pre-placed micro-sized Ti particles were utilized. • The structural analysis was revealed that the in situ formation of Al{sub 3}Ti nanophase. • The SZ grain structure was refined by PSN and ZHP mechanisms during DRX. • Hardness and tensile strength were improved up to ~2.5 times with a good ductility.« less

Double-sided laser beam welded T-joints for aluminum-lithium alloy aircraft fuselage panels: Effects of filler elements on microstructure and mechanical properties

NASA Astrophysics Data System (ADS)

Han, Bing; Tao, Wang; Chen, Yanbin; Li, Hao

2017-08-01

In the current work, T-joints consisting of 2.0 mm thick 2060-T8/2099-T83 aluminum-lithium alloys for aircraft fuselage panels have been fabricated by double-sided fiber laser beam welding with different filler wires. A new type wire CW3 (Al-6.2Cu-5.4Si) was studied and compared with conventional wire AA4047 (Al-12Si) mainly on microstructure and mechanical properties. It was found that the main combined function of Al-6.2%Cu-5.4%Si in CW3 resulted in considerable improvements especially on intergranular strength, hot cracking susceptibility and hoop tensile properties. Typical non-dendritic equiaxed zone (EQZ) was observed along welds' fusion boundary. Hot cracks and fractures during the load were always located within the EQZ, however, this typical zone could be restrained by CW3, effectively. Furthermore, changing of the main intergranular precipitated phase within the EQZ from T phase by AA4047 to T2 phase by CW3 also resulted in developments on microscopic intergranular reinforcement and macroscopic hoop tensile properties. In addition, bridging caused by richer substructure dendrites within CW3 weld's columnar zone resulted in much lower hot cracking susceptibility of the whole weld than AA4047.

Control of Reaction Kinetics During Friction Stir Processing

DOE PAGES

Das, Shamiparna; Martinez, Nelson Y.; Mishra, Rajiv S.; ...

2017-02-17

Friction stir processing (FSP) was used to successfully embed galfenol particles into aluminum (AA 1100 Al) matrix uniformly. But, intermetallic layer of Al 3Fe was formed around the galfenol particles. We estimated the activation energy for Al 3Fe formation during FSP, and attempts were made to minimize the Al 3Fe layer thickness. By changing the processing conditions, FSP successfully eliminated the intermetallic layer. Therefore, FSP, in addition to microstructural control, can successfully fabricate intermetallic-free embedded regions by controlling the reaction kinetics.

Crack Repair in Aerospace Aluminum Alloy Panels by Cold Spray

NASA Astrophysics Data System (ADS)

Cavaliere, P.; Silvello, A.

2017-04-01

The cold-spray process has recently been recognized as a very useful tool for repairing metallic sheets, achieving desired adhesion strengths when employing optimal combinations of material process parameters. We present herein the possibility of repairing cracks in aluminum sheets by cold spray. A 2099 aluminum alloy panel with a surface 30° V notch was repaired by cold spraying of 2198 and 7075 aluminum alloy powders. The crack behavior of V-notched sheets subjected to bending loading was studied by finite-element modeling (FEM) and mechanical experiments. The simulations and mechanical results showed good agreement, revealing a remarkable K factor reduction, and a consequent reduction in crack nucleation and growth velocity. The results enable prediction of the failure initiation locus in the case of repaired panels subjected to bending loading and deformation. The stress concentration was quantified to show how the residual stress field and failure are affected by the mechanical properties of the sprayed materials and by the geometrical and mechanical properties of the interface. It was demonstrated that the crack resistance increases more than sevenfold in the case of repair using AA2198 and that cold-spray repair can contribute to increased global fatigue life of cracked structures.

Microstructure and texture of a nano-grained complex Al alloy fabricated by accumulative roll-bonding of dissimilar Al alloys.

PubMed

Lee, Seong-Hee; Jeon, Jae-Yeol; Lee, Kwang-Jin

2013-01-01

An ultrafine grain (UFG) complex lamella aluminum alloy sheet was successfully fabricated by ARB process using AA1050 and AA6061. The lamella thickness of the alloy became thinner and elongated to the rolling direction with increasing the number of ARB cycles. By TEM observation, it is revealed that the aspect ratio of UFGs formed by ARB became smaller with increasing the number of ARB cycles. In addition, the effect of ARB process on the development of deformation texture at the quarter thickness of ARB-processed sheets was clarified. ARB process leaded to the formation of the rolling texture with shear texture and weak cube orientation. The subdivision of the grains to the rolling direction began to occur after 3 cycles of the ARB, resulting in formation of ultrafine grains with small aspect ratio. After 5 cycles, the ultrafine grained structure with the average grain diameter of 560 nm develops in almost whole regions of the sample.

Emission of nanoparticles during friction stir welding (FSW) of aluminium alloys.

PubMed

Gomes, J F; Miranda, R M; Santos, T J; Carvalho, P A

2014-01-01

Friction stir welding (FSW) is now well established as a welding process capable of joining some different types of metallic materials, as it was (1) found to be a reliable and economical way of producing high quality welds, and (2) considered a "clean" welding process that does not involve fusion of metal, as is the case with other traditional welding processes. The aim of this study was to determine whether the emission of particles during FSW in the nanorange of the most commonly used aluminum (Al) alloys, AA 5083 and AA 6082, originated from the Al alloy itself due to friction of the welding tool against the item that was being welded. Another goal was to measure Al alloys in the alveolar deposited surface area during FSW. Nanoparticles dimensions were predominantly in the 40- and 70-nm range. This study demonstrated that microparticles were also emitted during FSW but due to tool wear. However, the biological relevance and toxic manifestations of these microparticles remain to be determined.

Gas Forming a V-Shape Aluminum Sheet into a Trough of Saddle-Contour

NASA Astrophysics Data System (ADS)

Lee, Shyong; Lan, Hsien-Chin; Lee, Jye; Wang, Jian-Yih; Huang, J. C.; Chu, Chun Lin

2012-11-01

A sheet metal trough of aluminum alloys is manufactured by gas-forming process at 500 °C. The product with slope walls is of ~1.2 m long and ~260 mm opening width, comprising two conical sinks at two ends. The depth of one sink apex is ~350 mm, which results in the depth/width ratio reaching 1.4. To form such a complex shape with high aspect ratio, a pre-form of V-shape groove is prepared prior to the gas-forming work. When this double concave trough is turned upside down, the convex contour resembles the back of a twin hump camel. The formability of this configuration depends on the gas pressurization rate profile, the working temperature, material's micro-structure, as well as pre-form design. The latter point is demonstrated by comparing two aluminum alloys, AA5182 and SP5083, with nearly same compositions but very different grain sizes.

Effects of process parameters on friction self-piercing riveting of dissimilar materials

DOE PAGES

Liu, Xun; Lim, Yong Chae; Li, Yongbing; ...

2016-05-24

In the present work, a recently developed solid state joining technique, Friction self-piercing riveting (F-SPR), has been applied for joining high strength aluminum alloy AA7075-T6 to magnesium alloy AZ31B. The process was performed on a specially designed machine where the spindle can achieve the motion of sudden stop. Effects of rivet rotating rate and punch speed on axial plunge force, torque, joint microstructure and quality have been analyzed systematically. During F-SPR, higher rotating rate and slower punch speed can reduce axial force and torque, which correspondingly results in a slightly smaller interlock between rivet leg and joined materials. Improved localmore » flowability of both aluminum and magnesium alloys under a higher rotating speed results in a thicker aluminum layer surrounding the rivet leg, where formation of Al-Mg intermetallics was observed. Equivalent joint strength obtained in this study are higher than the yield strength of the AZ31 Mg alloy. One of the tensile failure modes is the rivet fracture, which is due to local softening of rivet leg from frictional heat. Lastly, other two failure modes include rivet pullout and shear through of bottom sheet.« less

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

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.

Stress Ratio Effects on Crack Opening Loads and Crack Growth Rates in Aluminum Alloy 2024

NASA Technical Reports Server (NTRS)

Riddell, William T.; Piascik, Robert S.

1998-01-01

The effects of stress ratio (R) and crack opening behavior on fatigue crack growth rates (da/dN) for aluminum alloy (AA) 2024-T3 were investigated using constant-delta K testing, closure measurements, and fractography. Fatigue crack growth rates were obtained for a range of delta K and stress ratios. Results show that constant delta K fatigue crack growth for R ranging from near 0 to 1 is divided into three regions. In Region 1, at low R, da/dN increases with increasing R. In Region 2, at intermediate R, fatigue crack growth rates are relatively independent of R. In Region 3, at high R, further increases in da/dN are observed with increasing R.

Corrosion and wear resistance of titanium- and aluminum-based metal matrix composites fabricated by direct metal laser deposition

NASA Astrophysics Data System (ADS)

Waldera, Benjamin L.

Titanium- and Aluminum-based metal matrix composites (MMC) have shown favorable properties for aerospace applications such as airframes, reinforcement materials and joining elements. In this research, such coatings were developed by direct metal laser deposition with a powder-fed fiber coupled diode laser. The MMC formulations consisted of pure titanium and aluminum matrices with reinforcing powder blends of chromium carbide and tungsten carbide nickel alloy. Two powder formulations were investigated for each matrix material (Ti1, Ti2, Al1 and Al2). Titanium based composites were deposited onto a Ti6Al4V plate while aluminum composites were deposited onto AA 7075 and AA 5083 for Al1 and Al2, respectively. Microstructures of the MMCs were studied by optical and scanning electron microscopy. The hardness and reduced Young's modulus (Er) were assessed through depth-sensing instrumented nanoindentation. microhardness (Vickers) was also analyzed for each composite. The corrosion resistance of the MMCs were compared by monitoring open circuit potential (OCP), polarization resistance (Rp) and potentiodynamic polarization in 0.5 M NaCl to simulate exposure to seawater. The Ti-MMCs demonstrated improvements in hardness between 205% and 350% over Ti6Al4V. Al-MMCs showed improvements between 47% and 79% over AA 7075 and AA 5083. The MMCs showed an increase in anodic current density indicating the formation of a less protective surface oxide than the base metals.

On the Similarity of Deformation Mechanisms During Friction Stir Welding and Sliding Friction of the AA5056 Alloy

NASA Astrophysics Data System (ADS)

Kolubaev, A. V.; Zaikina, A. A.; Sizova, O. V.; Ivanov, K. V.; Filippov, A. V.; Kolubaev, E. A.

2018-04-01

A comparative investigation of the structure of an aluminum-manganese alloy is performed after its friction stir welding and sliding friction. Using the methods of optical and electron microscopy, it is shown that during friction identical ultrafine-grained structures are formed in the weld nugget and in the surface layer, in which the grains measure 5 μm irrespective of the initial grain size of the alloy. An assumption is made that the microstructure during both processes under study is formed by the mechanism of rotational plasticity.

Application of Pre-heating to Improve the Consistency and Quality in AA5052 Resistance Spot Welding

NASA Astrophysics Data System (ADS)

Luo, Zhen; Ao, Sansan; Chao, Yuh Jin; Cui, Xuetuan; Li, Yang; Lin, Ye

2015-10-01

Making consistent resistance spot welds of aluminum alloy with good quality and at high volume has several obstacles in automotive industry. One of the difficult issues arises from the presence of a tough non-conducting oxide film on the aluminum sheet surface. The oxide film develops over time and often is non-uniform across the surface of the aluminum alloy sheet, which makes the contact resistance characteristics irregular at the faying interface during welding. The consistency in quality of the final spot welds is therefore problematic to control. To suppress the effect of the irregular oxide film on the spot weld quality, application of a pre-heating treatment in the welding schedule for aluminum alloy 5052 is investigated in this present work. The current level of the pre-heating required to reduce the scatter of the contact resistance at the W/W (workpiece-to-workpiece) faying interface is quantified experimentally. The results indicate that the contact resistance at the W/W faying interface with a pre-heating treatment becomes much consistent and can be reduced by two orders of magnitude. Having the uncertain variation of the contact resistance at the W/W faying surface virtually reduced or removed, the quality of the spot welds in terms of the peak load and nugget diameter is examined and shows a great improvement. The proposed method may provide a robust method for high-volume spot welding of aluminum alloy sheets in auto industry.

Primary and secondary creep in aluminum alloys as a solid state transformation

NASA Astrophysics Data System (ADS)

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

2016-08-01

Despite the massive literature and the efforts devoted to understand the creep behavior of aluminum alloys, a full description of this phenomenon on the basis of microstructural parameters and experimental conditions is, at present, still missing. The analysis of creep is typically carried out in terms of the so-called steady or secondary creep regime. The present work offers an alternative view of the creep behavior based on the Orowan dislocation dynamics. Our approach considers primary and secondary creep together as solid state isothermal transformations, similar to recrystallization or precipitation phenomena. In this frame, it is shown that the Johnson-Mehl-Avrami-Kolmogorov equation, typically used to analyze these transformations, can also be employed to explain creep deformation. The description is fully compatible with present (empirical) models of steady state creep. We used creep curves of commercially pure Al and ingot AA6061 alloy at different temperatures and stresses to validate the proposed model.

Mechanical Characteristics of Welded Joints of Aluminum Alloy 6061 T6 Formed by Arc and Friction Stir Welding

NASA Astrophysics Data System (ADS)

Astarita, A.; Squillace, A.; Nele, L.

2016-01-01

Butt welds formed by arc welding in inert gas with nonconsumable electrode (tungsten inert gas (TIG) welding) and by friction stir welding (FSW) from aluminum alloy AA6061 T6 are studied. Comparative analysis of the structures and mechanical properties of the welded joints is performed using the results of optical and electron microscopy, tensile tests, tests for residual bending ductility, and measurements of microhardness. The changes in the microstructure in different zones and the degrees of degradation of the mechanical properties after the welding are determined. It is shown that the size of the tool for the friction stir welding affects the properties of the welds. Quantitative results showing the relation between the microscopic behavior of the alloy and the welding-induced changes in the microstructure are obtained. Friction stir welding is shown to provide higher properties of the welds.

Measurements and Modeling of Stress in Precipitation-Hardened Aluminum Alloy AA2618 during Gleeble Interrupted Quenching and Constrained Cooling

NASA Astrophysics Data System (ADS)

Chobaut, Nicolas; Carron, Denis; Saelzle, Peter; Drezet, Jean-Marie

2016-11-01

Solutionizing and quenching are the key steps in the fabrication of heat-treatable aluminum parts such as AA2618 compressor impellers for turbochargers as they highly impact the mechanical characteristics of the product. In particular, quenching induces residual stresses that can cause unacceptable distortions during machining and unfavorable stresses in service. Predicting and controlling stress generation during quenching of large AA2618 forgings are therefore of particular interest. Since possible precipitation during quenching may affect the local yield strength of the material and thus impact the level of macroscale residual stresses, consideration of this phenomenon is required. A material model accounting for precipitation in a simple but realistic way is presented. Instead of modeling precipitation that occurs during quenching, the model parameters are identified using a limited number of tensile tests achieved after representative interrupted cooling paths in a Gleeble machine. This material model is presented, calibrated, and validated against constrained coolings in a Gleeble blocked-jaws configuration. Applications of this model are FE computations of stress generation during quenching of large AA2618 forgings for compressor impellers.

Analysis of Particle-Stimulated Nucleation (PSN)-Dominated Recrystallization for Hot-Rolled 7050 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Adam, Khaled F.; Long, Zhengdong; Field, David P.

2017-04-01

In 7xxx series aluminum alloys, the constituent large and small second-phase particles present during deformation process. The fraction and spatial distribution of these second-phase particles significantly influence the recrystallized structure, kinetics, and texture in the subsequent treatment. In the present work, the Monte Carlo Potts model was used to model particle-stimulated nucleation (PSN)-dominated recrystallization and grain growth in high-strength aluminum alloy 7050. The driving force for recrystallization is deformation-induced stored energy, which is also strongly affected by the coarse particle distribution. The actual microstructure and particle distribution of hot-rolled plate were used as an initial point for modeling of recrystallization during the subsequent solution heat treatment. Measurements from bright-field TEM images were performed to enhance qualitative interpretations of the developed microstructure. The influence of texture inhomogeneity has been demonstrated from a theoretical point of view using pole figures. Additionally, in situ annealing measurements in SEM were performed to track the orientational and microstructural changes and to provide experimental support for the recrystallization mechanism of PSN in AA7050.

The behavior of ZrO2/20%Y2O3 and Al2O3 coatings deposited on aluminum alloys at high temperature regime

NASA Astrophysics Data System (ADS)

Pintilei, G. L.; Crismaru, V. I.; Abrudeanu, M.; Munteanu, C.; Baciu, E. R.; Istrate, B.; Basescu, N.

2015-10-01

Aluminum alloy present numerous advantages like lightness, high specific strength and diversity which recommend them to a high number of applications from different fields. In extreme environments the protection of aluminum alloys is difficult and requires a high number of requirements like high temperature resistance, thermal fatigue resistance, corrosion fatigue resistance and galvanic corrosion resistance. To obtain these characteristics coatings can be applied to the surfaces so they can enhance the mechanical and chemical properties of the parts. In this paper two coatings were considered for deposition on an AA2024 aluminum alloy, ZrO2/20%Y2O3 and Al2O3. To obtain a better adherence of the coating to the base material an additional bond layer of NiCr is used. Both the coatings and bond layer were deposited by atmospheric plasma spraying on the samples. The samples were subjected to a temperature of 500 °C and after that slowly cooled to room temperature. The samples were analyzed by electron microscopy and X-ray diffraction to determine the morphological and phase changes that occurred during the temperature exposure. To determine the stress level in the parts due to thermal expansion a finite element analysis was performed in the same conditions as the tests.

Material characterization and finite element simulations of aluminum alloy sheets during non-isothermal forming process

NASA Astrophysics Data System (ADS)

Zhang, Nan

The utilization of more non-ferrous materials is one of the key factors to succeed out of the constantly increasing demand for lightweight vehicles in automotive sector. Aluminum-magnesium alloys have been identified as the most promising substitutions to the conventional steel without significant compromise in structural stiffness and strength. However, the conventional forming methods to deform the aluminum alloy sheets are either costly or insufficient in formability which limit the wide applications of aluminum alloy sheets. A recently proposed non-isothermal hot stamping approach, which is also referred as Hot Blank - Cold Die (HB-CD) stamping, aims at fitting the commercial grade aluminum alloy sheets, such as AA5XXX and AA7XXX, into high-volume and cost-effective production for automotive sector. In essence, HB-CD is a mutation of the conventional hot stamping approach for boron steel (22MnB5) which deforms the hot blank within the cold tool set. By elevating the operation temperature, the formability of aluminum alloy sheets can be significantly improved. Meanwhile, heating the blank only and deforming within the cold tool sets allow to reduce the energy and time consumed. This research work aims at conducting a comprehensive investigation of HB-CD with particular focuses on material characterization, constitutive modeling and coupled thermo-mechanical finite element simulations with validation. The material properties of AA5182-O, a popular commercial grade of aluminum alloy sheet in automotive sector, are obtained through isothermal tensile testing at temperatures from 25° to 300°, covering a quasi-static strain-rate range (0.001--0.1s-1). As the state-of-the-art non-contact strain measurement technique, digital image correlation (DIC) system is utilized to evaluate the stress-strain curves as well as to reveal the details of material deformation with full-field and multi-axis strain measurement. Material anisotropy is characterized by extracting the evolving yield stresses and Lankford coefficients (r-value) at various temperatures with specimens in 0°, 45° and 90° to the rolling direction. Besides, thermally-activated deformation mechanisms, dynamic strain ageing and dislocation climb, are identified to control the material deformation at the ambient-to-warm temperature range. For biaxial loading condition, the hydraulic bulge test has been performed and the evaluated effective stress-strain curve is found to be identical to that from uniaxial tests. A new piece-wised temperature-dependent phenomenological constitutive model has been developed to describe and predict the evolving stress-strain curves within the experimental condition. The power-law model is chosen for temperature ranges from 25° to 100° where negative strain rate sensitivity is observed. At elevated temperatures, a new model has been developed and expressed as the product of two power-law models. This proposed model has been proved to be capable of capturing both strain hardening and thermal softening behaviors of material, even for perfect plasticity with large strain conditions. To account for the directionality of the material properties in sheet metal, Yld2000-2d, which has been proved to be one of the most accurate and efficient yield functions for aluminum alloys in numerical analysis, is selected as the anisotropic yield function in this work. Eight parameters in Yld2000-2d have been determined and calibrated using the experimental results from uniaxial and biaxial testing of AA5182-O. Moreover, those eight parameters are fitted in to the temperature-dependent functions, hence the evolution of yield surface is predictable in response to the temperature changes. It is noticed that the material carries more anisotropy at ambient temperatures and tends to approach the isotropic behavior when the temperature elevated to 300°. The strain-based and stress-based forming limit diagrams (FLD) of AA5182-O at various temperatures have been constructed by calculating the theoretical M-K model with Newton method and backtracking algorithm. The obtained FLDs are found to be instructive and will be applied in the post-processing of FE simulation for stamping so as to identify the critical area of failure. The developed constitutive model and modified yield function are implemented in the form of user defined subroutine (VUMAT) in ABAQUS/Explicit. An explicit stress integration algorithm has been selected for the stress integration with rate-depend viscoplasticity model at temperature higher than 150°. In the low temperature range, the Newton method and cutting plane algorithm are utilized to update the stress tensor with a classic elastoplastic constitutive model. To validate the VUMAT, a non-isothermal tensile testing has been performed with aids of infrared thermal camera and DIC. The heat transfer coefficients in FE model are calibrated with captured thermal images. With appropriate selection of mesh size and mass scaling factor, the punch load vs. displacement curve obtained from the simulation perfectly correlates the experimental result.

Improvements to the strength and corrosion resistance of aluminum-magnesium-manganese alloys of near-AA5083 chemistry

NASA Astrophysics Data System (ADS)

Carroll, Mark Christopher

Aluminum alloys of the 5000 series (AI-Mg-Mn) are extremely popular in a wide range of applications that call for a balance of moderately high strength, good corrosion resistance, and light weight, all at a moderate cost. One of the most popular 5000 series alloys is designated A1-5083, containing, in addition to aluminum, approximately 4 wt% magnesium and 0.7 wt% manganese. In order to increase the range of versatility of this particular alloy, a number of modifications have been examined that will potentially improve the strength and corrosion resistance characteristics while maintaining a chemical composition that is very close to the proven 5083 alloy. The strength of the 5083-based alloys under study are investigated with two goals in mind---to maximize the potential strength characteristics in a "standard" 5083 form through changes in minor processing parameters or through minor alloying additions. Increasing the standard alloy's potential is possible through improved efficiency of "preprocessing" heat treatments that maximize the homogeneous dispersion of secondary manganese-based particles. For the modified alloy study, additions of scandium and zirconium are shown to improve strength not only by forming secondary particles in the alloy, but also through substitutional solid solution strengthening, even when added at very small levels. Corrosion resistance of these 5083-based alloys is investigated once again through minor alloying additions; specifically zinc, copper, and silver. Zinc is particularly effective in that it changes the corrosion-susceptible binary aluminum-magnesium phase that would otherwise form on grain boundaries following exposure to moderately elevated temperatures for extended periods of time to a ternary aluminum-magnesium-zinc phase. This chemical composition of this ternary phase that forms following zinc additions can be further altered through minor additions of copper and silver. By determining threshold levels for these modifications while maintaining a chemical composition that is very near that of standard Al-5083, it can be shown that even minor modifications to processing and alloying parameters can have a favorable effect on the final bulk properties of the alloy. The increased range of strength and corrosion resistance of these lightly modified alloys make them more attractive in a broadened range of potential applications.

Dynamic Behavior of AA2519-T8 Aluminum Alloy Under High Strain Rate Loading in Compression

NASA Astrophysics Data System (ADS)

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

2018-06-01

In this study, the effects of strain rate on the dynamic behavior, microstructure evolution and hence, failure of the AA2519-T8 aluminum alloy were investigated under compression at strain rates ranging from 1000 to 3500 s-1. Cylindrical specimens of dimensions 3.3 mm × 3.3 mm (L/D = 1) were tested using the split-Hopkinson pressure bar integrated with a digital image correlation system. The microstructure of the alloy was assessed using optical and scanning electron microscopes. Results showed that the dynamic yield strength of the alloy is strain rate dependent, with the maximum yield strength attained by the material being 500 MPa. The peak flow stress of 562 MPa was attained by the material at 3500 s-1. The alloy also showed a significant rate of strain hardening that is typical of other Al-Cu alloys; the rate of strain hardening, however, decreased with increase in strain rate. It was determined that the strain rate sensitivity coefficient of the alloy within the range of high strain rates used in this study is approximately 0.05 at 0.12 plastic strain; a more significant value than what was reported in literature under quasi-static loading. Micrographs obtained showed potential sites for the evolution of adiabatic shear band at 3500 s-1, with a characteristic circular-shaped surface profile comprising partially dissolved second phase particles in the continuous phase across the incident plane of the deformed specimen. The regions surrounding the site showed little or no change in the size of particles. However, the constituent coarse particles were observed as agglomerations of fractured pieces, thus having a shape factor different from those contained in the as-received alloy. Since the investigated alloy is a choice material for military application where it can be exposed to massive deformation at high strain rates, this study provides information on its microstructural and mechanical responses to such extreme loading condition.

Dynamic Behavior of AA2519-T8 Aluminum Alloy Under High Strain Rate Loading in Compression

NASA Astrophysics Data System (ADS)

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

2018-02-01

In this study, the effects of strain rate on the dynamic behavior, microstructure evolution and hence, failure of the AA2519-T8 aluminum alloy were investigated under compression at strain rates ranging from 1000 to 3500 s-1. Cylindrical specimens of dimensions 3.3 mm × 3.3 mm (L/D = 1) were tested using the split-Hopkinson pressure bar integrated with a digital image correlation system. The microstructure of the alloy was assessed using optical and scanning electron microscopes. Results showed that the dynamic yield strength of the alloy is strain rate dependent, with the maximum yield strength attained by the material being 500 MPa. The peak flow stress of 562 MPa was attained by the material at 3500 s-1. The alloy also showed a significant rate of strain hardening that is typical of other Al-Cu alloys; the rate of strain hardening, however, decreased with increase in strain rate. It was determined that the strain rate sensitivity coefficient of the alloy within the range of high strain rates used in this study is approximately 0.05 at 0.12 plastic strain; a more significant value than what was reported in literature under quasi-static loading. Micrographs obtained showed potential sites for the evolution of adiabatic shear band at 3500 s-1, with a characteristic circular-shaped surface profile comprising partially dissolved second phase particles in the continuous phase across the incident plane of the deformed specimen. The regions surrounding the site showed little or no change in the size of particles. However, the constituent coarse particles were observed as agglomerations of fractured pieces, thus having a shape factor different from those contained in the as-received alloy. Since the investigated alloy is a choice material for military application where it can be exposed to massive deformation at high strain rates, this study provides information on its microstructural and mechanical responses to such extreme loading condition.

Microhardness and Strain Field Characterization of Self-Reacting Friction Stir and Plug Welds of Dissimilar Aluminum Alloys

NASA Technical Reports Server (NTRS)

Horton, Karla Renee

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. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. This work reports on material properties and strain patterns developed in a SR-FSW with a friction plug weld. Specifically, this study examines the behavior of a SR-FSW formed between an AA 2014-T6 plate on the advancing side and an AA 2219-T87 plate on the retreating side and a SR-FSW (AA 2014-T6 to AA 2219-T87) with a 2219-T87 plug weld. This study presents the results of a characterization of the micro-hardness, joint strength, and strain field characterization of SR-FSW and FPW joints tested at room temperature and cryogenic temperatures.

Springback of aluminum alloy brazing sheet in warm forming

NASA Astrophysics Data System (ADS)

Han, Kyu Bin; George, Ryan; Kurukuri, Srihari; Worswick, Michael J.; Winkler, Sooky

2017-10-01

The use of aluminum is increasing in the automotive industry due to its high strength-to-weight ratio, recyclability and corrosion resistance. However, aluminum is prone to significant springback due to its low elastic modulus coupled with its high strength. In this paper, a warm forming process is studied to improve the springback characteristics of 0.2 mm thick brazing sheet with an AA3003 core and AA4045 clad. Warm forming decreases springback by lowering the flow stress. The parts formed have complex features and geometries that are representative of automotive heat exchangers. The key objective is to utilize warm forming to control the springback to improve the part flatness which enables the use of harder temper material with improved strength. The experiments are performed by using heated dies at several different temperatures up to 350 °C and the blanks are pre-heated in the dies. The measured springback showed a reduction in curvature and improved flatness after forming at higher temperatures, particularly for the harder temper material conditions.

Interfacial Reaction During Dissimilar Joining of Aluminum Alloy to Magnesium and Titanium Alloys

NASA Astrophysics Data System (ADS)

Robson, J. D.; Panteli, A.; Zhang, C. Q.; Baptiste, D.; Cai, E.; Prangnell, P. B.

Ultrasonic welding (USW), a solid state joining process, has been used to produce welds between AA6111 aluminum alloy and AZ31 magnesium alloys or titanium alloy Ti-6Al-4V. The mechanical properties of the welds have been assessed and it has been shown that it is the nature and thickness of the intermetallic compounds (IMCs) at the joint line that are critical in determining joint strength and particularly fracture energy. Al-Mg welds suffer from a very low fracture energy, even when strength is comparable with that of similar metal Mg-Mg welds, due to a thick IMC layer always being formed. It is demonstrated that in USW of Al-Ti alloy the slow interdiffusion kinetics means that an IMC layer does not form during welding, and fracture energy is greater. A model has been developed to predict IMC formation during welding and provide an understanding of the critical factors that determine the IMC thickness. It is predicted that in Al-Mg welds, most of the lMC thickening occurs whilst the IMC regions grow as separate islands, prior to the formation of a continuous layer.

Controlled Release from Core-Shell Nanoporous Silica Particles for Corrosion Inhibition of Aluminum Alloys

DOE PAGES

Jiang, Xingmao; Jiang, Ying-Bing; Liu, Nanguo; ...

2011-01-01

Ceriumore » m (Ce) corrosion inhibitors were encapsulated into hexagonally ordered nanoporous silica particles via single-step aerosol-assisted self-assembly. The core/shell structured particles are effective for corrosion inhibition of aluminum alloy AA2024-T3. Numerical simulation proved that the core-shell nanostructure delays the release process. The effective diffusion coefficient elucidated from release data for monodisperse particles in water was 1.0 × 10 − 14  m 2 s for Ce 3+ compared to 2.5 × 10 − 13  m 2 s for NaCl. The pore size, pore surface chemistry, and the inhibitor solubility are crucial factors for the application. Microporous hydrophobic particles encapsulating a less soluble corrosion inhibitor are desirable for long-term corrosion inhibition.« less

Anisotropic Effects on Constitutive Model Parameters of Aluminum Alloys

NASA Astrophysics Data System (ADS)

Brar, Nachhatter; Joshi, Vasant

2011-06-01

Simulation of low velocity impact on structures or high velocity penetration in armor materials heavily rely on constitutive material models. The model constants are required input to computer codes (LS-DYNA, DYNA3D or SPH) to accurately simulate fragment impact on structural components made of high strength 7075-T651 aluminum alloys. Johnson-Cook model constants determined for Al7075-T651 alloy bar material failed to simulate correctly the penetration into 1' thick Al-7075-T651plates. When simulations go well beyond minor parameter tweaking and experimental results are drastically different it is important to determine constitutive parameters from the actual material used in impact/penetration experiments. To investigate anisotropic effects on the yield/flow stress of this alloy we performed quasi-static and high strain rate tensile tests on specimens fabricated in the longitudinal, transverse, and thickness directions of 1' thick Al7075-T651 plate. Flow stresses at a strain rate of ~1100/s in the longitudinal and transverse direction are similar around 670MPa and decreases to 620 MPa in the thickness direction. These data are lower than the flow stress of 760 MPa measured in Al7075-T651 bar stock.

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.

Specialized mechanical properties of pure aluminum by using non-equal channel angular pressing for developing its electrical applications

NASA Astrophysics Data System (ADS)

Fereshteh-Saniee, Faramarz; Asgari, Mohammad; Fakhar, Naeimeh

2016-08-01

Despite valuable electrical characteristics, the use of pure aluminum in different applications has been limited due to its low strength. Non-equal channel angular pressing (NECAP) is a recently proposed severe plastic deformation process with greater induced plastic strain and, consequently, better grain refinement in the product, compared with the well-known equal channel angular pressing technique. This research is concerned with the effects of the process temperature and ram velocity on the mechanical, workability and electrical properties of AA1060 aluminum alloy. Increasing the process temperature can concurrently increase the workability, ductility and electrical conductivity, while it has a reverse influence on the strength of the NECAPed specimen, although the strengths of all the products are higher than the as-received alloy. The influence of the ram speed on the mechanical properties of the processed samples is lower than the process temperature. Finally, a compromised process condition is introduced in order to attain a good combination of workability and strength with well-preserved electrical conductivity for electrical applications of components made of pure aluminum.

Nanoprecipitates and Their Strengthening Behavior in Al-Mg-Si Alloy During the Aging Process

NASA Astrophysics Data System (ADS)

Li, Hui; Liu, Wenqing

2017-04-01

The different nanoprecipitates formed in a 6061 aluminum alloy during aging at 453 K (180 °C), with or without 168 hours of pre-natural aging (NA), and the age-hardening response of the alloy were investigated by atom probe tomography (APT) and hardness testing. A hardness plateau developed between 2 and 8 hours in both the artificial aging (AA) and artificial aging with pre-natural aging (NAAA) samples. The hardness of NAAA samples was lower than that of AA samples when artificially aged for the same time. A 168-hour NA led to the formation of solute atom clusters in the matrix. The NA accelerated the precipitation kinetics of the following AA. The solute atom clusters gave the highest hardness increment per unit volume fraction. The β″ precipitates were dominant in the samples at the hardness plateau. The average normalized Mg:Si ratios of the solute atom clusters and GP zones were near 1. The average Mg:Si ratio of β″ precipitates increased from 1.3 to 1.5 upon aging for 2 hours. The microstructural evolution of samples with or without NA and its influence on the strengthening effects are discussed based on the experimental results.

Pitting and Stress Corrosion Cracking Susceptibility of Nanostructured Al-Mg Alloys in Natural and Artificial Environments

NASA Astrophysics Data System (ADS)

Sharma, Mala M.; Ziemian, Constance W.

2008-12-01

The stress corrosion cracking (SCC) behavior of two developmental nanocrystalline 5083 alloys with varied composition and processing conditions was studied. The results were compared to a commercial aluminum AA 5083 (H111) alloy. The pitting densities, size and depths, and residual tensile strengths were measured after alternate immersion in artificial seawater and atmospheric exposure under different loading conditions. Optical and scanning electron microscopy (SEM) with EDX was used to analyze the fracture surfaces of failed specimen after removal at selected intervals and tensile testing. One of the nanostructured Al-Mg alloys exhibited significantly superior pitting resistance when compared to conventional microstructured AA 5083. Under conditions where pitting corrosion showed up as local tunnels toward phase inclusions, transgranular cracking was observed, whereas under conditions when pitting corrosion evolved along grain boundaries, intergranular cracking inside the pit was observed. Pit initiation resistance of the nano alloys appears to be better than that of the conventional alloys. However, long-term pit propagation is a concern and warrants further study. The objective of this investigation was to obtain information regarding the role that ultra-fine microstructures play in their degradation in marine environments and to provide insight into the corrosion mechanisms and damage processes of these alloys.

Calculated mammographic spectra confirmed with attenuation curves for molybdenum, rhodium, and tungsten targets.

PubMed

Blough, M M; Waggener, R G; Payne, W H; Terry, J A

1998-09-01

A model for calculating mammographic spectra independent of measured data and fitting parameters is presented. This model is based on first principles. Spectra were calculated using various target and filter combinations such as molybdenum/molybdenum, molybdenum/rhodium, rhodium/rhodium, and tungsten/aluminum. Once the spectra were calculated, attenuation curves were calculated and compared to measured attenuation curves. The attenuation curves were calculated and measured using aluminum alloy 1100 or high purity aluminum filtration. Percent differences were computed between the measured and calculated attenuation curves resulting in an average of 5.21% difference for tungsten/aluminum, 2.26% for molybdenum/molybdenum, 3.35% for rhodium/rhodium, and 3.18% for molybdenum/rhodium. Calculated spectra were also compared to measured spectra from the Food and Drug Administration [Fewell and Shuping, Handbook of Mammographic X-ray Spectra (U.S. Government Printing Office, Washington, D.C., 1979)] and a comparison will also be presented.

Fabrication of electrodeposited Co-Pt nano-arrays embedded in an anodic aluminum oxide/Ti/Si substrate

NASA Astrophysics Data System (ADS)

Lim, S. K.; Jeong, G. H.; Park, I. S.; Na, S. M.; Suh, S. J.

An anodic aluminum oxide (AAO) template, which is filled with the Co-Pt alloys, is a promising material for high-density magnetic recording media due to its high magnetic anisotropy and high coercivity. The porous AAO templates were fabricated by the two-step anodizing of 1-μm-thick Al thin film evaporated on top of the titanium layer with the thickness of 250 nm. The AAO template with pore size of approximately 60 nm and aspect ratio of 10 was obtained at voltage of 40 V, temperature of 5 °C, oxalic acid of 0.3 M and widening time of 55 min. Then the thickness of barrier is less than 20 nm. The Co-Pt alloy electrodeposited at pulsed current density, pH of 4 and room temperature was successfully filled in the AAO template with pore size of 80 nm and aspect ratio of 3. Then the Co-Pt alloy with Pt concentration of 45 at% was uniformly filled in the template and the coercivity of 1100 Oe was observed by VSM.

Microstructural-Scale Model for Surfaces Spreading of Intergranular Corrosion in Sensitized Stainless Steels and Aluminum-Magnesium (AA5XXX) Alloys

NASA Astrophysics Data System (ADS)

Jain, Swati

Components from AA5XXX (Al-Mg alloys with more than 3 wt% Mg) alloys are X attractive due to availability of low cost, high strength to weight ratio and good weldability. Therefore, these alloys have potential applications in Naval ships. However, these alloys become susceptible to IGC (intergranular corrosion) due to beta-phase precipitation due to improper heat treatment or inadvertent thermal exposure. Stainless steels may also become susceptible due to carbide precipitation and chromium depletion on grain boundaries. IGC susceptibility depends on the interplay between the metallurgical conditions, electrochemical conditions, and chemical conditions. Specific combinations cause IGC while others do not. The objective of this study is to investigate the conditions which bring about surface spreading of IGC in these alloy classes. To accomplish this goal, a microstructure scale model was developed with experimental inputs to understand the 2-D IGC spreading in stainless steels and AA5XXX alloys. The conditions strongly affecting IGC spreading were elucidated. Upon natural and artificial aging, the stainless steels become susceptible to intergranular corrosion because of chromium depletion in the grain boundaries. After aging Al-Mg (AA5XXX) alloys show susceptibility due to the precipitation of the beta-phase (Al3Mg7) in the grain boundaries. Chromium depleted grain boundaries in stainless steels are anodically more active as compared to the interior of the grains. (3-phase rich grain boundaries have lower OCP (open circuit potential) and pitting potentials as compared to the Al-Mg solid solutions. A new approach to modeling the IGC surface spreading in polycrystalline materials that is presented. This model is the first to couple several factors into one granular scale model that illustrates the way in which they interact and IGC occurs. It sheds new information on conditions which cause IGC spreading in two alloy classes and describes a new theory for the critical potential associated with IGC. The outcomes from this contribute to ways to advance the goal of corrosion resistant computational design of alloys, guiding mitigation strategies for suppressing IGC in existing alloys, and to damage prognosis aimed at predicting damage and structural integrity.

Effect of Material Thermo-viscoplastic Modeling on the Prediction of Forming Limit Curves of Aluminum Alloy 5086

NASA Astrophysics Data System (ADS)

Chu, Xingrong; Leotoing, Lionel; Guines, Dominique; Ragneau, Eric

2015-09-01

A solution to improve the formability of aluminum alloy sheets can consist in investigating warm forming processes. The optimization of forming process parameters needs a precise evaluation of material properties and sheet metal formability for actual operating environment. Based on the analytical M-K theory, a finite element (FE) M-K model was proposed to predict forming limit curves (FLCs) at different temperatures and strain rates. The influences of initial imperfection value ( f 0) and material thermos-viscoplastic model on the FLCs are discussed in this work. The flow stresses of AA5086 were characterized by uniaxial tensile tests at different temperatures (20, 150, and 200 °C) and equivalent strain rates (0.0125, 0.125, and 1.25 s-1). Three types of hardening models (power law model, saturation model, and mixed model) were proposed and adapted to correlate the experimental flow stresses. The three hardening models were implemented into the FE M-K model in order to predict FLCs for different forming conditions. The predicted limit strains are very sensitive to the thermo-viscoplastic modeling of AA5086 and to the calibration of the initial geometrical imperfection which controls the onset of necking.

The FEM simulation of continuous rotary extrusion (CRE) of aluminum alloy AA3003

NASA Astrophysics Data System (ADS)

Rajendran, Nijenthan; Valberg, Henry; Misiolek, Wojciech Z.

2017-10-01

Continuous Rotary Extrusion (CRE) process is also known in literature under Conform TM name and it is mainly used for the continuous extrusion of Aluminum and Copper alloys. CRE use a feedstock in the form of rod, powders and chips, which are fed into the groove of the rotating wheel. As the wheel rotates the feedstock moves along with it due to friction with the wheel. Once the feedstock reaches the abutment the material deforms plastically and it is extruded through the die. CRE has lot to offer when compared to other more conventional extrusion processes such as low energy input, no limit in billet length as it is a continuous process as well as improved material physical properties due to plastic deformation under constant parameters. In this work a FEM model has been developed using Deform TM 3D, to study the metal flow and state variables of AA3003 CRE extrusion. The effect of extrusion wheel velocity has been investigated. The results show that increase in wheel velocity will heat up the feedstock metal due to high shear deformation and higher friction, which significantly changes metal flow conditions at the die exit.

A hot-cracking mitigation technique for welding high-strength aluminum alloy

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

Yang, Y.P.; Dong, P.; Zhang, J.

2000-01-01

A hot-cracking mitigation technique for gas tungsten arc welding (GTAW) of high-strength aluminum alloy 2024 is presented. The proposed welding technique incorporates a trailing heat sink (an intense cooling source) with respect to the welding torch. The development of the mitigation technique was based on both detailed welding process simulation using advanced finite element techniques and systematic laboratory experiments. The finite element methods were used to investigate the detailed thermomechanical behavior of the weld metal that undergoes the brittle temperature range (BTR) during welding. As expected, a tensile deformation zone within the material BTR region was identified behind the weldmore » pool under conventional GTA welding process conventional GTA welding process conditions for the aluminum alloy studied. To mitigate hot cracking, the tensile zone behind the weld pool must be eliminated or reduce to a satisfactory level if the weld metal hot ductility cannot be further improved. With detailed computational modeling, it was found that by the introduction of a trailing heat sink at some distance behind the welding arc, the tensile strain rate with respect to temperature in the zone encompassing the BTR region can be significantly reduced. A series of parametric studies were also conducted to derive optimal process parameters for the trailing heat sink. The experimental results confirmed the effectiveness of the trailing heat sink technique. With a proper implementation of the trailing heat sink method, hot cracking can be completely eliminated in welding aluminum alloy 2024 (AA 2024).« less

Experimental Investigation on Friction Stir Welding of Cryorolled AA2219 Aluminum Alloy Joints

NASA Astrophysics Data System (ADS)

Babu, K. Kamal; Panneerselvam, K.; Sathiya, P.; Haq, A. Noorul; Sundarrajan, S.; Mastanaiah, P.; Murthy, C. V. Srinivasa

2017-07-01

In this paper, experimental investigation on cryorolled aluminum AA2219-T87 plate by using friction stir welding (FSW) process is carried out. AA2219-T87 plates with a size of 200×100×22.4 mm were rolled and reduced to 12.2mm thickness (more than 45% of reduction in total thickness of the base material) at cryogenic temperature (operating temperature range -90--30∘C). The cryorolled (CR) plates have reduced grain size, improved hardness and increased corrosion resistance property compared with the uncryorolled AA2219-T87 plates. FSW joints of cryorolled AA2219-T87 plates were prepared using cylindrical threaded FSW tool pin profile. Mechanical and metallurgical behaviors of friction stir welded joints were analyzed and the effects of the FSW process parameters are discussed in this paper. The variation of microhardness in the FSW joint regions were correlated with the microstructure of FSW joints. Cryorolled plate and FSW joints were tested for corrosion resistance using potentiodynamic polarization test. FSW joints shows better result during the corrosion resistance analysis compared to base AA2219-T87. The X-ray diffraction (XRD) test results showed that fine α-Al grains with eutectic phase (Al2Cu) were present in the weld nugget (WN). The large clusters of strengthening precipitates were reduced in size and merged with the weld nugget portion.

New technique of skin embedded wire double-sided laser beam welding

NASA Astrophysics Data System (ADS)

Han, Bing; Tao, Wang; Chen, Yanbin

2017-06-01

In the aircraft industry, double-sided laser beam welding is an approved method for producing skin-stringer T-joints on aircraft fuselage panels. As for the welding of new generation aluminum-lithium alloys, however, this technique is limited because of high hot cracking susceptibility and strengthening elements' uneven distributions within weld. In the present study, a new technique of skin embedded wire double-sided laser beam welding (LBW) has been developed to fabricate T-joints consisting of 2.0 mm thick 2060-T8/2099-T83 aluminum-lithium alloys using eutectic alloy AA4047 filler wire. Necessary dimension parameters of the novel groove were reasonably designed for achieving crack-free welds. Comparisons were made between the new technique welded T-joint and conventional T-joint mainly on microstructure, hot crack, elements distribution features and mechanical properties within weld. Excellent crack-free microstructure, uniform distribution of silicon and superior tensile properties within weld were found in the new skin embedded wire double-sided LBW T-joints.

Chemically activated nanodiamonds for aluminum alloy corrosion protection and monitoring

NASA Astrophysics Data System (ADS)

Hannstein, Inga; Adler, Anne-Katrin; Lapina, Victoria; Osipov, Vladimir; Opitz, Jörg; Schreiber, Jürgen; Meyendorf, Norbert

2009-03-01

In the present study, a smart coating for light metal alloys was developed and investigated. Chemically activated nanodiamonds (CANDiT) were electrophoretically deposited onto anodized aluminum alloy AA2024 substrates in order to increase corrosion resistance, enhance bonding properties and establish a means of corrosion monitoring based on the fluorescence behavior of the particles. In order to create stable aqueous CANDiT dispersions suitable for electrophoretic deposition, mechanical milling had to be implemented under specific chemical conditions. The influence of the CANDiT volume fraction and pH of the dispersion on the electrochemical properties of the coated samples was investigated. Linear voltammetry measurements reveal that the chemical characteristics of the CANDiT dispersion have a distinct influence on the quality of the coating. The fluorescence spectra as well as fluorescence excitation spectra of the samples show that corrosion can be easily detected by optical means. Furthermore, an optimization on the basis of "smart" - algorithms for the data processing of a surface analysis by the laser-speckle-method is presented.

The Effects of Specimen Geometry on the Plastic Deformation of AA 2219-T8 Aluminum Alloy Under Dynamic Impact Loading

NASA Astrophysics Data System (ADS)

Owolabi, G. M.; Bolling, D. T.; Odeshi, A. G.; Whitworth, H. A.; Yilmaz, N.; Zeytinci, A.

2017-12-01

The effects of specimen geometry on shear strain localization in AA 2219-T8 aluminum alloy under dynamic impact loading were investigated. The alloy was machined into cylindrical, cuboidal and conical (frustum) test specimens. Both deformed and transformed adiabatic shear bands developed in the alloy during the impact loading. The critical strain rate for formation of the deformed band was determined to be 2500 s-1 irrespective of the specimen geometry. The critical strain rate required for formation of transformed band is higher than 3000 s-1 depending on the specimen geometry. The critical strain rate for formation of transformed bands is lowest (3000 s-1) in the Ø5 mm × 5 mm cylindrical specimens and highest (> 6000 s-1) in the conical specimens. The cylindrical specimens showed the greatest tendency to form transformed bands, whereas the conical specimen showed the least tendency. The shape of the shear bands on the impacted plane was also observed to be dependent on the specimen geometry. Whereas the shear bands on the compression plane of the conical specimens formed elongated cycles, two elliptical shaped shear bands facing each other were observed on the cylindrical specimens. Two parallel shear bands were observed on the compression planes of the cuboidal specimens. The dynamic stress-strain curves vary slightly with the specimen geometry. The cuboidal specimens exhibit higher tendency for strain hardening and higher maximum flow stress than the other specimens. The microstructure evolution leading to the formation of transformed bands is also discussed in this paper.

Coating of 6028 Aluminum Alloy Using Aluminum Piston Alloy and Al-Si Alloy-Based Nanocomposites Produced by the Addition of Al-Ti5-B1 to the Matrix Melt

NASA Astrophysics Data System (ADS)

El-Labban, Hashem F.; Abdelaziz, M.; Mahmoud, Essam R. I.

2014-10-01

The Al-12 pctSi alloy and aluminum-based composites reinforced with TiB2 and Al3Ti intermetallics exhibit good wear resistance, strength-to-weight ratio, and strength-to-cost ratio when compared to equivalent other commercial Al alloys, which make them good candidates as coating materials. In this study, structural AA 6028 alloy is used as the base material. Four different coating materials were used. The first one is Al-Si alloy that has Si content near eutectic composition. The second, third, and fourth ones are Al-6 pctSi-based reinforced with TiB2 and Al3Ti nano-particles produced by addition of Al-Ti5-B1 master alloy with different weight percentages (1, 2, and 3 pct). The coating treatment was carried out with the aid of GTAW process. The microstructures of the base and coated materials were investigated using optical microscope and scanning electron microscope equipped with EDX analyzer. Microhardness of the base material and the coated layer were evaluated using a microhardness tester. GTAW process results in almost sound coated layer on 6028 aluminum alloy with the used four coating materials. The coating materials of Al-12 pct Si alloy resulted in very fine dendritic Al-Si eutectic structure. The interface between the coated layer and the base metal was very clean. The coated layer was almost free from porosities or other defects. The coating materials of Al-6 pct Si-based mixed with Al-Ti5-B1 master alloy with different percentages (1, 2, and 3 pct), results in coated layer consisted of matrix of fine dendrite eutectic morphology structure inside α-Al grains. Many fine in situ TiAl3 and TiB2 intermetallics were precipitated almost at the grain boundary of α-Al grains. The amounts of these precipitates are increased by increasing the addition of Al-Ti5-B1 master alloy. The surface hardness of the 6028 aluminum alloy base metal was improved with the entire four used surface coating materials. The improvement reached to about 85 pct by the first type of coating material (Al-12 pctSi alloy), while it reached to 77, 83, and 89 pct by the coating materials of Al-6 pct Si-based mixed with Al-Ti5-B1 master alloy with different percentages 1, 2, and 3 pct, respectively.

Studying the Issues in Laser Joining of Lightweight Materials in a Coach-Peel Joint Configuration

NASA Astrophysics Data System (ADS)

Yang, Guang

In the automotive industry, aluminum alloys have been widely used and partially replaced the conventional steel structures in order to decrease the weight of a car and improve its fuel efficiency. This Thesis focuses on the development of laser joining of light-weight materials, such as aluminum alloys and high-strength galvanized steels. Among different joint types, the coach-peel configuration is of a specific design that requires a heat source capable of heating up a large surface area of the joint. Coach-peel joints applied on the visible exterior of a car require a smooth transition from the weld surface to the panel surface and low surface roughness without any need for post-processing. Although these joints are used as non-load-bearing components, a desirable strength of the weld is also needed. A fusion-brazing process using a dual-beam laser allows the automotive components such as the roof and side member panels to be joined in a coach-peel configuration with a high surface quality as well as an acceptable strength of the weld. To improve the weld surface quality, processing parameters such as laser beam configuration, laser-wire position, and shielding gas parameters were optimized for joining of aluminum alloy to aluminum alloy. Laser power was optimized for dual-beam laser joining of aluminum alloy to galvanized steel at high speed. The feasibility of joining as-received panels with lubricant was also explored. The identification of strain hardening models of aluminum alloys was conducted for the mechanical finite element analysis of the joint. Control of the molten pool solidification through the selection of laser beam configuration is one approach to improve joint quality. Laser joining of aluminum alloy AA 6111-T4 coach peel panels with the addition of AA 4047 filler wire was investigated using three configurations of laser beam: a single beam, dual beams in-line with the weld bead, and dual beams aligned perpendicular to the weld bead (herein referred to as cross-beam). To compare the three joining processes, the transient heat distribution, cooling rates, and solidification rates were analyzed by three-dimensional finite element models using ANSYS. Microstructure evolution, tensile strength, fracture mechanisms, and surface roughness of joints were investigated accordingly. To improve the weld surface quality of aluminum joints, the laser-wire position and the gas parameters were optimized. Visualization of the gas flow by a CCD camera revealed the effects of nozzle shape, flow rate, inclination angle of the gas tube, nozzle position, and gas compositions (argon and helium) on the weld surface quality. The suppression of plasma plume and the effects of oxidation on the molten pool were illustrated in detail. With an optimized set of processing parameters, the weld surface roughness (Ra) of approximately 1 microm can be achieved. The feasibility of fabricating the aluminum alloy panel joint in the as-received condition, i.e., with stamping lubricant, by using the cross-beam laser was investigated. Two commercial mineral oils, Bonderite L-FM MP-404 and Ferrocote 61 MAL HCL, were applied onto clean panels prior to joining in order to simulate the conditions of the production environment. The formation and growth of hydrogen bubbles inside the molten pool, the stability of welding process, and the possible energy absorption capability of the porous weld were explained. Besides joining of similar materials, cross-beam laser was applied to join aluminum alloy 6111 to hot-dip galvanized steel in the coach-peel configuration. The filler material was not only brazed onto the galvanized steel but also partially fusion-welded with the aluminum panel. Through adjusting the laser power to 3.4 kW, a desirable wetting and spreading of filler wire on both panel surfaces could be achieved, and the thickness of intermetallic layer in the middle section of the interface between the weld bead and steel was less than 2 microm. To better understand the solid/liquid interfacial reaction at the brazing interface, two rotary Gaussian heat source models were introduced to simulate the temperature distribution in the molten pool by using the finite element method. Joint properties were examined in terms of microstructure and mechanical properties. Simulation of the mechanical response of a coach-peel joint is instructive for improvement of the joining process. The effective true stress-strain curve of fusion-brazed AA 4047 was difficult to obtain experimentally. Therefore, the von Mises isotropic flow function of the weld bead was inversely derived by image-based finite element analysis. Through iterative correction, the predicted tensile response of the coach-peel joint matched well with the experiment. The von Mises fracture stresses at the fusion zone boundary and the brazing interface were identified, respectively.

Sustained Protection against Superficial Bacterial and Fungal Infection by Topical Treatment.

DTIC Science & Technology

1974-12-31

from 1:100 to 1:1,000,000. The test organisms were a cutaneous micrococcus (Baird-Parker type 3), a diphtheroid, C. minutis- simum, Pseudomonas...all aluminum salts. Aluminum chlorhydroxide killed the micrococcus and diphtheroid out to the 1:1000 dilution. Aluminum chloride was lethal to the... micrococcus and diphtheroid only at the 1:100 concentration. Aluminum acetate was lethal only to the micrococcU . at the 1:100 concentration. COMMENT All

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.

Cross-Beam Laser Joining of AA 6111 to Galvanized Steel in a Coach Peel Configuration

NASA Astrophysics Data System (ADS)

Yang, Guang; Mohammadpour, Masoud; Yazdian, Nima; Ma, Junjie; Carlson, Blair; Wang, Hui-Ping; Kovacevic, Radovan

2017-06-01

Cross-beam laser joining of aluminum alloy 6111 to hot-dip galvanized steel in the coach-peel configuration was investigated with the addition of AA 4047 filler wire. The filler material was not only brazed onto the galvanized steel but also partially fusion-welded with the aluminum panel. Through adjusting the laser power to 3.4 kW, a desirable wetting and spreading of filler wire on both panel surfaces could be achieved, and the thickness of intermetallic layer in the middle section of the interface between the weld bead and steel was less than 2 μm. To better understand the solid/liquid interfacial reaction at the brazing interface, two rotary Gaussian heat source models were introduced to simulate the temperature distribution in the molten pool by using the finite element method. Joint properties were examined in terms of microstructure and mechanical properties. During the tensile test, the fracture of coupons took place at the aluminum side rather than along the interface between the intermetallic layer and steel panel. No failure occurred during the three-point bending test.

Through-thickness recrystallization characteristics of a laminated AA3xxx–AA6xxx aluminum alloy system

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

Liao, L.H., E-mail: l2liao@uwaterloo.ca; Jin, H.; Gallerneault, M.

2015-03-15

The through-thickness annealing behavior of a laminated AA3xxx–AA6xxx alloy system at 300 °C has been studied by scanning electron microscopy, electron backscatter diffraction analysis, electron probe micro-analysis, differential scanning calorimetry, and hardness measurement. Results show that the recrystallization process starts at the interface region between the AA3xxx (clad) and AA6xxx (core) layers. Subsequently, the recrystallization process front progresses into the core layer, while the clad layer is the last region to recrystallize. It is also found that precipitation precedes recrystallization in the entire laminate at the investigated temperature. The preferential onset of recrystallization at the interface region is attributed tomore » the net driving pressure being the highest in this region. The factors that lead to such enhanced net driving pressure are (a) deformation incompatibility between the two alloy layers, (b) lower solute content of the interface, which also leads to lower volume fraction of precipitates, and (c) an accelerated rate of precipitate coarsening due to the presence of a higher density of dislocations. The gradual progress of recrystallization from the interface towards the core layer is dictated by precipitate coarsening and the dependence of its rate on the density of deformation-induced dislocations. The lower driving pressure due to lower work hardening capacity, high solute drag pressure due to Mn, and additional Zener drag from precipitates that form due to solute redistribution during annealing explain the late initiation of recrystallization in the clad layer. - Highlights: • The through-thickness recrystallization of a laminated system is investigated. • The early onset of recrystallization at the interface is discussed. • The effects of precipitation and coarsening on recrystallization are analyzed.« less

Development and Testing of a Hydropneumatic Suspension System on a USMC AAV7A1

DTIC Science & Technology

1991-07-30

original material, SAE 4140 steel alloy hardened to 30/34 Rc, has a yield strength of 130,000 psi. All of the ISU’s were disassembled and were reassembled...plugged and welded in place. Aluminum I-beams were welded in place in the water jet tunnels to act as jounce stops for the aft suspension units. The...following Is a tabulation of components attributed to the vehicle: 1000 Hull, Welded & machined 1100 Bow Plane 2000 Powertrain 3000 Transmission 4000

HIGH-RATE FORMABILITY OF HIGH-STRENGTH ALUMINUM ALLOYS: A STUDY ON OBJECTIVITY OF MEASURED STRAIN AND STRAIN RATE

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

Upadhyay, Piyush; Rohatgi, Aashish; Stephens, Elizabeth V.

2015-02-18

Al alloy AA7075 sheets were deformed at room temperature at strain-rates exceeding 1000 /s using the electrohydraulic forming (EHF) technique. A method that combines high speed imaging and digital image correlation technique, developed at Pacific Northwest National Laboratory, is used to investigate high strain rate deformation behavior of AA7075. For strain-rate sensitive materials, the ability to accurately model their high-rate deformation behavior is dependent upon the ability to accurately quantify the strain-rate that the material is subjected to. This work investigates the objectivity of software-calculated strain and strain rate by varying different parameters within commonly used commercially available digital imagemore » correlation software. Except for very close to the time of crack opening the calculated strain and strain rates are very consistent and independent of the adjustable parameters of the software.« less

Effect of Thermomechanical Treatment on the Environmentally Induced Cracking Behavior of AA7075 Alloy

NASA Astrophysics Data System (ADS)

Ghosh, Rahul; Venugopal, A.; Sankaravelayudham, P.; Panda, Rajiv; Sharma, S. C.; George, Koshy M.; Raja, V. S.

2015-02-01

The influence of thermomechanical treatment on the stress corrosion cracking behavior of AA7075 aluminum alloy forgings was examined in 3.5% NaCl solution by varying the extent of thermomechanical working imparted to each of the conditions. The results show that inadequate working during billet processing resulted in inferior corrosion and mechanical properties. However, more working with intermediate pre-heating stages also led to precipitation of coarse particles resulting in lowering of mechanical properties marginally and a significant reduction in the general/pitting corrosion resistance. The results obtained in the present study indicate that optimum working with controlled pre-heating levels is needed during forging to achieve the desired properties. It is also demonstrated that AA7075 in the over aged condition does not show any environmental cracking susceptibility in spite of the microstructural variations in terms of size and volume fraction of the precipitates. However, the above microstructural variations definitely affected the pitting corrosion and mechanical properties significantly and hence a strict control over the working and pre-heating stages during billet processing is suggested.

Three-dimensional flow characteristics of aluminum alloy in multi-pass equal channel angular pressing

NASA Astrophysics Data System (ADS)

Jin, Young-Gwan; Son, Il-Heon; Im, Yong-Taek

2010-06-01

Experiments with a square specimen made of commercially pure aluminum alloy (AA1050) were conducted to investigate deformation behaviour during a multi-pass Equal Channel Angular Pressing (ECAP) for routes A, Bc, and C up to four passes. Three-dimensional finite element numerical simulations of the multi-pass ECAP were carried out in order to evaluate the influence of processing routes and number of passes on local flow behaviour by applying a simplified saturation model of flow stress under an isothermal condition. Simulation results were investigated by comparing them with the experimentally measured data in terms of load variations and microhardness distributions. Also, transmission electron microscopy analysis was employed to investigate the microstructural changes. The present work clearly shows that the three-dimensional flow characteristics of the deformed specimen were dependent on the strain path changes due to the processing routes and number of passes that occurred during the multi-pass ECAP.

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

Microstructure and corrosion resistance of a fluorosilane modified silane-graphene film on 2024 aluminum alloy

NASA Astrophysics Data System (ADS)

Dun, Yuchao; Zhao, Xuhui; Tang, Yuming; Dino, Sahib; Zuo, Yu

2018-04-01

Heptadecafluorodecyl trimethoxysilane (FAS-17) was incorporated into γ-(2,3-epoxypropoxy) propyltrimethoxysilane/graphene (GPTMS/rGO) by adding pre-hydrolyzed FAS-17 solution in GPTMS solution, and a hybrid silane-graphene film (FG/rGO) was prepared on 2024 aluminum alloy surface. The FG/rGO film showed better thermal shock resistance, good adhesion force and high micro-hardness, compared with GPTMS/rGO film. In neutral 3.5 wt% NaCl solution, the corrosion current density for 2024 AA sample with FG/rGO film was 3.40 × 10-3 μA/cm2, which is about one fifth of that for the sample with GPTMS/rGO film. In acidic and alkaline NaCl solutions, the FG/rGO film also showed obviously better corrosion resistance than GPTMS/rGO film. EIS results confirm that the FG/rGO film showed longer performance than GPTMS/rGO film for 2024 AA in NaCl solution. The hydrophobic FAS-17 increased water contact angle of the film surface from 68° to 113°, and changed the stacking structure of graphene in the film. The higher crosslink degree and less interfaces promoted the barrier property of FG/rGO film against aggressive ions and prolonged the performance time in NaCl solution.

Stress-corrosion behavior of aluminum-lithium alloys in aqueous salt environments

NASA Technical Reports Server (NTRS)

Pizzo, P. P.; Galvin, R. P.; Nelson, H. G.

1984-01-01

The stress corrosion susceptibility of two powder metallurgy (P/M) alloys, Al-Li-Cu and Al-Li-Cu-Mg; two mechanically attrited (M/A) alloys, Al-Li-Cu and Al-Li-Mg; and two wrought, ingot alloys, X-2020 and AA7475, are compared. Time-dependent fracture in an aqueous sodium chloride environment under alternate immersion condition was found to vary significantly between alloys. The stress corrosion behavior of the two powder metallurgy processed alloys was studied in detail under conditions of crack initiation, static crack growth, and fatigue crack growth. A variety of stress corrosion tests were performed including smooth surface, time-to-failure tests; potentiostatic tests on smooth surfaces exposed to constant applied strain rates; and fracture mechanics-type tests under static and cyclic loads. Both alloys show surface pitting and subsequent intergranular corrosion. Pitting is more severe in the magnesium-bearing alloy and is associated with stringer particles strung along the extrusion direction as a result of P/M processing.

Stress-corrosion behavior of aluminum-lithium alloys in aqueous environments

NASA Technical Reports Server (NTRS)

Pizzo, P. P.; Galvin, R. P.; Nelson, H. G.

1983-01-01

The stress corrosion susceptibility of two powder metallurgy (P/M) alloys, Al-Li-Cu and Al-Li-Cu-Mg two mechanically attrited (M/A) alloys, Al-Li-Cu and Al-Li-Mg; and two wrought, ingot alloys, X-2020 and AA7475, are compared. Time-dependent fracture in an aqueous sodium chloride environment under alternate immersion condition was found to vary significantly between alloys. The stress corrosion behavior of the two powder metallurgy processed alloys was studied in detail under conditions of crack initiation, static crack growth, and fatigue crack growth. A variety of stress corrosion tests were performed including smooth surface, time-to-failure tests; potentiostatic tests on smooth surfaces exposed to constant applied strain rates; and fracture mechanics-type tests under static and cyclic loads. Both alloys show surface pitting and subsequent intergranular corrosion. Pitting is more severe in the magnesium-bearing alloy and is associated with stringer particles strung along the extrusion direction as a result of P/M processing.

Stress Corrosion Cracking Behavior of Multipass TIG-Welded AA2219 Aluminum Alloy in 3.5 wt pct NaCl Solution

NASA Astrophysics Data System (ADS)

Venugopal, A.; Sreekumar, K.; Raja, V. S.

2012-09-01

The stress corrosion cracking (SCC) behavior of the AA2219 aluminum alloy in the single-pass (SP) and multipass (MP) welded conditions was examined and compared with that of the base metal (BM) in 3.5 wt pct NaCl solution using a slow-strain-rate technique (SSRT). The reduction in ductility was used as a parameter to evaluate the SCC susceptibility of both the BM and welded joints. The results showed that the ductility ratio ( ɛ NaCl/( ɛ air) was 0.97 and 0.96, respectively, for the BM and MP welded joint, and the same was marginally reduced to 0.9 for the SP welded joint. The fractographic examination of the failed samples revealed a typical ductile cracking morphology for all the base and welded joints, indicating the good environmental cracking resistance of this alloy under all welded conditions. To understand the decrease in the ductility of the SP welded joint, preexposure SSRT followed by microstructural observations were made, which showed that the decrease in ductility ratio of the SP welded joint was caused by the electrochemical pitting that assisted the nucleation of cracks in the form of corrosion induced mechanical cracking rather than true SCC failure of the alloy. The microstructural examination and polarization tests demonstrated a clear grain boundary (GB) sensitization of the PMZ, resulting in severe galvanic corrosion of the SP weld joint, which initiated the necessary conditions for the localized corrosion and cracking along the PMZ. The absence of PMZ and a refined fusion zone (FZ) structure because of the lesser heat input and postweld heating effect improved the galvanic corrosion resistance of the MP welded joint greatly, and thus, failure occurred along the FZ.

In-Situ Synthetic TiB2 Particulate Reinforced Metal Matrix Composite Coating on AA2024 Aluminum Alloy by Laser Cladding Technology

NASA Astrophysics Data System (ADS)

Xu, Jiang; Kan, Yide; Liu, Wenjin

In order to improve the wear resistance of aluminum alloy, in-situ synthesized TiB2 and Ti3B4 peritectic composite particulate reinforced metal matrix composite, formed on a 2024 aluminum alloy by laser cladding with a powder mixture of Fe-coated Boron, Ti and Al, was successfully achieved using 3-KW CW CO2 laser. The chemical composition, microstructure and phase structure of the composite clad coating were analyzed by energy dispersive X-ray spectroscopy (EDX), SEM, AFM and XRD. The typical microstructure of the composite coating is composed of TiB2, Ti3B4, Al3Ti, Al3Fe and α-Al. The surface hardness of cladding coating increases with the amount of added Fe-coated B and Ti powder which determines the amount of TiB2 and Ti3B4 peritectic composite particulate. The nanohardness and the elastic modulus at the interface of the TiB2 and Ti3B4 peritectic composite particulate/matrix were investigated using the nanoindentation technique. The results showed that the nanohardness and the reduced elastic modulus from the peritectic composite particulate to the matrix is a gradient distribution.

The effect of welding parameters on surface quality of AA6351 aluminium alloy

NASA Astrophysics Data System (ADS)

Yacob, S.; MAli, M. A.; Ahsan, Q.; Ariffin, N.; Ali, R.; Arshad, A.; Wahab, M. I. A.; Ismail, S. A.; Roji, NS M.; Din, W. B. W.; Zakaria, M. H.; Abdullah, A.; Yusof, M. I.; Kamarulzaman, K. Z.; Mahyuddin, A.; Hamzah, M. N.; Roslan, R.

2015-12-01

In the present work, the effects of gas metal arc welding-cold metal transfer (GMAW-CMT) parameters on surface roughness are experimentally assessed. The purpose of this study is to develop a better understanding of the effects of welding speed, material thickness and contact tip to work distance on the surface roughness. Experiments are conducted using single pass gas metal arc welding-cold metal transfer (GMAW-CMT) welding technique to join the material. The material used in this experiment was AA6351 aluminum alloy with the thickness of 5mm and 6mm. A Mahr Marsuft XR 20 machine was used to measure the average roughness (Ra) of AA6351 joints. The main and interaction effect analysis was carried out to identify process parameters that affect the surface roughness. The results show that all the input process parameters affect the surface roughness of AA6351 joints. Additionally, the average roughness (Ra) results also show a decreasing trend with increased of welding speed. It is proven that gas metal arc welding-cold metal transfer (GMAW-CMT)welding process has been successful in term of providing weld joint of good surface quality for AA6351 based on the low value surface roughness condition obtained in this setup. The outcome of this experimental shall be valuable for future fabrication process in order to obtained high good quality weld.

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

Effect of chloride contamination in MON-1 propellant on crack growth properties of metals

NASA Technical Reports Server (NTRS)

Moran, C. M.; Toth, L. R.

1981-01-01

The effect of a high level of chloride content (800 ppm) in MON-1 propellant on the crack growth properties of seven materials was investigated. Sustained load tests were conducted at 49 C (120 F) temperature with thin gauge tensile specimens having a semi-elliptical surface flaw. Alloys included aluminum 1100, 3003, 5086 and 6061; corrosion resistant steel types A286 and 347; and titanium 6Al-4V. The configurations tested with precracked flaws exposed to MON-1 were: parent or base metal, center weld, and heat affected zone. It was concluded that this chloride level in MON-1 does not affect the stress corrosion, crack growth properties of these alloys after 1000 hour exposure duration under high stresses.

Theoretical Prediction of the Forming Limit Band

NASA Astrophysics Data System (ADS)

Banabic, D.; Vos, M.; Paraianu, L.; Jurco, P.

2007-04-01

Forming Limit Band (FLB) is a very useful tool to improve the sheet metal forming simulation robustness. Until now, the study of the FLB was only experimental. This paper presents the first attempt to model the FLB. The authors have established an original method for predicting the two margins of the limit band. The method was illustrated on the AA6111-T43 aluminum alloy. A good agreement with the experiments has been obtained.

The Use of Austenitic Stainless Steel versus Monel (Ni-Cu) Alloy in Pressurized Gaseous Oxygen (GOX) Life Support Systems.

DTIC Science & Technology

1985-03-01

Carbon Steel AISI 1025 2. AISI 4140 3. Ductile Iron 4. 304 Stainless Steel 5. 17-4 PH Stainless Steel 6. 410 Stainless Steel 7. Lead Babbit 8. Tin Babbit...9. Inconel 718 i0. Aluminum 1100 30 6- AISI 4140 steel, all the results were negative (no ignitions). The single exception was with a sample of 4140 ...rates for austenitic stainless steel ( AISI 316), Monel (63% Ni - 34% Cu) and carbon steel (AMS 5050) tubing in this environment. 12 - 14-660 A 7

Forming characteristics of artificial aging Al-Mg-Si-Cu sheet alloys

NASA Astrophysics Data System (ADS)

Klos, Artur; Kellner, Sven; Wortberg, Daniel; Walter, Philipp; Bassi, Corrado; Merklein, Marion

2017-10-01

AA6111 is a commonly used aluminum alloy for body-in-white (BIW) components with good bake-hardening response, high strength and excellent formability. For industrial applications various process strategies are considered to reach strength of about 250 MPa in the final body part with that type of alloy. The purpose of this paper is to discuss recent process strategies of high-strength AA6111 sheets to evaluate the forming characteristics, precipitation kinetics dissolution and mechanical properties in the final condition. The forming behavior is investigated by four potential process chains after single-stage or multi-stage heat treatment including T4 (pre-aged at > 80 °C after quenching), T61 (T4 + artificial aged at 120-150 °C for 10-18 h), T6 (T4 + artificial aged at 180-220°C up to 12 h) and PFHT (T4 + post form heat treatment at 205°C for 30 min). The experimental input for characterization of the formability consists of tensile tests, bending tests and drawing tests. Differential Scanning Calorimetry (DSC) is used, to correlate the forming behavior with the precipitation distribution in the advanced stages of aging. The study shows that the forming behavior is strongly dependent on the condition the alloy.

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.

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.

Characterization of Tensile Properties, Limiting Strains, and Deep Drawing Behavior of AA5754-H22 Sheet at Elevated Temperature

NASA Astrophysics Data System (ADS)

Panicker, Sudhy S.; Singh, Har Govind; Panda, Sushanta Kumar; Dashwood, Richard

2015-11-01

Automotive industries are very much interested in characterization of formability improvement of aluminum alloys at elevated temperatures before designing tools, heating systems, and processing sequences for fabrication of auto-body panels by warm forming technology. In this study, tensile tests of AA5754-H22 aluminum alloy were carried out at five different temperatures and three different strain rates to investigate the deformation behavior correlating with Cowper-Symonds constitutive equation. Laboratory scale warm forming facilities were designed and fabricated to perform limiting dome height and deep drawing tests to evaluate forming limit strains and drawability of sheet metal at different tool temperatures. The forming limit strain and dome height improved significantly when both the die and punch were heated to 200 °C. Remarkable improvement in deep drawn cup depth was observed when die and punch temperatures were maintained at 200 and 30 °C, respectively, producing a non-isothermal temperature gradient of approximately 93 °C across the blank from flange to center. The forming behavior at different isothermal and non-isothermal conditions were predicted successfully using a thermo-mechanical FE model incorporating temperature-dependent properties in Barlat-89 yield criterion coupled with Cowper-Symonds hardening model, and the thinning/failure location in deformed cups were validated implementing the experimental limiting strains as damage model.

The Effect of Premixed Al-Cu Powder on the Stir Zone in Friction Stir Welding of AA3003-H18

NASA Astrophysics Data System (ADS)

Abnar, B.; Kazeminezhad, M.; Kokabi, A. H.

2015-02-01

In this research, 3-mm-thick AA3003-H18 non-heat-treatable aluminum alloy plates were joined by friction stir welding (FSW). It was performed by adding pure Cu and premixed Cu-Al powders at various rotational speeds of 800, 1000, and 1200 rpm and constant traveling speeds of 100 mm/min. At first, the powder was filled into the gap (0.2 or 0.4 mm) between two aluminum alloy plates, and then the FSW process was performed in two passes. The microstructure, mechanical properties, and formation of intermetallic compounds were investigated in both cases of using pure Cu and premixed Al-Cu powders. The results of using pure Cu and premixed Al-Cu powders were compared in the stir zone at various rotational speeds. The copper particle distribution and formation of Al-Cu intermetallic compounds (Al2Cu and AlCu) in the stir zone were desirable using premixed Al-Cu powder into the gap. The hardness values were significantly increased by formation of Al-Cu intermetallic compounds in the stir zone and it was uniform throughout the stir zone when premixed Al-Cu powder was used. Also, longitudinal tensile strength from the stir zone was higher when premixed Al-Cu powder was used instead of pure Cu powder.

Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys

NASA Astrophysics Data System (ADS)

Grujicic, M.; Arakere, G.; Pandurangan, B.; Ochterbeck, J. M.; Yen, C.-F.; Cheeseman, B. A.; Reynolds, A. P.; Sutton, M. A.

2012-09-01

Workpiece material flow and stirring/mixing during the friction stir welding (FSW) process are investigated computationally. Within the numerical model of the FSW process, the FSW tool is treated as a Lagrangian component while the workpiece material is treated as an Eulerian component. The employed coupled Eulerian/Lagrangian computational analysis of the welding process was of a two-way thermo-mechanical character (i.e., frictional-sliding/plastic-work dissipation is taken to act as a heat source in the thermal-energy balance equation) while temperature is allowed to affect mechanical aspects of the model through temperature-dependent material properties. The workpiece material (AA5059, solid-solution strengthened and strain-hardened aluminum alloy) is represented using a modified version of the classical Johnson-Cook model (within which the strain-hardening term is augmented to take into account for the effect of dynamic recrystallization) while the FSW tool material (AISI H13 tool steel) is modeled as an isotropic linear-elastic material. Within the analysis, the effects of some of the FSW key process parameters are investigated (e.g., weld pitch, tool tilt-angle, and the tool pin-size). The results pertaining to the material flow during FSW are compared with their experimental counterparts. It is found that, for the most part, experimentally observed material-flow characteristics are reproduced within the current FSW-process model.

Study on the rheoformability of semi-solid 7075 wrought aluminum alloy using seed process =

NASA Astrophysics Data System (ADS)

Zhao, Qinfu

Semisolid metal forming is becoming more and more attractive in the foundry industry due to its low cost and easy operation to produce high quality near-net-shape components. Over the past years, semisolid forming technique is mainly applied on the casting aluminum alloys due to their superior castability because of low melting temperature and viscosity. In semisolid forming field, thixoforming has been majorly used which involves of reheating the billet into semisolid state followed by casting process. Rheocasting is a more economic semisolid processing compared to thixoforming, which the semisolid billet is produced directly from liquid phase. The SEED process is one of reliable rheocasting techniques to produce high quality semisolid billets. To produce high quality semisolid billets, their unique rheological properties have been the most important issue need to be fully investigated. The aim of present project is to produce high quality semisolid AA7075 billets by SEED process and analyze their rheological properties under various process conditions. The effect of the SEED processing parameters and grain refiners on the semisolid microstructure and rheoformability were investigated. The deformation and rheological behavior of the semisolid billets of AA7075 base and its grain-refined alloys were studied using parallel-plate viscometer. In the first part, the evolution of liquid fraction to temperature of semisolid AA7075 alloy was investigated using Differential Scanning Calorimetry (DSC). It was found that the liquidus and solidus temperature of AA7075 alloy were 631 °C and 490°C respectively. And the corresponding temperatures of solid fraction of 40% and 60% were 622°C and 610°C, which was recognized as the temperature window for semisolid forming of this alloy. In the second part, the semisolid slurries were rheocasted using SEED technology and the effect of the SEED process parameters like swirling frequency and demolding temperature on evolution of microstructure was studied. It was found that the swirling frequency has a strong influence on the mean grain size and morphology of primary alpha-Al particles. With increasing swirling frequency, the mean size of alpha-Al particles first decreased significantly and then kept constant or increased slightly, due to the fragment and aggregation of solid particles. Microstructures also revealed that the alpha-Al particles tend to transform from dendrite-like to rosette-like to globular-like morphology due to the stirring movement. In the third part, the effects of TiB2 and Zr on the microstructure of semisolid AA7075 alloy were investigated. The microstructure observation and the intermetallic phase identification were carried out by optical microscopy equipped with Clemex analyzer and scanning electron microscopy (SEM). The mean size of primary alpha-Al particles decreases from more than 110 mum to less than 90 mum and the morphology changes from dendritic-like to globular-like with the addition of TiB2. With the addition of Zr or Zr + TiB 2, the mean size and morphology of primary alpha-Al particles didn't show significant modification. Furthermore, the addition of TiB2 shows significant refinement on three intermetallic phases (Mg(Zn,Cu,Al) 2, Fe-rich Al(Fe,Mn)Si and Mg2Si. All the intermetallic phases become finer in size and more uniform distribution among the grains. Finally, the rheological behavior and microstructure of deformed semisolid billets of AA7075 base and grain-refined alloys were investigated using parallel-plate viscometer. Images analysis shows that liquid segregates from center to edge of the billet during compression and with increasing temperature the liquid segregation becomes more significant. The apparent viscosity of two alloys decreases with the increasing shear rate, indicating shear thinning behavior. Shear rate jump phenomenon (first increase and then decrease) occurred at lower solid fraction, reaching a maximum shear rate value. The whole compression processing is divided into two parts: shear rate increasing part and shear rate decreasing part. For higher solid fraction, the shear rate decreases continuously and slowly. The attainable maximum shear rate value increases with the decreasing solid fraction. During the shear rate decreasing part, at any given shear rate the viscosity increases with the increasing solid fraction. The comparison of the viscosity of two alloys indicated that the TiB2-refined AA7075 alloy has lower viscosity (shear rate decreasing part) due to small grain size and globular grain shape. In addition, the grain refinement significantly expands the solid fraction range of good rheoformability from 42%-48% for the base alloy to 42%-55% for the refined alloy.

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.

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.

Dry sliding behavior of aluminum alloy 8011 with 12% fly ash composites

NASA Astrophysics Data System (ADS)

Magibalan, S.; Senthilkumar, P.; Palanivelu, R.; Senthilkumar, C.; Shivasankaran, N.; Prabu, M.

2018-05-01

This research focused on the fabrication of aluminum alloy 8011 with 12% fly ash (FA) composite (AA8011%–12% FA) using the stir casting method. A three-level central composite design experiment was developed using response surface methodology with various parameters such as load, time, and sliding velocity varied in the range of 5 to 15 N, 5 to 15 min, and 1.5 to 4.5 m.s‑1, respectively. Dry sliding wear tests were performed as per the experimental design using a pin on disc at room temperature. The obtained regression result indicated that the developed model performed well in relating the wear process parameters and predicted the wear behavior of the composite. The surface plot showed that the wear rate increases with increase in load, time, and sliding velocity. Hardness was evaluated by Vickers hardness testing machine. Moreover, the surface morphology of the worn-out composite was examined using a scanning electron microscope.

Non-destructive identification of unknown minor phases in polycrystalline bulk alloys using three-dimensional X-ray diffraction

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

Yang, Yiming, E-mail: yangyiming1988@outlook.com

Minor phases make considerable contributions to the mechanical and physical properties of metals and alloys. Unfortunately, it is difficult to identify unknown minor phases in a bulk polycrystalline material using conventional metallographic methods. Here, a non-destructive method based on three-dimensional X-ray diffraction (3DXRD) is developed to solve this problem. Simulation results demonstrate that this method is simultaneously able to identify minor phase grains and reveal their positions, orientations and sizes within bulk alloys. According to systematic simulations, the 3DXRD method is practicable for an extensive sample set, including polycrystalline alloys with hexagonal, orthorhombic and cubic minor phases. Experiments were alsomore » conducted to confirm the simulation results. The results for a bulk sample of aluminum alloy AA6061 show that the crystal grains of an unexpected γ-Fe (austenite) phase can be identified, three-dimensionally and nondestructively. Therefore, we conclude that the 3DXRD method is a powerful tool for the identification of unknown minor phases in bulk alloys belonging to a variety of crystal systems. This method also has the potential to be used for in situ observations of the effects of minor phases on the crystallographic behaviors of alloys. - Highlights: •A method based on 3DXRD is developed for identification of unknown minor phase. •Grain position, orientation and size, is simultaneously acquired. •A systematic simulation demonstrated the applicability of the proposed method. •Experimental results on a AA6061 sample confirmed the practicability of the method.« less

Effect of pin tool design on the material flow of dissimilar AA7075-AA6061 friction stir welds

NASA Astrophysics Data System (ADS)

Hasan, Mohammed M.; Ishak, M.; Rejab, M. R. M.

2017-10-01

Tool design is the most influential aspect in the friction stir welding (FSW) technology. Influence of pin tool geometry on material flow pattern are studied in this work during the FSW of dissimilar AA7075 and AA6061 aluminium alloys. Three truncated pin tool profiles (threaded, threaded with single flat, and unthreaded with single flat) were used to prepare the weldments. The workpieces were joined using a custom-made clamping system under 1100 rpm of spindle speed, 300 mm/min of traverse rate and 3° of tilt angle. The metallographic analysis showed that defect-free welds can be produced using the three pin tools with significant changes in the mixing stir zone structure. The results declared that the introducing of the flat on the cone of the probe deviates the pattern of the onion rings without changing the chemical composition of the created layers. This in turn improves the hardness distribution and tensile strength of the welded joint. It was also noted that both heat affected zone (HAZ) and thermal-mechanical affected zone (TMAZ) are similar in composition to their corresponding base materials (BM).

Mechanisms of fatigue crack retardation following single tensile overloads in powder metallurgy aluminum alloys

NASA Technical Reports Server (NTRS)

Bray, G. H.; Reynolds, A. P.; Starke, E. A., Jr.

1992-01-01

In ingot metallurgy (IM) alloys, the number of delay cycles following a single tensile overload typically increases from a minimum at an intermediate baseline stress intensity range, Delta-K(B), with decreasing Delta-K(B) approaching threshold and increasing Delta-K(B) approaching unstable fracture to produce a characteristic 'U' shaped curve. Two models have been proposed to explain this behavior. One model is based on the interaction between roughness and plasticity-induced closure, while the other model only utilizes plasticity-induced closure. This article examines these models, using experimental results from constant amplitude and single overload fatigue tests performed on two powder metallurgy (PM) aluminum alloys, AL-905XL and AA 8009. The results indicate that the 'U'-shaped curve is primarily due to plasticity-induced closure, and that the plasticity-induced retardation effect is through-thickness in nature, occurring in both the surface and interior regions. However, the retardation effect is greater at the surface, because the increase in plastic strain at the crack tip and overload plastic zone size are larger in the plane-stress surface regions than in the plane-strain interior regions. These results are not entirely consistent with either of the proposed models.

The influence of surface friction on the AA2024 microstructure

NASA Astrophysics Data System (ADS)

Eliseev, A. A.; Kolubaev, E. A.; Fortuna, S. V.

2017-12-01

This work is devoted to the study of the effect of sliding at velocities close to those achieved during friction stir welding or friction drilling on the microstructural evolution of 2024 aluminum alloy. The distribution of both solid solution grains and intermetallic precipitates is analyzed. No layers of recrystallized grains depleted by precipitates, which is a common finding in FSW or friction drilling, are found below the worn surface independently of the sliding velocity. A small precipitate content and size changes alone are observed.

Seal Integrity of Selected Fuzes as Measured by Three Leak Test Methods

DTIC Science & Technology

1976-09-01

the worst fuze from the seal standpoint. The M503A-2 fuze body is made from a cast aluminum alloy . The casting process leaves voids which, after...leak resistance of the joint. WDU4A/A The design of this fuze depends upon ultrasonic welding to seal lid to case. The specified leak test merely...test is probably one of the better leakage tests from an effectiveness standpoint. However, from lot quantities of 690 and 480, reject rates of 20% were

Effect of Repair Welding on Electrochemical Corrosion and Stress Corrosion Cracking Behavior of TIG Welded AA2219 Aluminum Alloy in 3.5 Wt Pct NaCl Solution

NASA Astrophysics Data System (ADS)

Venugopal, A.; Sreekumar, K.; Raja, V. S.

2010-12-01

The stress corrosion cracking (SCC) behavior of AA2219 aluminum alloy in the as-welded (AW) and repair-welded (RW) conditions was examined and compared with that of the base metal (BM) in 3.5 wt pct NaCl solution using the slow strain rate technique (SSRT). The reduction in ductility was used as a parameter to evaluate the SCC susceptibility of both BM and welded joints. The results show that the ductility ratio ( ɛ NaCl/( ɛ air)) of the BM was close to one (0.97) and reduced to 0.9 for the AW joint. This value further reduced to 0.77 after carrying out one repair welding operation. However, the RW specimen exhibited higher ductility than the single-weld specimens even in 3.5 wt pct NaCl solution. SSRT results obtained using pre-exposed samples followed by post-test metallographic observations clearly showed localized pitting corrosion along the partially melted zone (PMZ), signifying that the reduction in ductility ratio of both the AW and RW joints was more due to mechanical overload failure, caused by the localized corrosion and a consequent reduction in specimen thickness, than due to SCC. Also, the RW joint exhibited higher ductility than the AW joint both in air and the environment, although SCC index (SI) for the former is lower than that of the latter. Fractographic examination of the failed samples, in general, revealed a typical ductile cracking morphology for all the base and welded joints, indicating the good environmental cracking resistance of this alloy. Microstructural examination and polarization tests further demonstrate grain boundary melting along the PMZ, and that provided the necessary electrochemical condition for the preferential cracking on that zone of the weldment.

An analytical and experimental study of the behavior of semi-infinite metal targets under hypervelocity impact

NASA Technical Reports Server (NTRS)

Chakrapani, B.; Rand, J. L.

1971-01-01

The material strength and strain rate effects associated with the hypervelocity impact problem were considered. A yield criterion involving the second and third invariants of the stress deviator and a strain rate sensitive constitutive equation were developed. The part of total deformation which represents change in shape is attributable to the stress deviator. Constitutive equation is a means for analytically describing the mechanical response of a continuum under study. The accuracy of the yield criterion was verified utilizing the published two and three dimensional experimental data. The constants associated with the constitutive equation were determined from one dimensional quasistatic and dynamic experiments. Hypervelocity impact experiments were conducted on semi-infinite targets of 1100 aluminum, 6061 aluminum alloy, mild steel, and commercially pure lead using spherically shaped and normally incident pyrex projectiles.

Property Criteria for Automotive Al-Mg-Si Sheet Alloys

PubMed Central

Prillhofer, Ramona; Rank, Gunther; Berneder, Josef; Antrekowitsch, Helmut; Uggowitzer, Peter J.; Pogatscher, Stefan

2014-01-01

In this study, property criteria for automotive Al-Mg-Si sheet alloys are outlined and investigated in the context of commercial alloys AA6016, AA6005A, AA6063 and AA6013. The parameters crucial to predicting forming behavior were determined by tensile tests, bending tests, cross-die tests, hole-expansion tests and forming limit curve analysis in the pre-aged temper after various storage periods following sheet production. Roping tests were performed to evaluate surface quality, for the deployment of these alloys as an outer panel material. Strength in service was also tested after a simulated paint bake cycle of 20 min at 185 °C, and the corrosion behavior was analyzed. The study showed that forming behavior is strongly dependent on the type of alloy and that it is influenced by the storage period after sheet production. Alloy AA6016 achieves the highest surface quality, and pre-ageing of alloy AA6013 facilitates superior strength in service. Corrosion behavior is good in AA6005A, AA6063 and AA6016, and only AA6013 shows a strong susceptibility to intergranular corrosion. The results are discussed below with respect to the chemical composition, microstructure and texture of the Al-Mg-Si alloys studied, and decision-making criteria for appropriate automotive sheet alloys for specific applications are presented. PMID:28788119

Casting Characteristics of High Cerium Content Aluminum Alloys

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

Weiss, D; Rios, O R; Sims, Z C

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

Cast B2-phase iron-aluminum alloys with improved fluidity

DOEpatents

Maziasz, Philip J.; Paris, Alan M.; Vought, Joseph D.

2002-01-01

Systems and methods are described for iron aluminum alloys. A composition includes iron, aluminum and manganese. A method includes providing an alloy including iron, aluminum and manganese; and processing the alloy. The systems and methods provide advantages because additions of manganese to iron aluminum alloys dramatically increase the fluidity of the alloys prior to solidification during casting.

Anisotropic effects on constitutive model parameters of aluminum alloys

NASA Astrophysics Data System (ADS)

Brar, Nachhatter S.; Joshi, Vasant S.

2012-03-01

Simulation of low velocity impact on structures or high velocity penetration in armor materials heavily rely on constitutive material models. Model constants are determined from tension, compression or torsion stress-strain at low and high strain rates at different temperatures. These model constants are required input to computer codes (LS-DYNA, DYNA3D or SPH) to accurately simulate fragment impact on structural components made of high strength 7075-T651 aluminum alloy. Johnson- Cook model constants determined for Al7075-T651 alloy bar material failed to simulate correctly the penetration into 1' thick Al-7075-T651plates. When simulation go well beyond minor parameter tweaking and experimental results show drastically different behavior it becomes important to determine constitutive parameters from the actual material used in impact/penetration experiments. To investigate anisotropic effects on the yield/flow stress of this alloy quasi-static and high strain rate tensile tests were performed on specimens fabricated in the longitudinal "L", transverse "T", and thickness "TH" directions of 1' thick Al7075 Plate. While flow stress at a strain rate of ~1/s as well as ~1100/s in the thickness and transverse directions are lower than the longitudinal direction. The flow stress in the bar was comparable to flow stress in the longitudinal direction of the plate. Fracture strain data from notched tensile specimens fabricated in the L, T, and Thickness directions of 1' thick plate are used to derive fracture constants.

Liquid Film Migration in Warm Formed Aluminum Brazing Sheet

NASA Astrophysics Data System (ADS)

Benoit, M. J.; Whitney, M. A.; Wells, M. A.; Jin, H.; Winkler, S.

2017-10-01

Warm forming has previously proven to be a promising manufacturing route to improve formability of Al brazing sheets used in automotive heat exchanger production; however, the impact of warm forming on subsequent brazing has not previously been studied. In particular, the interaction between liquid clad and solid core alloys during brazing through the process of liquid film migration (LFM) requires further understanding. Al brazing sheet comprised of an AA3003 core and AA4045 clad alloy, supplied in O and H24 tempers, was stretched between 0 and 12 pct strain, at room temperature and 523K (250 °C), to simulate warm forming. Brazeability was predicted through thermal and microstructure analysis. The rate of solid-liquid interactions was quantified using thermal analysis, while microstructure analysis was used to investigate the opposing processes of LFM and core alloy recrystallization during brazing. In general, liquid clad was consumed relatively rapidly and LFM occurred in forming conditions where the core alloy did not recrystallize during brazing. The results showed that warm forming could potentially impair brazeability of O temper sheet by extending the regime over which LFM occurs during brazing. No change in microstructure or thermal data was found for H24 sheet when the forming temperature was increased, and thus warm forming was not predicted to adversely affect the brazing performance of H24 sheet.

Tensile Properties of Friction Stir Welded Joints of AA 2024-T6 Alloy at Different Welding Speeds

NASA Astrophysics Data System (ADS)

Avula, Dhananjayulu; Devuri, Venkateswarlu; Cheepu, Muralimohan; Dwivedi, Dheerendra Kumar

2018-03-01

The influence of welding speed on the friction stir welded joint properties of hardness, tensile properties, defects and microstructure characterization are studied in the present study. The friction stir welding was conducted on AA2014-T6 heat treated alloy with 5 mm thickness plate in butt joint configuration. The welding speed was varied from 8 mm/min to 120 mm/min at the fixed travel speed and load conditions. It is observed that the welding speeds at higher rate with wide range can be possible to weld this alloy at higher rates of tool revolution suggesting that the inherent capability of friction stir welding technique for aluminum 2014 alloys. The strength of the joints gradually increases with enhancing of welding speed. The micro structural observations exhibited the formation of equiaxed grains in the stir zone and slightly in the thermo-mechanically affected zone. In addition, the size of the grains decreases with increase in welding speed owing to the presence of low heat input. Hence the hardness of the joints slightly increased in the stir zones over the other zones of the weld nugget. The joint strength initially increases with the welding speed and starts to decreases after reaching to the maximum value. The relationship between the welding conditions and friction stir welded joint properties has been discussed.

Method for welding beryllium

DOEpatents

Dixon, Raymond D.; Smith, Frank M.; O'Leary, Richard F.

1997-01-01

A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon.

Method for welding beryllium

DOEpatents

Dixon, R.D.; Smith, F.M.; O`Leary, R.F.

1997-04-01

A method is provided for joining beryllium pieces which comprises: depositing aluminum alloy on at least one beryllium surface; contacting that beryllium surface with at least one other beryllium surface; and welding the aluminum alloy coated beryllium surfaces together. The aluminum alloy may be deposited on the beryllium using gas metal arc welding. The aluminum alloy coated beryllium surfaces may be subjected to elevated temperatures and pressures to reduce porosity before welding the pieces together. The aluminum alloy coated beryllium surfaces may be machined into a desired welding joint configuration before welding. The beryllium may be an alloy of beryllium or a beryllium compound. The aluminum alloy may comprise aluminum and silicon. 9 figs.

Feasibility study of tungsten as a diffusion barrier between nickel-chromium-aluminum and Gamma/Gamma prime - Delta eutectic alloys

NASA Technical Reports Server (NTRS)

Young, S. G.; Zellars, G. R.

1978-01-01

Coating systems proposed for potential use on eutectic alloy components in high-temperature gas turbine engines were studied with emphasis on deterioration of such systems by diffusion. A 1-mil thick W sheet was placed between eutectic alloys and a NiCrAl layer. Layered test specimens were aged at 1100 C for as long as long as 500 hours. Without the W barrier, the delta phase of the eutectic deteriorated by diffusion of Nb into the NiCrAl. Insertion of the W barrier stopped the diffusion of Nb from delta. Chromium diffusion from the NiCrAl into the gamma/gamma prime phase of the eutectic was greatly reduced by the barrier. However, the barrier thickness decreased with time; and W diffused into both the NiCrAl and the eutectic. When the delta platelets were alined parallel to the NiCrAl layer, rather than perpendicular, diffusion into the eutectic was reduced.

Statistical and Graphical Assessment of Circumferential and Radial Hardness Variation of AISI 4140, AISI 1020 and AA 6082 Aluminum Alloy

PubMed Central

Al-Khalid, Hamad; Alaskari, Ayman; Oraby, Samy

2011-01-01

Hardness homogeneity of the commonly used structural ferrous and nonferrous engineering materials is of vital importance in the design stage, therefore, reliable information regarding material properties homogeneity should be validated and any deviation should be addressed. In the current study the hardness variation, over wide spectrum radial locations of some ferrous and nonferrous structural engineering materials, was investigated. Measurements were performed over both faces (cross-section) of each stock bar according to a pre-specified stratified design, ensuring the coverage of the entire area both in radial and circumferential directions. Additionally the credibility of the apparatus and measuring procedures were examined through a statistically based calibration process of the hardness reference block. Statistical and response surface graphical analysis are used to examine the nature, adequacy and significance of the measured hardness values. Calibration of the apparatus reference block proved the reliability of the measuring system, where no strong evidence was found against the stochastic nature of hardness measures over the various stratified locations. Also, outlier elimination procedures were proved to be beneficial only at fewer measured points. Hardness measurements showed a dispersion domain that is within the acceptable confidence interval. For AISI 4140 and AISI 1020 steels, hardness is found to have a slight decrease trend as the diameter is reduced, while an opposite behavior is observed for AA 6082 aluminum alloy. However, no definite significant behavior was noticed regarding the effect of the sector sequence (circumferential direction). PMID:28817030

Statistical and Graphical Assessment of Circumferential and Radial Hardness Variation of AISI 4140, AISI 1020 and AA 6082 Aluminum Alloy.

PubMed

Al-Khalid, Hamad; Alaskari, Ayman; Oraby, Samy

2011-12-23

Hardness homogeneity of the commonly used structural ferrous and nonferrous engineering materials is of vital importance in the design stage, therefore, reliable information regarding material properties homogeneity should be validated and any deviation should be addressed. In the current study the hardness variation, over wide spectrum radial locations of some ferrous and nonferrous structural engineering materials, was investigated. Measurements were performed over both faces (cross-section) of each stock bar according to a pre-specified stratified design, ensuring the coverage of the entire area both in radial and circumferential directions. Additionally the credibility of the apparatus and measuring procedures were examined through a statistically based calibration process of the hardness reference block. Statistical and response surface graphical analysis are used to examine the nature, adequacy and significance of the measured hardness values. Calibration of the apparatus reference block proved the reliability of the measuring system, where no strong evidence was found against the stochastic nature of hardness measures over the various stratified locations. Also, outlier elimination procedures were proved to be beneficial only at fewer measured points. Hardness measurements showed a dispersion domain that is within the acceptable confidence interval. For AISI 4140 and AISI 1020 steels, hardness is found to have a slight decrease trend as the diameter is reduced, while an opposite behavior is observed for AA 6082 aluminum alloy. However, no definite significant behavior was noticed regarding the effect of the sector sequence (circumferential direction).

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.

Mitigating Intergranular Stress Corrosion Cracking in Age-Hardenable Al-Zn-Mg-Cu Alloys

NASA Astrophysics Data System (ADS)

Ajay Krishnan, M.; Raja, V. S.; Shukla, Shweta; Vaidya, S. M.

2018-04-01

This article reports an attempt to develop high-strength aluminum alloys of 7xxx series resistant to intergranular stress corrosion cracking (SCC). A novel aging technique reported in this work exhibited improved strength levels (as high as 100 MPa to that of conventional overaged temper for AA 7050) with significant resistance to SCC measured even at a low strain rate (10-7 s-1) in 3.5 wt pct NaCl. The novel aging heat treatment produced a microstructure that is finer and dense enough in the matrix to impart strength, whereas it is enriched with Cu on the grain boundaries to impart SCC resistance. A detailed explanation for the enhanced strength and SCC resistance is discussed.

Prediction of the bending behavior after pre-strain of an aluminum alloy

NASA Astrophysics Data System (ADS)

Pradeau, A.; Thuillier, S.; Yoon, J. W.

2016-10-01

The present work is focused on the modeling of sheet metal mechanical behavior up to rupture, including anisotropy and hardening. The mechanical behavior of an AA6016 alloy was characterized at room temperature in tension, simple shear and hydraulic bulging. The initial anisotropy was described with the Yld2004-18p yield criterion coupled to a mixed hardening law. Concerning rupture, an uncoupled phenomenological criterion of Mohr-Coulomb type will be used. For the material parameter identification, an inverse methodology was used with the objective of reducing the gap between experimental and numerical data. Finally, validation of the results was performed on bending tests with different amplitudes of tension pre-strain in order to reach or not rupture in the bent area.

Mitigating Intergranular Stress Corrosion Cracking in Age-Hardenable Al-Zn-Mg-Cu Alloys

NASA Astrophysics Data System (ADS)

Ajay Krishnan, M.; Raja, V. S.; Shukla, Shweta; Vaidya, S. M.

2018-06-01

This article reports an attempt to develop high-strength aluminum alloys of 7xxx series resistant to intergranular stress corrosion cracking (SCC). A novel aging technique reported in this work exhibited improved strength levels (as high as 100 MPa to that of conventional overaged temper for AA 7050) with significant resistance to SCC measured even at a low strain rate (10-7 s-1) in 3.5 wt pct NaCl. The novel aging heat treatment produced a microstructure that is finer and dense enough in the matrix to impart strength, whereas it is enriched with Cu on the grain boundaries to impart SCC resistance. A detailed explanation for the enhanced strength and SCC resistance is discussed.

Effect of the Microstructure on Diffusion Bonded AA5083, AA6082 and AA7075 Aluminium Alloys

NASA Astrophysics Data System (ADS)

Venugopal, S.; Mahendran, G.

2018-05-01

Rolled plates of aluminium alloys AA5083, AA6082 and AA7075 of 5 mm thickness are joined by diffusion bonding at varied parameters. The microstructure evolution of AA5083, AA6082 and AA7075 aluminium alloys is characterized by Transmission Electron Microscopy (TEM). Metallurgical investigations and mechanical tests are also performed to correlate the results of the TEM investigations with the mechanical properties of the produced diffusion bonded joints. It is observed that the bonding and shear strength of the alloys increase with the increase in bonding temperature, due to the diffusion of micro-constituents in the interface. High temperature enhances the uniform distribution of secondary phase particles and reduces pore formation/defects in the bonded joints.

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)

IEC 61267: Feasibility of type 1100 aluminium and a copper/aluminium combination for RQA beam qualities.

PubMed

Leong, David L; Rainford, Louise; Zhao, Wei; Brennan, Patrick C

2016-01-01

In the course of performance acceptance testing, benchmarking or quality control of X-ray imaging systems, it is sometimes necessary to harden the X-ray beam spectrum. IEC 61267 specifies materials and methods to accomplish beam hardening and, unfortunately, requires the use of 99.9% pure aluminium (Alloy 1190) for the RQA beam quality, which is expensive and difficult to obtain. Less expensive and more readily available filters, such as Alloy 1100 (99.0% pure) aluminium and copper/aluminium combinations, have been used clinically to produce RQA series without rigorous scientific investigation to support their use. In this paper, simulation and experimental methods are developed to determine the differences in beam quality using Alloy 1190 and Alloy 1100. Additional simulation investigated copper/aluminium combinations to produce RQA5 and outputs from this simulation are verified with laboratory tests using different filter samples. The results of the study demonstrate that although Alloy 1100 produces a harder beam spectrum compared to Alloy 1190, it is a reasonable substitute. A combination filter of 0.5 mm copper and 2 mm aluminium produced a spectrum closer to that of Alloy 1190 than Alloy 1100 with the added benefits of lower exposures and lower batch variability. Copyright © 2015 Associazione Italiana di Fisica Medica. Published by Elsevier Ltd. All rights reserved.

Shielding gas effect to diffusion activities of magnesium and copper on aluminum clad

NASA Astrophysics Data System (ADS)

Manurung, Charles SP; Napitupulu, Richard AM

2017-09-01

Aluminum is the second most metal used in many application, because of its corrosion resistance. The Aluminum will be damaged in over time if it’s not maintained in good condition. That is important to give protection to the Aluminums surface. Cladding process is one of surface protection methodes, especially for metals. Aluminum clad copper (Al/Cu) or copper clad aluminum (Cu/Al) composite metals have been widely used for many years. These mature protection method and well tested clad metal systems are used industrially in a variety application. The inherent properties and behavior of both copper and aluminum combine to provide unique performance advantages. In this paper Aluminum 2024 series will be covered with Aluminum 1100 series by hot rolling process. Observations will focus on diffusion activities of Mg and Cu that not present on Aluminum 1100 series. The differences of clad material samples is the use of shielding gas during heating before hot rolling process. The metallurgical characteristics will be examined by using optical microscopy. Transition zone from the interface cannot be observed but from Energy Dispersive Spectrometry it’s found that Mg and Cu are diffused from base metal (Al 2024) to the clad metal (Al 1100). Hardness test proved that base metals hardness to interface was decrease.

Effects of aluminum-copper alloy filtration on photon spectra, air kerma rate and image contrast.

PubMed

Gonçalves, Andréa; Rollo, João Manuel Domingos de Almeida; Gonçalves, Marcelo; Haiter Neto, Francisco; Bóscolo, Frab Norberto

2004-01-01

This study evaluated the performance of aluminum-copper alloy filtration, without the original aluminum filter, for dental radiography in terms of x-ray energy spectrum, air kerma rate and image quality. Comparisons of various thicknesses of aluminum-copper alloy in three different percentages were made with aluminum filtration. Tests were conducted on an intra-oral dental x-ray machine and were made on mandible phantom and on step-wedge. Depending on the thickness of aluminum-copper alloy filtration, the beam could be hardened and filtrated. The use of the aluminum-copper alloy filter resulted in reductions in air kerma rate from 8.40% to 47.33%, and indicated the same image contrast when compared to aluminum filtration. Aluminum-copper alloy filtration may be considered a good alternative to aluminum filtration.

Variation of strain rate sensitivity index of a superplastic aluminum alloy in different testing methods

NASA Astrophysics Data System (ADS)

Majidi, Omid; Jahazi, Mohammad; Bombardier, Nicolas; Samuel, Ehab

2017-10-01

The strain rate sensitivity index, m-value, is being applied as a common tool to evaluate the impact of the strain rate on the viscoplastic behaviour of materials. The m-value, as a constant number, has been frequently taken into consideration for modeling material behaviour in the numerical simulation of superplastic forming processes. However, the impact of the testing variables on the measured m-values has not been investigated comprehensively. In this study, the m-value for a superplastic grade of an aluminum alloy (i.e., AA5083) has been investigated. The conditions and the parameters that influence the strain rate sensitivity for the material are compared with three different testing methods, i.e., monotonic uniaxial tension test, strain rate jump test and stress relaxation test. All tests were conducted at elevated temperature (470°C) and at strain rates up to 0.1 s-1. The results show that the m-value is not constant and is highly dependent on the applied strain rate, strain level and testing method.

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

Influence of ECAP temperature on the formability of a particle reinforced 2017 aluminum alloy

NASA Astrophysics Data System (ADS)

Wagner, S.; Härtel, M.; Frint, P.; F-X Wagner, M.

2017-03-01

Severe plastic deformation methods are commonly used to increase the strength of materials by generating ultrafine-grained microstructures. The application of these methods to Al-Cu alloys is, however, difficult because of their poor formability at room temperature. An additional reduction of formability of such alloys occurs when ceramic particles are added as reinforcement: this often triggers shear localization and crack initiation during ECAP. This is the main reason why equal-channel angular pressing (ECAP) of aluminum matrix composites (AMCs) can generally only be performed at elevated temperatures and using ECAP dies with a channel angle larger than 90° (e.g. 120°). In this study we present a brief first report on an alternative approach for the improvement of the formability of an AMC (AA2017, 10 % SiC): ECAP at low temperatures. We show that, using a temperature of -60 °C and a channel angle of 90° (corresponding to an equivalent strain of 1.1), ECAP of the AMC can be successfully performed without material failure. The mechanical properties of the strongly deformed AMC are analyzed by tensile testing. Our results indicate that the increased formability of the AMC at low temperatures can be attributed to the suppression of unstable plastic flow that affects formability at room temperature.

Effects of Different R ratios on Fatigue Crack Growth in Laser Peened Friction Stir Welds

NASA Technical Reports Server (NTRS)

Hatamleh, Omar; Hackel, Lloyd; Forth, Scott

2007-01-01

The influence of laser peening on the fatigue crack growth behavior of friction stir welded (FSW) Aluminum Alloy (AA) 7075-T7351 sheets was investigated. The surface modification resulting from the peening process on the fatigue crack growth of FSW was assessed for two different R ratios. The investigation indicated a significant decrease in fatigue crack growth rates resulting from using laser shock peening compared with unpeened, welded and unwelded specimens. The slower fatigue crack growth rate was attributed to the compressive residual stresses induced by the peening.

AA6082 to DX56-Steel Laser Brazing: Process Parameter-Intermetallic Formation Correlation

NASA Astrophysics Data System (ADS)

Narsimhachary, D.; Pal, S.; Shariff, S. M.; Padmanabham, G.; Basu, A.

2017-09-01

In the present study, laser-brazed AA6082 to DX56-galvanized steel joints were investigated to understand the influence of process parameters on joint strength in terms of intermetallic layer formation. 1.5-mm-thick sheet of aluminum alloy (AA6082-T6) and galvanized steel (DX56) sheet of 0.7 mm thickness were laser-brazed with 1.5-mm-diameter Al-12% Si solid filler wire. During laser brazing, laser power (4.6 kW) and wire feed rate (3.4 m/min) were kept constant with a varying laser scan speed of 3.5, 3, 2.5, 2, 1.5, and 1 m/min. Microstructure of brazed joint reveals epitaxial growth at the aluminum side and intermetallic layer formation at steel interface. Intermetallic layer formation was confirmed by EDS analysis and XRD study. Hardness profile showed hardness drop in filler region, and failure during tensile testing was initiated through the filler region near the steel interface. As per both experimental study and numerical analysis, it was observed that intermetallic layer thickness decreases with increasing brazing speed. Zn vaporization from galvanized steel interface also affected the joint strength. It was found that high laser scan speed or faster cooling rate can be chosen for suppressing intermetallic layer formation or at least decreasing the layer thickness which results in improved mechanical properties.

The adhesion performance of epoxy coating on AA6063 treated in Ti/Zr/V based solution

NASA Astrophysics Data System (ADS)

Zhu, Wen; Li, Wenfang; Mu, Songlin; Yang, Yunyu; Zuo, Xi

2016-10-01

An environment-friendly titanium/zirconium/vanadium-based (Ti/Zr/V) conversion coating was prepared on aluminum alloy 6063 (AA6063). The epoxy powder coatings were applied on the AA6063 samples with/without Ti/Zr/V conversion coatings via electrostatic spraying. The morphology and composition of the conversion coating were studied by scanning electron microscope (SEM) and X-ray photoelectron spectroscopy (XPS), respectively. The surface free energy components of AA6063 samples were measured by a static contact angle measuring device with Owens method. The adhesion properties of the epoxy coating on AA6063 treated with different conversion times were evaluated using a pull-off tester. The Ti/Zr/V conversion coating was mainly composed of metal oxide (TiO2, ZrO2, V2O5, Al2O3, etc.), metal fluoride (ZrF4, AlF3, etc.) and metal organic complex. The formation time of this conversion coating was reduced to 50 s. After such surface treatment, the samples' surface roughness was increased and the contact angle with water was decreased. Both the surface free energy and the work of adhesion were increased. The adhesion strength between the epoxy coating and AA6063 was enhanced significantly.

A Study on Tooling and Its Effect on Heat Generation and Mechanical Properties of Welded Joints in Friction Stir Welding

NASA Astrophysics Data System (ADS)

Tikader, Sujoy; Biswas, Pankaj; Puri, Asit Baran

2018-04-01

Friction stir welding (FSW) has been the most attracting solid state welding process as it serves numerous advantages like good mechanical, metallurgical properties etc. Non weldable aluminium alloys like 5XXX, 7XXX series can be simply joined by this process. In this present study a mathematical model has been developed and experiments were successfully performed to evaluate mechanical properties of FSW on similar aluminium alloys i.e. AA1100 for different process parameters and mainly two kind of tool geometry (straight cylindrical and conical or cylindrical tapered shaped pin with flat shoulder). Tensile strength and micro hardness for different process parameters are reported of the welded plate sample. It was noticed that in FSW of similar alloy with tool made of SS-310 tool steel, friction is the major contributor for the heat generation. It was seen that tool geometry, tool rotational speed, plunging force by the tool and traverse speed have significant effect on tensile strength and hardness of friction stir welded joints.

Solid state welding processes for an oxide dispersion strengthened nickel-chromium-aluminum alloy

NASA Technical Reports Server (NTRS)

Moore, T. J.

1975-01-01

Solid-state welding processes were evaluated for joining TD-NiCrAl (Ni-16Cr-4Al-2ThO2) alloy sheet. Both hot-press and resistance spot welding techniques were successfully applied in terms of achieving grain growth across the bond line. Less success was achieved with a resistance seam welding process. In stress-rupture shear and tensile shear tests of lap joints at 1100 C, most failures occurred in the parent material, which indicates that the weld quality was good and that the welds were not a plane of weakness. The overall weld quality was not as good as previously attained with TD-NiCr, probably because the presence of alumina at the faying surfaces and the developmental TD-NiCrAl sheet, which was not of the quality of the TD-NiCr sheet in terms of surface flatness and dimensional control.

Creep of Refractory Fibers and Modeling of Metal and Ceramic Matrix Composite Creep Behavior

NASA Technical Reports Server (NTRS)

Tewari, S.N.

1995-01-01

Our concentration during this research was on the following subprograms. (1) Ultra high vacuum creep tests on 218, ST300 and WHfC tungsten and MoHfC molybdenum alloy wires, temperature range from 1100 K to 1500 K, creep time of 1 to 500 hours. (2) High temperature vacuum tensile tests on 218, ST300 and WHfC tungsten and MoHfC molybdenum alloy wires. (3) Air and vacuum tensile creep tests on polycrystalline and single crystal alumina fibers, such as alumina-mullite Nextel fiber, yttrium aluminum ganet (YAG) and Saphikon, temperature range from 1150 K to 1470 K, creep time of 2 to 200 hours. (4) Microstructural evaluation of crept fibers, TEM study on the crept metal wires, SEM study on the fracture surface of ceramic fibers. (5) Metal Matrix Composite creep models, based on the fiber creep properties and fiber-matrix interface zone formation.

Composite material reinforced with atomized quasicrystalline particles and method of making same

DOEpatents

Biner, Suleyman B.; Sordelet, Daniel J.; Lograsso, Barbara K.; Anderson, Iver E.

1998-12-22

A composite material comprises an aluminum or aluminum alloy matrix having generally spherical, atomized quasicrystalline aluminum-transition metal alloy reinforcement particles disposed in the matrix to improve mechanical properties. A composite article can be made by consolidating generally spherical, atomized quaiscrystalline aluminum-transition metal alloy particles and aluminum or aluminum alloy particles to form a body that is cold and/or hot reduced to form composite products, such as composite plate or sheet, with interfacial bonding between the quasicrystalline particles and the aluminum or aluminum alloy matrix without damage (e.g. cracking or shape change) of the reinforcement particles. The cold and/or hot worked compositehibits substantially improved yield strength, tensile strength, Young's modulus (stiffness).

Estimation of dislocations density and distribution of dislocations during ECAP-Conform process

NASA Astrophysics Data System (ADS)

Derakhshan, Jaber Fakhimi; Parsa, Mohammad Habibi; Ayati, Vahid; Jafarian, Hamidreza

2018-01-01

Dislocation density of coarse grain aluminum AA1100 alloy (140 µm) that was severely deformed by Equal Channel Angular Pressing-Conform (ECAP-Conform) are studied at various stages of the process by electron backscattering diffraction (EBSD) method. The geometrically necessary dislocations (GNDs) density and statistically stored dislocations (SSDs) densities were estimate. Then the total dislocations densities are calculated and the dislocation distributions are presented as the contour maps. Estimated average dislocations density for annealed of about 2×1012 m-2 increases to 4×1013 m-2 at the middle of the groove (135° from the entrance), and they reach to 6.4×1013 m-2 at the end of groove just before ECAP region. Calculated average dislocations density for one pass severely deformed Al sample reached to 6.2×1014 m-2. At micrometer scale the behavior of metals especially mechanical properties largely depend on the dislocation density and dislocation distribution. So, yield stresses at different conditions were estimated based on the calculated dislocation densities. Then estimated yield stresses were compared with experimental results and good agreements were found. Although grain size of material did not clearly change, yield stress shown intensive increase due to the development of cell structure. A considerable increase in dislocations density in this process is a good justification for forming subgrains and cell structures during process which it can be reason of increasing in yield stress.

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.

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

Hot cracking during welding and casting

NASA Astrophysics Data System (ADS)

Cao, Guoping

Aluminum welds are susceptible to liquation cracking in the partially melted zone (PMZ). Using the multicomponent Scheil model, curves of temperature vs. fraction solid (T-fS) during solidification were calculated for the PMZ and weld metals (WMs). These curves were used to predict the crack susceptibility by checking if the harmful condition of WM fS > PMZ fS exists during PMZ solidification and reduce the susceptibility by minimizing this condition. This approach was tested against full-penetration welds of alloys 7075 and 2024 and it can be used to guide the selection or development of filler metals. Liquation cracking in the PMZ in welds of Al-Si cast alloys was also investigated. The crack susceptibility was evaluated by circular-patch test, and full-penetration welds made with filler metals 1100, 4043, 4047 and 5356. Liquation cracking was significant with filler metals 1100 and 5356 but slight with filler metals 4043 and 4047. In all welds, liquation cracks were completely backfilled, instead of open as in full-penetration welds of wrought alloys 2219 and 6061. The T-fS curves showed that alloy A357 has a much higher fraction liquid for backfilling before PMZ solidification was essentially over. Hot tearing in Mg-xAl-yCa alloys was studied by constrained rod casting (CRC) in a steel mold. The hot tearing susceptibility decreased significantly with increasing Ca content (y) but did not change much with the Al content (x). An instrumented CRC with a steel mold was developed to detect the onset of hot tearing. The secondary phases, eutectic content, solidification path, and freezing range were examined. Hot tearing in Mg-Al-Sr alloys was also studied by CRC in a steel mold. With Mg-(4,6,8)Al-1.5Sr alloys, the hot tearing susceptibility decreased significantly with increasing Al content. With Mg-(4,6,8)Al-3Sr alloys, the trend was similar but not as significant. At the same Al content, the hot tearing susceptibility decreased significantly with increasing Sr content. Instrumented CRC with a steel mold was also used to test hot tearing of Mg-Al-Sr alloys. Cracking occurred at a higher temperature in alloys most susceptible to cracking than in alloys least susceptible.

Modeling of AA5083 Material-Microstructure Evolution During Butt Friction-Stir Welding

NASA Astrophysics Data System (ADS)

Grujicic, M.; Arakere, G.; Yalavarthy, H. V.; He, T.; Yen, C.-F.; Cheeseman, B. A.

2010-07-01

A concise yet a fairly comprehensive overview of the friction stir welding (FSW) process is provided. This is followed by a computational investigation in which FSW behavior of a prototypical solution-strengthened and strain-hardened aluminum alloy, AA5083-H131, is modeled using a fully coupled thermo-mechanical finite-element procedure developed in our prior study. Particular attention is given to proper modeling of the welding work-piece material behavior during the FSW process. Specifically, competition and interactions between plastic-deformation and dynamic-recrystallization processes are considered to properly account for the material-microstructure evolution in the weld nugget zone. The results showed that with proper modeling of the material behavior under high-temperature/severe-plastic-deformation conditions, significantly improved agreement can be attained between the computed and measured post-FSW residual-stress and material-strength distribution results.

Composite material reinforced with atomized quasicrystalline particles and method of making same

DOEpatents

Biner, S.B.; Sordelet, D.J.; Lograsso, B.K.; Anderson, I.E.

1998-12-22

A composite material comprises an aluminum or aluminum alloy matrix having generally spherical, atomized quasicrystalline aluminum-transition metal alloy reinforcement particles disposed in the matrix to improve mechanical properties. A composite article can be made by consolidating generally spherical, atomized quasicrystalline aluminum-transition metal alloy particles and aluminum or aluminum alloy particles to form a body that is cold and/or hot reduced to form composite products, such as composite plate or sheet, with interfacial bonding between the quasicrystalline particles and the aluminum or aluminum alloy matrix without damage (e.g. cracking or shape change) of the reinforcement particles. The cold and/or hot worked composite exhibits substantially improved yield strength, tensile strength, Young`s modulus (stiffness). 3 figs.

Effects of composition and testing conditions on oxidation behavior of four cast commercial nickel-base superalloys

NASA Technical Reports Server (NTRS)

Lowell, C. E.; Probst, H. B.

1974-01-01

Four cast nickel-base superalloys were oxidized at 1000 and 1100 C for times up to 100 hr in static air and a Mach 1 gas stream. The oxidation resistance was judged by weight change, metal thickness loss, depletion-zone formation, and oxide formation and morphology. The alloys which formed mostly nickel aluminate (NiAl2O4) and aluminum oxide (Al2O3) (B-1900, VIA, and to a lesser extent 713C) were more oxidation resistant. Poorer oxidation resistance was associated with the appearance of chromium sesquioxide (Cr2O3) and chromite spinel (738X). Refractory metal content had little effect on oxidation resistance. Refractory metals appeared in the scale as tapiolite (NiM2O6, where M represents the refractory metal). Thermal cycling in static air appeared to supply sufficient data for the evaluation of oxidation resistance, especially for alloys which form oxides of low volatility. For alloys of higher chromium levels with high propensities toward forming a chromium-bearing scale of higher volatility, testing under conditions of high gas velocity is necessary to assess fully the behavior of the alloy.

Wear Resistance Increase by Friction Stir Processing for Partial Magnesium Replacement in Aluminium Alloys

NASA Astrophysics Data System (ADS)

Balos, Sebastian; Labus Zlatanovic, Danka; Janjatovic, Petar; Dramicanin, Miroslav; Rajnovic, Dragan; Sidjanin, Leposava

2018-03-01

In this paper, the influence of friction stir processing (FSP) was evaluated as a way of increasing mechanical properties and a way of replacing the magnesium content in aluminium alloys. FSP was done on AA5754 H111 aluminium alloy, containing 3 % Mg, by using various types of tools and different welding speeds, rotational speeds and tilt angles. Wear test was done against SiC abrasive papers. SiC was used to simulate extreme abrasive wear conditions. The wear test was done on untreated AA5754 specimens, processed AA5754 specimens and untreated AA5083 H111 specimens, the latter containing 4.5 % Mg. AA5083 was chosen as an alternative to AA5754, but with a significantly higher Mg content. Base material microhardness was 60 HV1 and 80 HV1 for AA5754 and AA5083 alloys respectively. To find the effect of FSP on AA5754 alloy, microstructures were studied, mainly grain size in the stir zone. It was found, that an elevated processing and rotational speed, without tilt angle and the tool without a reservoir resulted in an increase in hardness of the AA5754 to 70 HV1, but with the occurrence of tunneling defect and the wear rate of 79.3 mg. Lower FSP parameters and a tilted tool with a reservoir resulted in microhardness of 68 HV1 and wear rate of 68.2 mg without tunneling. These wear values are lower than those obtained with unmodified Al-alloys: AA5754 97.2 mg and AA5083 86.3 mg. An increased wear resistance can be attributed to the combined effect of grain boundary strengthening mechanism and solid solution strengthening, versus only the latter in untreated alloys.

Superior Ballistic Impact Resistance Achieved by the Co-Base Alloy Haynes 25

NASA Technical Reports Server (NTRS)

Hebsur, Mohan G.; Noebe, Ronald D.; Revilock, Duane M.

2003-01-01

The fan case in a jet engine is required to contain a fan blade in the rare event of a blade loss during operation. Because of its function, the fan case is the largest structural component in high-bypass-ratio turbofan engines used in commercial aircraft. Therefore, the use of lighter and stronger materials would be advantageous in most engines and is practically a necessity in the latest generation of high-bypass engines. Small panels, 7 in. wide by 7 in. long, of a number of metallic alloys were impact tested at room temperature with a 0.50-caliber blunt-nose titanium alloy projectile at the NASA Glenn Research Center (ref. 1). These metallic systems included several high-strength aluminum (Al) alloys, Al-based laminates, aluminum metal matrix composites (Al-MMCs), nickel-base superalloys (Inconel 718 and 625), several titanium (Ti) alloys in different heat treated conditions, 304L stainless steel, a stainless-steel-based laminate, and a high strength steel (Nitronic 60). It was determined that a simple Co-base alloy (Haynes 25) had the best impact resistance on an areal weight basis. Haynes 25 was at least 10 percent better than IMI 550, the best titanium alloy tested to date, and it was far superior to other metals, especially at higher impact velocities (greater than 1100 ft/sec). Because this material could be ideal for fan containment applications in supersonic aircraft as a replacement for titanium, impact tests were also conducted at 371 oC and compared with results from alloys tested at elevated temperature under previous programs (i.e., Inconel 718, Ti-6242, M-152, Timetal 21S, and Aeromet 100). Although cobalt-base alloys are used in some high-temperature engine applications, to our knowledge they are not used in any containment systems. Advantages of cobalt over titanium include lower cost, easier processing, better high-temperature strength, and no fire hazard if tip rub occurs. Future plans include testing of lightweight sandwich panels with Haynes 25 as a core material in the form of a foam or lattice block structure and scaling up the current tests by using blade-simulating projectiles impacting large plates and half rings.

Characterization of beta phase growth and experimental validation of long term thermal exposure sensitization of AA5XXX alloys

NASA Astrophysics Data System (ADS)

Zhu, Yakun

The United States Navy has a need for fast, light-weight ships to provide rapid deployment in its operations. Strong and corrosion-resistant aluminum alloys, such as AA5083 (UNS A95083) as well as other AA5XXX alloys, have properties that are well-suited for such applications. However, AA5XXX alloys are susceptible to intergranular corrosion (IGC) and stress corrosion cracking (SCC) because of sensitization which is a consequence of the formation of the grain boundary beta-phase, Al3Mg2, and the anodic dissolution of the beta-phase. Significant research has been performed to measure and understand the effects of time, temperature, stress, and sea water on sensitization and associated intergranular corrosion and stress corrosion cracking under steady-state conditions. In the present work, the behaviors of beta-phase nucleation and growth were characterized using optical and electron microscopy, the relationship between preexisting particles and beta-phase, as well as the effect of different heat treatment times and temperatures on IGC and SCC susceptibility of 5XXX alloys were investigated. Grain boundary beta-phase thickness was measured with high resolution transmission electron microscopy (TEM). The corrosion sensitization susceptibility was evaluated according to the American Society for Testing and Materials (ASTM) standard G67 tests, that is, nitric acid mass-loss testing (NAMLT). Diffusion of Mg is manifested by the thickening of beta-phase along the grainboundary because the grain boundary is considered as the preferential site for beta-phase nucleation. The beta-phase growth rate was monitored using high resolution TEM. The variety of precipitates and their subsequent effects on beta-phase nucleation and growth kinetics was investigated. The existence of various intermetallic particles was observed in both baseline and thermally exposed (70°C and 175°C) samples. These particles are usually either rod-shaped or equiaxed, and rich in Mn, Fe, and Cr. Indexing of lattice planes observed in a few of these particles suggested the composition is Al6Mn or Al6(Mn, Fe, Cr). This research also shows that the beta-phase precipitation occurs between the preexisting Mn rich particles. The basic model for the determination of diffusivity values, the prediction of beta-phase thickness growth, and corrosion sensitization prediction have been improved by new data from this research.

Development and study of aluminum-air electrochemical generator and its main components

NASA Astrophysics Data System (ADS)

Ilyukhina, A. V.; Kleymenov, B. V.; Zhuk, A. Z.

2017-02-01

Aluminum-air power sources are receiving increased attention for applications in portable electronic devices, transportation, and energy systems. This study reports on the development of an aluminum-air electrochemical generator (AA ECG) and provides a technical foundation for the selection of its components, i.e., aluminum anode, gas diffusion cathode, and alkaline electrolyte. A prototype 1.5 kW AA ECG with specific energy of 270 Wh kg-1 is built and tested. The results of this study demonstrate the feasibility of AA ECGs as portable reserve and emergency power sources, as well as power sources for electric vehicles.

Advanced Cast Aluminum Alloys

DTIC Science & Technology

2009-02-01

This production route has demonstrated that aluminum alloys with yield strengths in excess of 690 MPa with good elongation (reportedly 8%) are...series of aluminum alloys have poor-to-fair general corrosion resistance and poor-to-good stress corrosion cracking resistance. Wrought 2519...aluminum alloy has good strength, good ballistic performance, good stress corrosion cracking resistance but only fair general corrosion resistance

Characterization of Nanocrystalline Aluminum Alloy 5083 Powders Produced by Cryogenic Attrition

DTIC Science & Technology

2014-11-01

Characterization of Nanocrystalline Aluminum Alloy 5083 Powders Produced by Cryogenic Attrition by Tiffany Ngo ARL-TN-0643...November 2014 Characterization of Nanocrystalline Aluminum Alloy 5083 Powders Produced by Cryogenic Attrition Tiffany Ngo Weapons and...3. DATES COVERED (From - To) August 2014 4. TITLE AND SUBTITLE Characterization of Nanocrystalline Aluminum Alloy 5083 Powders Produced by

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

Charge-density-shear-moduli relationships in aluminum-lithium alloys.

PubMed

Eberhart, M

2001-11-12

Using the first principles full-potential linear-augmented-Slater-type orbital technique, the energies and charge densities of aluminum and aluminum-lithium supercells have been computed. The experimentally observed increase in aluminum's shear moduli upon alloying with lithium is argued to be the result of predictable changes to aluminum's total charge density, suggesting that simple rules may allow the alloy designer to predict the effects of dilute substitutional elements on alloy elastic response.

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).

A FEM simulation study of the solid state hydrostatic extrusion of PMMA

NASA Astrophysics Data System (ADS)

Costa, André L. M.; Riffel, Douglas B.; Misiolek, Wojciech Z.; Valberg, Henry S.

2018-05-01

Solid state hydrostatic extrusion (SSHE) of polymers below glass transition temperature is used to obtain highly oriented structures. Experimental studies on the SSHE of polymethyl-methacrylate (PMMA) have been made since early eighties but there is no information on internal temperature, stress and strain distribution. In this work we have made 3D FEM simulations of SSHE of PMMA by using the commercial DEFORM package with experimental flow curves and thermal properties from literature. The initial temperature of tooling and workpiece was 90°C, ram speeds were 1.0 and 10.0 mm/min with extrusion ratio R = 3.0. For a comparative analysis, SSHE simulation of the AA7108 aluminum alloy at 400°C was also performed. These ranges of parameters were chosen in order to encompass the parameters found in previously mentioned experiments. The best correlation with experimental hydrostatic pressure was verified for a shear friction coefficient at the material-conical die interface m = 0.50. Force-displacement curve for PMMA presented a constitutive and thermal softening in contrast to a constant force curve for aluminum. The internal temperature in the deformation zone increased in a characteristic "owl's face" profile in contrast to quasi-constant profile of aluminum alloy. In both PMMA and aluminum the stress is hydrostatic inside the container, but the stress profiles are significantly different inside the deformation zone. As expected, the strain and strain-rate profiles are practically the same for the two materials, but the temperature profile has promoted slightly differences in material flow. The velocity gradient from center to surface is higher in PMMA than aluminum. It's supposed that during hydrostatic extrusion solid PMMA has a characteristic thermally-inducted mechanical behavior.

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

NASA Astrophysics Data System (ADS)

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

2016-11-01

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

Ultrasonic assisted hot metal powder compaction.

PubMed

Abedini, Rezvan; Abdullah, Amir; Alizadeh, Yunes

2017-09-01

Hot pressing of metal powders is used in production of parts with similar properties to wrought materials. During hot pressing processes, particle rearrangement, plastic deformation, creep, and diffusion are of the most effective powder densification mechanisms. Applying ultrasonic vibration is thought to result in great rates of densification and therefore higher efficiency of the process is expected. This paper deals with the effects of power ultrasonic on the densification of AA1100 aluminum powder under constant applied stress. The effects of particle size and process temperature on the densification behavior are discussed. The results show that applying ultrasonic vibration leads to an improved homogeneity and a higher relative density. Also, it is found that the effect of ultrasonic vibration is greater for finer particles. Copyright © 2016 Elsevier B.V. All rights reserved.

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.

On Using Homogeneous Polynomials To Design Anisotropic Yield Functions With Tension/Compression Symmetry/Assymetry

NASA Astrophysics Data System (ADS)

Soare, S.; Yoon, J. W.; Cazacu, O.

2007-05-01

With few exceptions, non-quadratic homogeneous polynomials have received little attention as possible candidates for yield functions. One reason might be that not every such polynomial is a convex function. In this paper we show that homogeneous polynomials can be used to develop powerful anisotropic yield criteria, and that imposing simple constraints on the identification process leads, aposteriori, to the desired convexity property. It is shown that combinations of such polynomials allow for modeling yielding properties of metallic materials with any crystal structure, i.e. both cubic and hexagonal which display strength differential effects. Extensions of the proposed criteria to 3D stress states are also presented. We apply these criteria to the description of the aluminum alloy AA2090T3. We prove that a sixth order orthotropic homogeneous polynomial is capable of a satisfactory description of this alloy. Next, applications to the deep drawing of a cylindrical cup are presented. The newly proposed criteria were implemented as UMAT subroutines into the commercial FE code ABAQUS. We were able to predict six ears on the AA2090T3 cup's profile. Finally, we show that a tension/compression asymmetry in yielding can have an important effect on the earing profile.

Launcher Roadmap for the CrVI Substitution of Surface Treatments. Screening of Trivalent-Chromium Conversion Solutions and First Promising Results for Repair Applications on Aluminium Alloys

NASA Astrophysics Data System (ADS)

Debout, Vincent; Pettier, Sophie

2014-06-01

Airbus Defence and Space, Space System is involved in a global roadmap for launchers in order to substitute hexavalent chromium (CrVI) and Cadmium in the current surface treatments on metallic structures.Within this framework, a screening of trivalent chromium (CrIII) conversion solutions for touch-up applications has been carried out since this step is crucial to perform local application or to repair minor damages on launcher structures but it leads to higher risks of exposure for the workers.Three commercial CrIII conversion solutions have been evaluated on high performance aluminum alloys such as AA2024 T3 and AA7175 T7351 that are often used as structural materials.This preliminary investigation highlights the effect of surface preparation, rinsing and conversion process on the final corrosion performance of conversion coatings (CCs). The results are also discussed in terms of visual aspect and adhesion with new Cr-free primers.Two operating sets of parameters are identified with promising results that represent the first steps towards the development of a new Cr-free touch-up process.

Evaluation of dip and spray coating techniques in corrosion inhibition of AA2024 alloy using a silicon/zirconium sol-gel film as coating

NASA Astrophysics Data System (ADS)

Garcia, R. B. R.; Silva, F. S.; Kawachi, E. Y.

2017-02-01

For corrosion protection of aluminum alloy AA2024 -T3 a silicon/zirconium films were obtained via sol-gel process, prepared from tetraethoxysilane and zirconium acetate, in acid medium with a 5 wt% of nonionic surfactant in order to replace the pre-treatment based on chromium conversion coatings. A homogeneous film was obtained and deposited, at low viscosity condition of the sol (˜10cP), by dip and spray coating techniques. The films morphology was evaluated by Scanning Electron Microscopy (SEM), and to know more about the used deposition methodology, the deposited mass and the film thickness were measured. The corrosion protection efficiency of deposited films was evaluated by potentiodynamic polarization. The film deposition by both dip and spray coatings were effective for the deposition of a homogeneous film layer, and the results showed the thickness is directly related with the deposited mass, and the film deposited by spray technique presented the lower value. Potentiodynamic polarization indicated that the film deposited by spray coating apparently has a better inert ceramic film due the polarization resistance increased around 57% against 27 and 14% of dip coating samples (4 and 1 layer, respectively).

Multi-Objective Optimization of Friction Stir Welding Process Parameters of AA6061-T6 and AA7075-T6 Using a Biogeography Based Optimization Algorithm

PubMed Central

Tamjidy, Mehran; Baharudin, B. T. Hang Tuah; Paslar, Shahla; Matori, Khamirul Amin; Sulaiman, Shamsuddin; Fadaeifard, Firouz

2017-01-01

The development of Friction Stir Welding (FSW) has provided an alternative approach for producing high-quality welds, in a fast and reliable manner. This study focuses on the mechanical properties of the dissimilar friction stir welding of AA6061-T6 and AA7075-T6 aluminum alloys. The FSW process parameters such as tool rotational speed, tool traverse speed, tilt angle, and tool offset influence the mechanical properties of the friction stir welded joints significantly. A mathematical regression model is developed to determine the empirical relationship between the FSW process parameters and mechanical properties, and the results are validated. In order to obtain the optimal values of process parameters that simultaneously optimize the ultimate tensile strength, elongation, and minimum hardness in the heat affected zone (HAZ), a metaheuristic, multi objective algorithm based on biogeography based optimization is proposed. The Pareto optimal frontiers for triple and dual objective functions are obtained and the best optimal solution is selected through using two different decision making techniques, technique for order of preference by similarity to ideal solution (TOPSIS) and Shannon’s entropy. PMID:28772893

Multi-Objective Optimization of Friction Stir Welding Process Parameters of AA6061-T6 and AA7075-T6 Using a Biogeography Based Optimization Algorithm.

PubMed

Tamjidy, Mehran; Baharudin, B T Hang Tuah; Paslar, Shahla; Matori, Khamirul Amin; Sulaiman, Shamsuddin; Fadaeifard, Firouz

2017-05-15

The development of Friction Stir Welding (FSW) has provided an alternative approach for producing high-quality welds, in a fast and reliable manner. This study focuses on the mechanical properties of the dissimilar friction stir welding of AA6061-T6 and AA7075-T6 aluminum alloys. The FSW process parameters such as tool rotational speed, tool traverse speed, tilt angle, and tool offset influence the mechanical properties of the friction stir welded joints significantly. A mathematical regression model is developed to determine the empirical relationship between the FSW process parameters and mechanical properties, and the results are validated. In order to obtain the optimal values of process parameters that simultaneously optimize the ultimate tensile strength, elongation, and minimum hardness in the heat affected zone (HAZ), a metaheuristic, multi objective algorithm based on biogeography based optimization is proposed. The Pareto optimal frontiers for triple and dual objective functions are obtained and the best optimal solution is selected through using two different decision making techniques, technique for order of preference by similarity to ideal solution (TOPSIS) and Shannon's entropy.

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

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

NASA Astrophysics Data System (ADS)

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

2017-10-01

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

Effect of thermal exposure, forming, and welding on high-temperature, dispersion-strengthened aluminum alloy: Al-8Fe-1V-2Si

NASA Technical Reports Server (NTRS)

Kennedy, J. R.; Gilman, P. S.; Zedalis, M. S.; Skinner, D. J.; Peltier, J. M.

1991-01-01

The feasibility of applying conventional hot forming and welding methods to high temperature aluminum alloy, Al-8Fe-1V-2Si (FVS812), for structural applications and the effect of thermal exposure on mechanical properties were determined. FVS812 (AA8009) sheet exhibited good hot forming and resistance welding characteristics. It was brake formed to 90 deg bends (0.5T bend radius) at temperatures greater than or equal to 390 C (730 F), indicating the feasibility of fabricating basic shapes, such as angles and zees. Hot forming of simple contoured-flanged parts was demonstrated. Resistance spot welds with good static and fatigue strength at room and elevated temperatures were readily produced. Extended vacuum degassing during billet fabrication reduced porosity in fusion and resistance welds. However, electron beam welding was not possible because of extreme degassing during welding, and gas-tungsten-arc welds were not acceptable because of severely degraded mechanical properties. The FVS812 alloy exhibited excellent high temperature strength stability after thermal exposures up to 315 C (600 F) for 1000 h. Extended billet degassing appeared to generally improve tensile ductility, fatigue strength, and notch toughness. But the effects of billet degassing and thermal exposure on properties need to be further clarified. The manufacture of zee-stiffened, riveted, and resistance-spot-welded compression panels was demonstrated.

PREPARATION OF ACTINIDE-ALUMINUM ALLOYS

DOEpatents

Moore, R.H.

1962-09-01

BS>A process is given for preparing alloys of aluminum with plutonium, uranium, and/or thorium by chlorinating actinide oxide dissolved in molten alkali metal chloride with hydrochloric acid, chlorine, and/or phosgene, adding aluminum metal, and passing air and/or water vapor through the mass. Actinide metal is formed and alloyed with the aluminum. After cooling to solidification, the alloy is separated from the salt. (AEC)

The Inhibition of Aluminum Corrosion in Sulfuric Acid by Poly(1-vinyl-3-alkyl-imidazolium Hexafluorophosphate).

PubMed

Arellanes-Lozada, Paulina; Olivares-Xometl, Octavio; Guzmán-Lucero, Diego; Likhanova, Natalya V; Domínguez-Aguilar, Marco A; Lijanova, Irina V; Arce-Estrada, Elsa

2014-08-07

Compounds of poly(ionic liquid)s (PILs), derived from imidazole with different alkylic chain lengths located in the third position of the imidazolium ring (poly(1-vinyl-3-dodecyl-imidazolium) (PImC 12 ), poly(1-vinyl-3-octylimidazolium) (PImC₈) and poly(1-vinyl-3-butylimidazolium) (PImC₄) hexafluorophosphate) were synthesized. These compounds were tested as corrosion inhibitors on aluminum alloy AA6061 in diluted sulfuric acid (0.1-1 M H₂SO₄) by weight loss tests, polarization resistance measurements and inductively coupled plasma optical emission spectroscopy. Langmuir's isotherms suggested film formation on bare alloy while standard free energy indicated inhibition by a physisorption process. However, compound efficiencies as inhibitors ranked low (PImC 12 > PImC₈ > PImC₄) to reach 61% for PImC 12 in highly diluted acidic solution. Apparently, the high mobility of sulfates favored their adsorption in comparison to PILs. The surface film displayed general corrosion, and pitting occurred as a consequence of PILs' partial inhibition along with a continuous dissolution of defective patchy film on formation. A slight improvement in efficiency was displayed by compounds having high molecular weight and a long alkyl chain, as a consequence of steric hindrance and PIL interactions.

Mesoporous silica nanoparticles for active corrosion protection.

PubMed

Borisova, Dimitriya; Möhwald, Helmuth; Shchukin, Dmitry G

2011-03-22

This work presents the synthesis of monodisperse, mesoporous silica nanoparticles and their application as nanocontainers loaded with corrosion inhibitor (1H-benzotriazole (BTA)) and embedded in hybrid SiOx/ZrOx sol-gel coating for the corrosion protection of aluminum alloy. The developed porous system of mechanically stable silica nanoparticles exhibits high surface area (∼1000 m2·g(-1)), narrow pore size distribution (d∼3 nm), and large pore volume (∼1 mL·g(-1)). As a result, a sufficiently high uptake and storage of the corrosion inhibitor in the mesoporous nanocontainers was achieved. The successful embedding and homogeneous distribution of the BTA-loaded monodisperse silica nanocontainers in the passive anticorrosive SiOx/ZrOx film improve the wet corrosion resistance of the aluminum alloy AA2024 in 0.1 M sodium chloride solution. The enhanced corrosion protection of this newly developed active system in comparison to the passive sol-gel coating was observed during a simulated corrosion process by the scanning vibrating electrode technique (SVET). These results, as well as the controlled pH-dependent release of BTA from the mesoporous silica nanocontainers without additional polyelectrolyte shell, suggest an inhibitor release triggered by the corrosion process leading to a self-healing effect.

Microstructure and Residual Stress Distributions Under the Influence of Welding Speed in Friction Stir Welded 2024 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Moghadam, Danial Ghahremani; Farhangdoost, Khalil; Nejad, Reza Masoudi

2016-06-01

Friction stir welding was conducted on 8-mm-thick plates made of AA2024-T351 aluminum alloy at tool traverse speeds between 8 and 31.5 mm/minutes and tool rotational speed between 400 and 800 rpm. Metallographic analyses and mechanical tests including hardness, tensile, residual stress, and fracture toughness tests were carried out to evaluate the microstructural and mechanical properties of the joints as a function of the process parameters. The finite element simulation of the FSW process was also performed using a thermal model. The hardness test results show that the increase in rotational speed or decrease in traverse speed of the tool would cause a decrease in weld zone hardness. The best tensile properties are obtained at rotational/traverse speed ratio between 20 and 32. Also, the longitudinal residual stress profiles were evaluated by employing X-ray diffraction method. The numerical and experimental results showed that the increase in a traverse or rotational speed would increase the residual stress of the weld zone. From the fracture toughness results, it was found that the welding process decreases the joints fracture toughness 18 to 49 pct with respect to the base metal.

Development and Validation of Capabilities to Measure Thermal Properties of Layered Monolithic U-Mo Alloy Plate-Type Fuel

NASA Astrophysics Data System (ADS)

Burkes, Douglas E.; Casella, Andrew M.; Buck, Edgar C.; Casella, Amanda J.; Edwards, Matthew K.; MacFarlan, Paul J.; Pool, Karl N.; Smith, Frances N.; Steen, Franciska H.

2014-07-01

The uranium-molybdenum (U-Mo) alloy in a monolithic form has been proposed as one fuel design capable of converting some of the world's highest power research reactors from the use of high enriched uranium to low enriched uranium. One aspect of the fuel development and qualification process is to demonstrate appropriate understanding of the thermal-conductivity behavior of the fuel system as a function of temperature and expected irradiation conditions. The purpose of this paper is to verify functionality of equipment installed in hot cells for eventual measurements on irradiated uranium-molybdenum (U-Mo) monolithic fuel specimens, refine procedures to operate the equipment, and validate models to extract the desired thermal properties. The results presented here demonstrate the adequacy of the equipment, procedures, and models that have been developed for this purpose based on measurements conducted on surrogate depleted uranium-molybdenum (DU-Mo) alloy samples containing a Zr diffusion barrier and clad in aluminum alloy 6061 (AA6061). The results are in excellent agreement with thermal property data reported in the literature for similar U-Mo alloys as a function of temperature.

Corrosion of aluminum alloys by chlorinated hydrocarbon/methanol mixtures

NASA Technical Reports Server (NTRS)

De Forest, W. S.

1967-01-01

Laboratory investigations show that water-free mixtures of Freon MF /trichlorofluoromethane/ and methanol vigorously attack aluminum alloys which contain significant amounts of copper. Freon MF alone did not attack the aluminum alloys at room temperature. Pure methanol had only a slight corrosive effect on the alloy.

Effect of Temper Condition on the Corrosion and Fatigue Performance of AA2219 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Ghosh, Rahul; Venugopal, A.; Rao, G. Sudarshan; Ramesh Narayanan, P.; Pant, Bhanu; Cherian, Roy M.

2018-02-01

The effect of temper condition and corrosion on the fatigue behavior of alloy AA2219 has been investigated in different temper conditions (T87 and T851). Corrosion testing was performed by exposing the tensile specimens to 3.5% NaCl solution for different time periods, and the corrosion damage was quantified using a 3D profilometer. The exposure-tested specimens were subjected for fatigue testing at different stress levels, and the reduction in fatigue life was measured along with detailed fracture morphology variations. The results indicated that the alloy in both tempers suffers localized corrosion damage and the measured corrosion depth was 120 and 1200 µm, respectively, for T87 and T851 conditions. The loss in fatigue strength was found to be high for T851 (67%) when compared to that of T87 temper condition (58%) for a pre-corrosion time of 15 days. In both cases, fatigue crack initiation is associated with corrosion pits, which act as stress raisers. However, the crack propagation was predominantly transgranular for T87 and a mixed transgranular and intergranular fracture in the case of T851 temper condition. This was shown to be due to the heterogeneous microstructure due to the thermomechanical working and the delay in quench time imposed on the alloy forging in T851 temper condition. The findings in this paper present useful information for the selection of appropriate heat treatment condition to facilitate control of the corrosion behavior which is of great significance for their fatigue performance.

Predicting Hot Deformation of AA5182 Sheet

NASA Astrophysics Data System (ADS)

Lee, John T.; Carpenter, Alexander J.; Jodlowski, Jakub P.; Taleff, Eric M.

Aluminum 5000-series alloy sheet materials exhibit substantial ductilities at hot and warm temperatures, even when grain size is not particularly fine. The relatively high strain-rate sensitivity exhibited by these non-superplastic materials, when deforming under solute-drag creep, is a primary contributor to large tensile ductilities. This active deformation mechanism influences both plastic flow and microstructure evolution across conditions of interest for hot- and warm-forming. Data are presented from uniaxial tensile and biaxial bulge tests of AA5182 sheet material at elevated temperatures. These data are used to construct a material constitutive model for plastic flow, which is applied in finite-element-method (FEM) simulations of plastic deformation under multiaxial stress states. Simulation results are directly compared against experimental data to explore the usefulness of this constitutive model. The effects of temperature and stress state on plastic response and microstructure evolution are discussed.

Predicting the constitutive behavior of semi-solids via a direct finite element simulation: application to AA5182

NASA Astrophysics Data System (ADS)

Phillion, A. B.; Cockcroft, S. L.; Lee, P. D.

2009-07-01

The methodology of direct finite element (FE) simulation was used to predict the semi-solid constitutive behavior of an industrially important aluminum-magnesium alloy, AA5182. Model microstructures were generated that detail key features of the as-cast semi-solid: equiaxed-globular grains of random size and shape, interconnected liquid films, and pores at the triple-junctions. Based on the results of over fifty different simulations, a model-based constitutive relationship which includes the effects of the key microstructure features—fraction solid, grain size and fraction porosity—was derived using regression analysis. This novel constitutive equation was then validated via comparison with both the FE simulations and experimental stress/strain data. Such an equation can now be used to incorporate the effects of microstructure on the bulk semi-solid flow stress within a macro- scale process model.

Metallography of Aluminum and Its Alloys : Use of Electrolytic Polishing

NASA Technical Reports Server (NTRS)

Jacquet, Pierre A

1955-01-01

Recent methods are described for electropolishing aluminum and aluminum alloys. Numerous references are included of electrolytic micrographic investigations carried out during the period 1948 to 1952. A detailed description of a commercial electrolytic polishing unit, suitable for micrographic examination of aluminum and its alloys, is included.

In-situ biofouling of ocean thermal energy conversion (OTEC) evaporator tubes

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

Sasscer, D.S.; Morgan, T.

1981-05-01

The Puerto Rico Center for Energy and Environmental Research equipped a LCU facility in 1100 m of water near Punta Tuna, Puerto Rico to measure in situ biofouling of simulated Ocean Thermal Energy Conversion evaporator tubes. The system consisted of two 5052 aluminum alloy and two titanium tubes, through which a continuous flow of ocean water was maintained. The tubes were cleaned three times and the fouling resistance was measured, showing only slight differences between the tubes with respect to heat transfer loss resulting from biofouling. In all units, the average fouling rate after cleaning was greater than before cleaning,more » and only after the first cleaning did the aluminum units show greater fouling rates than did the titanium. The titanium units showed a progressive increase in the fouling rates with each cleaning. The subsequent average fouling rates for all units after eight months were between 4 and 4.6 x 0.000010 sq m-k/W-day.« less

Electronics Reliability Fracture Mechanics, Volume 2. Fracture Mechanics

DTIC Science & Technology

1992-05-01

alloy or strength level. Aluminum alloy 2024 - T351 was selected as being representative of the aluminum wire, and the fatigue ...to bracket the bond wire fatigue tests. 3-41 Also shown for comparison are two curves, which are the crack growth rates for 2024 aluminum alloy (Ref...is very similar to that for 2024 aluminum alloy . 3.2.6 Discussion of Loop Vibration Fatigue Testing Results This experimental and

Systems study of transport aircraft incorporating advanced aluminum alloys

NASA Technical Reports Server (NTRS)

Sakata, I. F.

1982-01-01

A study was performed to quantify the potential benefits of utilizing advanced aluminum alloys in commercial transport aircraft and to define the effort necessary to develop fully the alloys to a viable commercial production capability. The comprehensive investigation (1) established realistic advanced aluminum alloy property goals to maximize aircraft systems effectiveness (2) identified performance and economic benefits of incorporating the advanced alloy in future advanced technology commercial aircraft designs (3) provided a recommended plan for development and integration of the alloys into commercial aircraft production (4) provided an indication of the timing and investigation required by the metal producing industry to support the projected market and (5) evaluate application of advanced aluminum alloys to other aerospace and transit systems as a secondary objective. The results of the investigation provided a roadmap and identified key issues requiring attention in an advanced aluminum alloy and applications technology development program.

Long-term strategies for increased recycling of automotive aluminum and its alloying elements.

PubMed

Løvik, Amund N; Modaresi, Roja; Müller, Daniel B

2014-04-15

Aluminum recycling currently occurs in a cascading fashion, where some alloys, used in a limited number of applications, absorb most of the end-of-life scrap. An expected increase in scrap supply in coming decades necessitates restructuring of the aluminum cycle to open up new recycling paths for alloys and avoid a potential scrap surplus. This paper explores various interventions in end-of-life management and recycling of automotive aluminum, using a dynamic substance flow analysis model of aluminum and its alloying elements with resolution on component and alloy level (vehicle-component-alloy-element model). It was found that increased component dismantling before vehicle shredding can be an effective, so far underestimated, intervention in the medium term, especially if combined with development of safety-relevant components such as wheels from secondary material. In the long term, automatic alloy sorting technologies are most likely required, but could at the same time reduce the need for magnesium removal in refining. Cooperation between the primary and secondary aluminum industries, the automotive industry, and end-of-life vehicle dismantlers is therefore essential to ensure continued recycling of automotive aluminum and its alloying elements.

Mechanical Properties and Wear Behavior of AA5182/WC Nanocomposite Fabricated by Friction Stir Welding at Different Tool Traverse Speeds

NASA Astrophysics Data System (ADS)

Paidar, Moslem; Asgari, Ali; Ojo, Olatunji Oladimeji; Saberi, Abbas

2018-03-01

Grain growth inhibition at the heat-affected zone, improved weld strength and superior tribological properties of welds are desirable attributes of modern manufacturing. With the focused on these attributes, tungsten carbide (WC) nanoparticles were employed as reinforcements for the friction stir welding of 5-mm-thick AA5182 aluminum alloy by varying tool traverse speeds. The microstructure, microhardness, ultimate tensile strength, fracture and wear behavior of the resultant WC-reinforced welds were investigated, while unreinforced AA5182 welds were employed as controls for the study. The result shows that the addition of WC nanoparticles causes substantial grain refinement within the weld nugget. A decrease in traverse speed caused additional particle fragmentation, improved hardness value and enhanced weld strength in the reinforced welds. Improved wear rate and friction coefficient of welds were attained at a reduced traverse speed of 100 mm/min in the WC-reinforced welds. This improvement is attributed to the effects of reduced grain size/grain fragmentation and homogeneous dispersion of WC nanoparticles within the WC-reinforced weld nugget.

The Special Features of the Deformation Behavior of an Ultrafine-Grained Aluminum Alloy of the Al-Mg-Li System at Room Temperature

NASA Astrophysics Data System (ADS)

Naydenkin, E. V.; Mishin, I. P.; Ivanov, K. V.

2015-04-01

The special features of the deformation behavior of an ultrafine-grained aluminum alloy produced by severe plastic deformation are investigated. Unlike ultrafine-grained pure aluminum, the second-phase particles precipitated in the bulk and at the grain boundaries of the alloy are shown to hinder the development of grain boundary sliding and plastic strain localization. This increases the length of the strain hardening stage and uniformity of elongation of a heterogeneous aluminum alloy specimen as compared to pure aluminum.

Structure-Property Relationships of Solid State Additive Manufactured Aluminum Alloy 2219 and Inconel 625

NASA Astrophysics Data System (ADS)

Rivera Almeyda, Oscar G.

In this investigation, the processing-structure-property relations are correlated for solid state additively manufactured (SSAM) Inconel 625 (IN 625) and a SSAM aluminum alloy 2219 (AA2219). This is the first research of these materials processed by a new SSAM method called additive friction stir (AFS). The AFS process results in a refined grain structure by extruding solid rod through a rotating tool generating heat and severe plastic deformation. In the case of the AFS IN625, the IN625 alloy is known for exhibiting oxidation resistance and temperature mechanical stability, including strength and ductility. This study is the first to investigate the beneficial grain refinement and densification produced by AFS in IN625 that results in advantageous mechanical properties (YS, UTS, epsilonf) at both quasi-static and high strain rate. Electron Backscatter Diffraction (EBSD) observed dynamic recrystallization and grain refinement during the layer deposition in the AFS specimens, where the results identified fine equiaxed grain structures formed by dynamic recrystallization (DRX) with even finer grain structures forming at the layer interfaces. The EBSD quantified grains as fine as 0.27 microns in these interface regions while the average grain size was approximately 1 micron. Additionally, this is the first study to report on the strain rate dependence of AFS IN625 through quasi-static (QS) (0.001/s) and high strain rate (HR) (1500/s) tensile experiments using a servo hydraulic frame and a direct tension-Kolsky bar, respectively, which captured both yield and ultimate tensile strengths increasing as strain rate increased. Fractography performed on specimens showed a ductile fracture surface on both QS, and HR. Alternatively, the other AFS material system investigated in this study, AA2219, is mostly used for aerospace applications, specifically for rocket fuel tanks. EBSD was performed in the cross-section of the AA2219, also exhibiting DRX with equiaxed microstructure in the three directions and an average grain size of 2.5 microns. EBSD PFs showed that the material has a strong torsional fiber A texture in the top of the build, and this texture gets weaker in the middle and bottom sections. TEM showed that there are no theta' precipitates in the as-deposited cross-section, therefore no precipitation strengthening should be expected. Strain rate and stress state dependence was study, and in both tension and compression, with an increase in strain rate, the YS increase and the UTS decreased. Ductile fracture surface was observed on specimens tested to failure in both QS and HR. The AFS AA2219 processing-structure-property relations are being studied in this investigation to address the stress-state and strain rate dependence of AFS AA2219 with an internal sate variable (ISV) plasticity-damage model to capture the different yield stress, work hardening and failure strain in the AFS AA2219 for high fidelity modeling of AFS components. The ISV plasticity model successfully captured the material behavior in tension, compression, tension-followed-by-compression and compression-followed-by-tension experiments. Furthermore, the damage parameters of the model were calibrated using the final void density measured from the fracture surfaces.

Effects of Mars Atmosphere on Arc Welds: Phase 2

NASA Technical Reports Server (NTRS)

Courtright, Z. S.

2018-01-01

Gas tungsten arc welding (GTAW) is a vital fusion welding process widely used throughout the aerospace industry. Its use may be critical for the repair or manufacture of systems, rockets, or facilities on the Martian surface. Aluminum alloy AA2219-T87 and titanium alloy Ti-6Al-4V butt welds have been investigated for weldability and weld properties in a simulated Martian gas environment. The resulting simulated Martian welds were compared to welds made in a terrestrial atmosphere, all of which used argon shielding gas. It was found that GTAW is a process that may be used in a Martian gas environment, not accounting for pressure and gravitational effects, as long as adequate argon shielding gas is used to protect the weld metal. Simulated Martian welds exhibited higher hardness in all cases and higher tensile strength in the case of AA2219-T87. This has been attributed to the absorption of carbon into the fusion zone, causing carbide precipitates to form. These precipitates may act to pin dislocations upon tensile testing of AA2219-T87. Dissolved carbon may have also led to carburization, which may have caused the increase in hardness within the fusion zone of the welds. Based on the results of this experiment and other similar experiments, GTAW appears to be a promising process for welding in a Martian gas environment. Additional funding and experimentation is necessary to determine the effects of the low pressure and low gravity environment found on Mars on GTAW.

FRICTION STIR LAP WELDING OF ALUMINUM - POLYMER USING SCRIBE TECHNOLOGY

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

Upadhyay, Piyush; Hovanski, Yuri; Fifield, Leonard S.

2015-02-16

Friction Stir Scribe (FSS) technology is a relatively new variant of Friction Stir Welding (FSW) which enables lap joining of dissimilar material with very different melting points and different high temperature flow behaviors. The cutter scribe attached at the tip of FSW tool pin effectively cuts the high melting point material such that a mechanically interlocking feature is created between the dissimilar materials. The geometric shape of this interlocking feature determines the shear strength attained by the lap joint. This work presents first use of scribe technology in joining polymers to aluminum alloy. Details of the several runs of scribemore » welding performed in lap joining of ~3.175mm thick polymers including HDPE, filled and unfilled Nylon 66 to 2mm thick AA5182 are presented. The effect of scribe geometry and length on weld interlocking features is presented along with lap shear strength evaluations.« less

Investigation of the interfacial reactions between steel and aluminum coatings for hybrid casting

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Wiesner, S.; Gerdt, L.

2018-06-01

Coating of AA7075 was applied by means of cold gas spraying on steel substrates of 22MnB5 and DC04 as an interlayer for high pressure die casting of aluminum/steel hybrid components. The morphology and growth kinetics of intermetallic compounds formed at the interface between coating and steel has been investigated. Furthermore, the effect of alloying elements on the formation of the intermetallic phases was analyzed. The coated samples were heat treated by means of induction heating at the temperature T = 550 °C with different dwell times in the range of 10 s < t < 5 min. The reaction layer growth was examined by means of scanning electron microscope (SEM) with energy dispersive spectroscopy (EDS). Additionally, the intermetallic compounds were characterized by means of nanoindentation. Intermetallic compounds of AlFe phases occurred as the major constituent in the reaction zone for different combinations of coating and substrates.

Nonswelling alloy

DOEpatents

Harkness, S.D.

1975-12-23

An aluminum alloy containing one weight percent copper has been found to be resistant to void formation and thus is useful in all nuclear applications which currently use aluminum or other aluminum alloys in reactor positions which are subjected to high neutron doses.

Stress-Corrosion Cracking in High Strength Steels and in Titanium and Aluminum Alloys

DTIC Science & Technology

1972-01-01

EFFECTS 01: STRESS) 155 Table 2. Mechanical, Fracture, and Stress Corrosion Properties for Plates of Several Aluminum Alloys --Continued 4f’l14...One of the most effective SCC preventives for high strength aluminum alloys is surface working by shot peening, particularl) when used in combination...Aluminaut uses aluminum alloy anodes to supplement the protection of the pressure hull offered by several layers of polyurethane coating 175). 100 A

Fundamental Investigation of Fatigue Crack Growth Retardation in Aluminum Alloys

DTIC Science & Technology

1976-09-01

Fatigue Crack Propagation in 2024 -T3 Aluminum Alloy , " ASTM STP 536, p. 115, 1973. 9. J. Schijve, " Effect of Load Sequences...Hertzberg, " Effect of Multiple Over- loads on Fatigue Crack Propagation in 2024 -T3 Aluminum Alloy , " ASTM STP-536, p. 115, 1973. 9. J. Schijve... Effect of Thickness on Retardation Behavior of 7075 and 2024 Aluminum Alloys .......... 185 vi LIST OF ILLUSTRATIONS FIGURE PAGE 1 SEN

Adhesion enhancement of titanium nitride coating on aluminum casting alloy by intrinsic microstructures

NASA Astrophysics Data System (ADS)

Nguyen, Chuong L.; Preston, Andrew; Tran, Anh T. T.; Dickinson, Michelle; Metson, James B.

2016-07-01

Aluminum casting alloys have excellent castability, high strength and good corrosion resistance. However, the presence of silicon in these alloys prevents surface finishing with conventional methods such as anodizing. Hard coating with titanium nitride can provide wear and corrosion resistances, as well as the aesthetic finish. A critical factor for a durable hard coating is its bonding with the underlying substrate. In this study, a titanium nitride layer was coated on LM25 casting alloy and a reference high purity aluminum substrate using Ion Assisted Deposition. Characterization of the coating and the critical interface was carried out by a range of complementing techniques, including SIMS, XPS, TEM, SEM/EDS and nano-indentation. It was observed that the coating on the aluminum alloy is stronger compared to that on the pure aluminum counterpart. Silicon particles in the alloy offers the reinforcement though mechanical interlocking at microscopic level, even with nano-scale height difference. This reinforcement overcomes the adverse effect caused by surface segregation of magnesium in aluminum casting alloys.

Aluminum alloy anode materials for Li-ion batteries

NASA Astrophysics Data System (ADS)

Sun, Z. H.; Chen, Z. F.; Fu, Q. W.; Jiang, X. Y.

2017-03-01

Aluminum has larger theoretical capacity of 2235 mAh/g than that of graphite (372 mAh/g), but it has big disadvantages including shorter cycle life and higher irreversible capacity loss. Improving cycle performance can be obtained via alloying of aluminum. In this paper, two ternary aluminum alloy, Al7Cu2Fe and Al73Cu5Fe22 were prepared. The main phase of Al7Cu2Fe alloy was Al7Cu2Fe. The heat treatment increased the proportion of Al7Cu2Fe. The main phase of Al73Cu5Fe22 alloy was Al60Cu30Fe10. The heat treatment reduced the proportion of Al60Cu30Fe10. For two alloys, the heat treatment could increase discharge capacity compared with cast alloy. The discharge capacity was improved by 50%. The content of aluminum in alloys has little effect on improving cycle performance, and it has obvious influence on the phase structure of alloy with heat treatment.

Microstructures and properties of aluminum die casting alloys

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

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

1998-10-01

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

PROCESSING OF URANIUM-METAL-CONTAINING FUEL ELEMENTS

DOEpatents

Moore, R.H.

1962-10-01

A process is given for recovering uranium from neutronbombarded uranium- aluminum alloys. The alloy is dissolved in an aluminum halide--alkali metal halide mixture in which the halide is a mixture of chloride and bromide, the aluminum halide is present in about stoichiometric quantity as to uranium and fission products and the alkali metal halide in a predominant quantity; the uranium- and electropositive fission-products-containing salt phase is separated from the electronegative-containing metal phase; more aluminum halide is added to the salt phase to obtain equimolarity as to the alkali metal halide; adding an excess of aluminum metal whereby uranium metal is formed and alloyed with the excess aluminum; and separating the uranium-aluminum alloy from the fission- productscontaining salt phase. (AEC)

Investigation into the stress corrosion cracking properties of AA2099, an aluminum-lithium-copper alloy

NASA Astrophysics Data System (ADS)

Padgett, Barbara Nicole

Recently developed Al-Li-Cu alloys show great potential for implementation in the aerospace industry because of the attractive mix of good mechanical properties and low density. AA2099 is an Al-Li-Cu alloy with the following composition Al-2.69wt%Cu-1.8wt%Li-0.6wt%Zn-0.3wt%Mg-0.3wt%Mn-0.08wt%Zr. The environmental assisted cracking and localized corrosion behavior of the AA2099 was investigated in this thesis. The consequences of uncontrolled grain boundary precipitation via friction stir welding on the stress corrosion cracking (SCC) behavior of AA2099 was investigated first. Using constant extension rate testing, intergranular corrosion immersion experiments, and potentiodynamic scans, the heat-affected zone on the trailing edge of the weld (HTS) was determined to be most susceptible of the weld zones. The observed SCC behavior for the HTS was linked to the dissolution of an active phase (Al2CuLi, T1) populating the grain boundary. It should be stated that the SCC properties of AA2099 in the as-received condition were determined to be good. Focus was then given to the electrochemical behavior of precipitate phases that may occupy grain and sub-grain boundaries in AA2099. The grain boundary micro-chemistry and micro-electrochemistry have been alluded to within the literature as having significant influence on the SCC behavior of Al-Li-Cu alloys. Major precipitates found in this alloy system are T1 (Al 2CuLi), T2 (Al7.5Cu4Li), T B (Al6CuLi3), and theta (Al2 Cu). These phases were produced in bulk form so that the electrochemical nature of each phase could be characterized. It was determined T1 was most active electrochemically and theta was least. When present on grain boundaries in the alloy, electrochemical behavior of the individual precipitates aligned with the observed corrosion behavior of the alloy (e.g. TB was accompanied by general pitting corrosion and T 1 was accompanied by intergranular corrosion attack). In addition to the electrochemical behavior of the above-mentioned intermetallics, the phenomenon of Zn substituting for Cu in T1 was also studied. It was determined that for Zn substitutions up to 8.4wt%, improved corrosion behavior of T 1 would occur by dealloying of Zn and Li. Lastly, isothermal aging treatments at 160°C and 190°C were conducted to vary the grain boundary structures in a systematic way. The SCC behaviors for the under-aged, peak-aged, and over-aged condition were studied using CERT and alternate immersion testing at each temperature. The severely under-aged condition (≤ 9 hours) at 160°C proved to have poorest SCC resistance. The over-aged condition at 160°C (≥ 24 hours) also had degraded SCC resistance. In contrast the 190°C isothermal aging condition produced better SCC resistance than 160°C isothermal aging temperature for all conditions. The differences in behavior were linked to the species populating the grain boundaries in each isothermal aging condition (T2 at 190°C and T1 at 160°C).

Evaluation and control of environmental corrosion for aluminum and steel alloys

NASA Technical Reports Server (NTRS)

Franklin, D. B.

1977-01-01

Corrosion protection systems for aerospace application and the effects of surface treatments and methods of controlling stress corrosion are evaluated. Chromate pigmented systems were found to be most effective for aluminum alloys; zinc-rich coatings gave the greatest protection to steel alloys. Various steel and aluminum alloys are rated for stress corrosion resistance.

[Research on fast classification based on LIBS technology and principle component analyses].

PubMed

Yu, Qi; Ma, Xiao-Hong; Wang, Rui; Zhao, Hua-Feng

2014-11-01

Laser-induced breakdown spectroscopy (LIBS) and the principle component analysis (PCA) were combined to study aluminum alloy classification in the present article. Classification experiments were done on thirteen different kinds of standard samples of aluminum alloy which belong to 4 different types, and the results suggested that the LIBS-PCA method can be used to aluminum alloy fast classification. PCA was used to analyze the spectrum data from LIBS experiments, three principle components were figured out that contribute the most, the principle component scores of the spectrums were calculated, and the scores of the spectrums data in three-dimensional coordinates were plotted. It was found that the spectrum sample points show clear convergence phenomenon according to the type of aluminum alloy they belong to. This result ensured the three principle components and the preliminary aluminum alloy type zoning. In order to verify its accuracy, 20 different aluminum alloy samples were used to do the same experiments to verify the aluminum alloy type zoning. The experimental result showed that the spectrum sample points all located in their corresponding area of the aluminum alloy type, and this proved the correctness of the earlier aluminum alloy standard sample type zoning method. Based on this, the identification of unknown type of aluminum alloy can be done. All the experimental results showed that the accuracy of principle component analyses method based on laser-induced breakdown spectroscopy is more than 97.14%, and it can classify the different type effectively. Compared to commonly used chemical methods, laser-induced breakdown spectroscopy can do the detection of the sample in situ and fast with little sample preparation, therefore, using the method of the combination of LIBS and PCA in the areas such as quality testing and on-line industrial controlling can save a lot of time and cost, and improve the efficiency of detection greatly.

Measurement of the detective quantum efficiency in digital detectors consistent with the IEC 62220-1 standard: Practical considerations regarding the choice of filter material.

PubMed

Ranger, Nicole T; Samei, Ehsan; Dobbins, James T; Ravin, Carl E

2005-07-01

As part of a larger evaluation we attempted to measure the detective quantum efficiency (DQE) of an amorphous silicon flat-panel detector using the method described in the International Electrotechnical Commission standard 62220-1 published in October 2003. To achieve the radiographic beam conditions specified in the standard, we purchased scientific-grade ultrahigh purity aluminum (99.999% purity, type-11999 alloy) filters in thicknesses ranging from 0.1 through 10.0 mm from a well-known, specialty metals supplier. Qualitative evaluation of flat field images acquired at 71 kV (RQA5 beam quality) with 21 mm of ultrahigh purity aluminum filtration demonstrated a low frequency mottle that was reproducible and was not observed when the measurement was repeated at 74 kV (RQA5 beam quality) with 21 mm of lower-purity aluminum (99.0% purity, type-1100 alloy) filtration. This finding was ultimately attributed to the larger grain size (approximately 1-2 mm) of high purity aluminum metal, which is a well-known characteristic, particularly in thicknesses greater than 1 mm. The impact of this low frequency mottle is to significantly overestimate the noise power spectrum (NPS) at spatial frequencies ⩽0.2mm-1, which in turn would cause an underestimation of the DQE in this range. A subsequent evaluation of ultrahigh purity aluminum, purchased from a second source, suggests, that reduced grain size can be achieved by the process of annealing. Images acquired with this sample demonstrated vertical striated nonuniformities that are attributed to the manufacturing method and which do not appear to appreciably impact the NPS at spatial frequencies ⩾0.5mm-1, but do result in an asymmetry in the x- and y-NPS at spatial frequencies ⩽0.2mm-1. Our observations of markedly visible nonuniformities in images acquired with high purity aluminum filtration suggest that the uniformity of filter materials should be carefully evaluated and taken into consideration when measuring the DQE. © 2005 American Association of Physicists in Medicine.

Radiopacity of endodontic materials on film and a digital sensor.

PubMed

Rasimick, Brian J; Shah, Rinal P; Musikant, Barry Lee; Deutsch, Allan S

2007-09-01

The purpose of this study was to compare the radiographic appearance of 12 endodontic materials as visualized on either Kodak Ultra-speed D speed film (Eastman Kodak Company, Rochester, NY) or a Gendex eHD digital sensor (Gendex Dental Systems, Milan, Italy). Ten discs of each material were radiographed alongside an aluminum alloy 1100 (Alcoa, Pittsburgh, PA) stepwedge that was used for reference. For every radiograph, the average grayscale value of the material was converted into absorbance notation and compared with that of the reference stepwedge in order to determine the equivalent radiopacity in terms of millimeters of Al 1100 per millimeter of material. Two-way repeated-measures analysis of variance testing detected significant differences with respect to imaging system, material, and the interaction of the two factors (p < 0.001). The difference in a material's radiopacity as measured on the digital sensor compared with film was greater than 10% for 4 of the 12 materials and over 40% for InnoEndo (Heraus Kulzer, Armonk, NY). It was speculated that barium fillers cause this effect.

High-temperature corrosion of iron-aluminum and iron-aluminum-yttrium alloys

NASA Astrophysics Data System (ADS)

Insoo, Kim

The high-temperature corrosion behavior of Fe3Al alloy has been investigated by conducting two studies: (1) corrosion of Fe 3Al and Fe3Al-Y alloys in oxidizing atmosphere and (2) corrosion of Fe3Al in mixed chlorine/oxygen environments. In the first study, oxidation of the two alloys, Fe-14.3 wt% Al and Fe-14.1 wt% Al-0.3 wt% Y, was carried out in the temperature range of 800 to 1100°C to investigate the general oxidation behavior of Fe3Al and the effect of yttrium on the oxidation of Fe3Al in terms of oxidation kinetics, oxide scale adhesion and microstructure. At lower temperatures (<1000°C), the oxidation rate of the two alloys was nearly identical, and the parabolic rate constant obtained as a function of temperature was Kp = 5128 exp[--39500 (cal/mol)/RT] mg2/cm4 h. At higher temperatures, however, yttrium-added Fe3Al alloy exhibited lower oxidation rate and much more improved oxide adhesion. The lower oxidation rate observed in Fe3Al-Y alloy seems to be due to the followings: (1) a decrease in aluminum diffusion through alumina scale and (2) modification of the scale growth mechanism from simultaneous countercurrent diffusion of aluminum and oxygen to predominant inward diffusion of oxygen, which generates less growth stress and thus prevents the formation of fast diffusion paths such as microcracks. The adhesion improvement of alumina scale formed on the Fe3Al-Y was attributed to the modification of alumina growth mechanism by the addition of Y to the Fe3Al alloy. The change of growth mechanism leads to the formation of pegs, decrease of the oxide growth stress, and decrease of voids formation, which enhances the adhesion of alumina scale to the Fe3Al alloy. The second study has focused on the corrosion of Fe3Al in the temperature range of 600--800°C in Cl2-Ar gas mixtures containing traces of oxygen as an impurity. Weight gain was observed during the corrosion of Fe3Al at 600°C in 0.25% Cl2-Ar, which is due to the formation of Fe2O3, while continuous weight loss of the specimen in 5% Cl2-Ar at 800°C was observed because of the formation of volatile metal chlorides, FeCl2, FeCl 3, and AlCl3. Meanwhile, three distinct stages of weight change during the corrosion of Fe3Al at 700°C in 1% Cl 2-Ar were observed: (1) weight gain, (2) linear weight loss, and (3) gradual decrease of weight loss. Initial weight gain is due to the formation of Fe2O3, and the weight loss in the subsequent two stages is due to the formation of volatile metal chlorides, FeCl 2, FeCl3, and AlCl3. Based on the kinetic and microstructural analyses, a reaction mechanism is proposed for each stage.

Reduced-Pressure Foaming of Aluminum Alloys

NASA Astrophysics Data System (ADS)

Vinod Kumar, G. S.; Mukherjee, M.; Garcia-Moreno, F.; Banhart, J.

2013-01-01

We developed a novel process for foaming aluminum and its alloys without using a blowing agent. The process involves a designated apparatus in which molten aluminum and its alloys are first foamed under reduced pressure and then solidified quickly. Foaming was done for pure aluminum (99.99 pct) and AlMg5 alloy not containing stabilizing particles and AlMg5 and AlSi9Mg5 alloys containing 5 vol pct SiO2 particles. We discuss the foaming mechanism and develop a model for estimating the porosity that can be achieved in this process. The nucleation of pores in foams is also discussed.

Study of Plastic Deformation in Binary Aluminum Alloys by Internal-Friction Methods

NASA Technical Reports Server (NTRS)

Olson, E. C.; Maringer, R. E.; Marsh, L. L.; Manning, G. K.

1959-01-01

The damping capacity of several aluminum-copper alloys has been investigated during tensile elongation. This damping is shown to depend on strain rate, strain, temperature, alloy content, and heat treatment. A tentative hypothesis, based on the acceleration of solute atom diffusion by deformation-produced vacancies, is proposed to account for the observed behavior. Internal-friction maxima are observed in deformed aluminum and aluminum-copper alloys at -70 deg and -50 deg C. The peaks appear to be relatively insensitive to frequency and alloy content, but they disappear after annealing at temperatures nearing the recrystallization temperature.

Laboratory Powder Metallurgy Makes Tough Aluminum Sheet

NASA Technical Reports Server (NTRS)

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

1993-01-01

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

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

Stress Corrosion Cracking Behavior of LD10 Aluminum Alloy in UDMH and N2O4 propellant

NASA Astrophysics Data System (ADS)

Zhang, Youhong; Chang, Xinlong; Liu, Wanlei

2018-03-01

The LD10 aluminum alloy double cantilever beam specimens were corroded under the conditions of Unsymmetric Uimethyl Hydrazine (UDMH), Dinitrogen Tetroxide (N2O4), and 3.5% NaCl environment. The crack propagation behavior of the aluminum alloy in different corrosion environment was analyzed. The stress corrosion cracking behavior of aluminum alloy in N2O4 is relatively slight and there are not evident stress corrosion phenomenons founded in UDMH.

Properties of welded joints in laser welding of aeronautic aluminum-lithium alloys

NASA Astrophysics Data System (ADS)

Malikov, A. G.; Orishich, A. M.

2017-01-01

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

U-Mo Monolithic Fuel for Nuclear Research and Test Reactors

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

Prabhakaran, Ramprashad

The metallic fuel selected to replace the current HEU fuels in the research and test reactors is the LEU-10 weight % Mo alloy in the form of a thin sheet or foil encapsulated in AA6061 aluminum alloy with a zirconium interlayer. In order to effectively lead this pursuit, new developments in processing and fabrication of the fuel elements have been initiated, along with a better understanding of material behavior before and after irradiation as a result of these new developments. This editorial note gives an introduction about research and test reactors, need for HEU to LEU conversion, fuel requirements, highmore » uranium density monolithic fuel development and an overview of the four articles published in the December 2017 issue of JOM under a special topic titled “U-Mo Monolithic Fuel for Nuclear Research and Test Reactors”.« less

Fused silicon-rich coatings for superalloys

NASA Technical Reports Server (NTRS)

Smialek, J. L.

1974-01-01

Various compositions of nickel-silicon and aluminum-silicon slurries were sprayed on IN 100 specimens and fusion-sintered to form fully dense coatings. Cyclic furnace oxidation tests in 1 atm air at 1100 C showed all the coatings to be protective for at least 600 hours, and one slurry, Al-60Si, was protective for 1000 hours. This coating also protected NASA TAZ 8A and NASA-TRW VIA for 1000 hours in the same furnace test. Alloys B 1900, TD-NiCr, and Mar-M200 were protected for lesser times, while NX 188 and NASA WAZ 20 were scarcely protected at all. Limited stress-rupture testing on 0.64-cm-diam IN 100 specimens detected no degradation of mechanical properties due to silicon diffusion.

Cracking evolution behaviors of lightweight materials based on in situ synchrotron X-ray tomography: A review

NASA Astrophysics Data System (ADS)

Luo, Y.; Wu, S. C.; Hu, Y. N.; Fu, Y. N.

2018-03-01

Damage accumulation and failure behaviors are crucial concerns during the design and service of a critical component, leading researchers and engineers to thoroughly identifying the crack evolution. Third-generation synchrotron radiation X-ray computed microtomography can be used to detect the inner damage evolution of a large-density material or component. This paper provides a brief review of studying the crack initiation and propagation inside lightweight materials with advanced synchrotron three-dimensional (3D) X-ray imaging, such as aluminum materials. Various damage modes under both static and dynamic loading are elucidated for pure aluminum, aluminum alloy matrix, aluminum alloy metal matrix composite, and aluminum alloy welded joint. For aluminum alloy matrix, metallurgical defects (porosity, void, inclusion, precipitate, etc.) or artificial defects (notch, scratch, pit, etc.) strongly affect the crack initiation and propagation. For aluminum alloy metal matrix composites, the fracture occurs either from the particle debonding or voids at the particle/matrix interface, and the void evolution is closely related with fatigued cycles. For the hybrid laser welded aluminum alloy, fatigue cracks usually initiate from gas pores located at the surface or sub-surface and gradually propagate to a quarter ellipse or a typical semi-ellipse profile.

Microstructure evolution in dissimilar AA6060/copper friction stir welded joints

NASA Astrophysics Data System (ADS)

Kalashnikova, T. A.; Shvedov, M. A.; Vasilyev, P. A.

2017-12-01

Friction stir welding process has been applied for making a dissimilar copper/aluminum alloy joint. The grain microstructure and mechanical properties of the obtained joint were studied. The structure of the cross-section of the FSW compound was analyzed. The microstructural evolution of the joint was examined using optical microscopy. The mechanical properties of the intermetallic particles were evaluated by measuring the microhardness according to the Vickers method. The microhardness of the intermetallic particles was by a factor of 4 lower than that of the particles obtained by fusion welding. The results of the investigations enable using friction stir welding for making dissimilar joints.

New water-soluble metal working fluids additives from phosphonic acid derivatives for aluminum alloy materials.

PubMed

Kohara, Ichitaro; Tomoda, Hideyuki; Watanabe, Shoji

2007-01-01

Water-soluble metal working fluids are used for processing of aluminum alloy materials. This short paper describes properties of new additives for water-soluble cutting fluids for aluminum alloy materials. Some alkyldiphosphonic acids were prepared with known method. Amine salts of these phosphonic acids showed anti-corrosion property for aluminum alloy materials. However, they have no hard water tolerance. Monoesters of octylphosphonic acid were prepared by the reaction of octylphosphonic acid dichloride with various alcohols in the presence of triethylamine. Amine salts of monoester of octylphosphonic acid with diethyleneglycol monomethyl ether, ethyleneglycol monomethyl ether and triethyleneglycol monomethyl ether showed both of a good anti-corrosion property for aluminum alloy materials and hard water tolerance.

Gas-tungsten arc welding of aluminum alloys

DOEpatents

Frye, Lowell D.

1984-01-01

A gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to provide a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surfaces are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy contiguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

Effect of Sensitization on Corrosion-Fatigue Cracking in Al 5083 Alloy

DTIC Science & Technology

2015-01-21

Report Corrosion-fatigue Stress-corrosion cracking Aluminum alloys Sensitization October 2011 – September 2014 63-2634-A4 Unclassified Unlimited... alloy 5083-H131 is an armor-grade aluminum alloy that is non-heat-treatable and derives its strength from magnesium solute hardening and strain hardening...marine environments (references1-2). Even though the damaging effect of grain boundary β and sensitization on SCC in 5 -series aluminum alloys is

Reinforcing aluminum alloys with high strength fibers

NASA Technical Reports Server (NTRS)

Kolpashnikov, A. I.; Manuylov, V. F.; Chukhin, B. D.; Shiryayev, Y. V.; Shurygin, A. S.

1982-01-01

A study is made of the possibility of reinforcing aluminum and aluminum based alloys with fibers made of high strength steel wire. The method of introducing the fibers is described in detail. Additional strengthening by reinforcement of the high alloy system Al - An - Mg was investigated.

Stress Corrosion Cracking of Certain Aluminum Alloys

NASA Technical Reports Server (NTRS)

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

1983-01-01

SC resistance of new high-strength alloys tested. Research report describes progress in continuing investigation of stress corrosion (SC) cracking of some aluminum alloys. Objective of program is comparing SC behavior of newer high-strength alloys with established SC-resistant alloy.

Fume generation rates for stainless steel, nickel and aluminum alloys

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

Castner, H.R.

1996-12-01

This paper describes a study of the effects of pulsed welding current on fume produced during gas metal arc welding (GMAW) of stainless steel, nickel, and aluminum alloys. This is an extension of earlier studies of mild steel electrode wire. Reduction of welding fume is important because steady current GMAW of stainless steels and nickel alloys may produce fume that exceeds recommended worker exposure limits for some of the fume constituents. Fume generation from aluminum alloy ER5356 was studied because steady current welding with this alloy produces much higher fume generation rates than ER4043 alloy electrode wire. This work showsmore » that pulsed current can reduce GMAW fume generation rates for Er308L, ER310, and ER312 stainless steel, ERNiCr-3 nickel alloy, and ER5356 aluminum-magnesium alloy electrode wires.« less

Method to increase the toughness of aluminum-lithium alloys at cryogenic temperatures

NASA Technical Reports Server (NTRS)

Sankaran, Krishnan K. (Inventor); Sova, Brian J. (Inventor); Babel, Henry W. (Inventor)

2006-01-01

A method to increase the toughness of the aluminum-lithium alloy C458 and similar alloys at cryogenic temperatures above their room temperature toughness is provided. Increasing the cryogenic toughness of the aluminum-lithium alloy C458 allows the use of alloy C458 for cryogenic tanks, for example for launch vehicles in the aerospace industry. A two-step aging treatment for alloy C458 is provided. A specific set of times and temperatures to age the aluminum-lithium alloy C458 to T8 temper is disclosed that results in a higher toughness at cryogenic temperatures compared to room temperature. The disclosed two-step aging treatment for alloy 458 can be easily practiced in the manufacturing process, does not involve impractical heating rates or durations, and does not degrade other material properties.

Use of low-cost aluminum in electric energy production

NASA Astrophysics Data System (ADS)

Zhuk, Andrey Z.; Sheindlin, Alexander E.; Kleymenov, Boris V.; Shkolnikov, Eugene I.; Lopatin, Marat Yu.

Suppression of the parasitic corrosion while maintaining the electrochemical activity of the anode metal is one of the serious problems that affects the energy efficiency of aluminum-air batteries. The need to use high-purity aluminum or special aluminum-based alloys results in a significant increase in the cost of the anode, and thus an increase in the total cost of energy generated by the aluminum-air battery, which narrows the range of possible applications for this type of power source. This study considers the process of parasitic corrosion as a method for hydrogen production. Hydrogen produced in an aluminum-air battery by this way may be further employed in a hydrogen-air fuel cell (Hy-air FC) or in a heat engine, or it may be burnt to generate heat. Therefore, anode materials may be provided by commercially pure aluminum, commercially produced aluminum alloys, and secondary aluminum. These materials are much cheaper and more readily available than special anode alloys of aluminum and high-purity aluminum. The aim of present study is to obtain experimental data for comparison of energy and cost parameters of some commercially produced aluminum alloys, of high-purity aluminum, and of a special Al-ln anode alloy in the context of using these materials as anodes for an Al-air battery and for combined production of electrical power and hydrogen.

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

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

Fasoyinu, Yemi

2014-03-31

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

The Effects of Specimen Geometry and Size on the Dynamic Failure of Aluminum Alloy 2219-T8 Under Impact Loading

NASA Astrophysics Data System (ADS)

Bolling, Denzell Tamarcus

A significant amount of research has been devoted to the characterization of new engineering materials. Searching for new alloys which may improve weight, ultimate strength, or fatigue life are just a few of the reasons why researchers study different materials. In support of that mission this study focuses on the effects of specimen geometry and size on the dynamic failure of AA2219 aluminum alloy subjected to impact loading. Using the Split Hopkinson Pressure Bar (SHPB) system different geometric samples including cubic, rectangular, cylindrical, and frustum samples are loaded at different strain rates ranging from 1000s-1 to 6000s-1. The deformation properties, including the potential for the formation of adiabatic shear bands, of the different geometries are compared. Overall the cubic geometry achieves the highest critical strain and the maximum stress values at low strain rates and the rectangular geometry has the highest critical strain and the maximum stress at high strain rates. The frustum geometry type consistently achieves the lowest the maximum stress value compared to the other geometries under equal strain rates. All sample types clearly indicated susceptibility to strain localization at different locations within the sample geometry. Micrograph analysis indicated that adiabatic shear band geometry was influenced by sample geometry, and that specimens with a circular cross section are more susceptible to shear band formation than specimens with a rectangular cross section.

Determination of forming limit diagrams of AA6013-T6 aluminum alloy sheet using a time and position dependent localized necking criterion

NASA Astrophysics Data System (ADS)

Dicecco, S.; Butcher, C.; Worswick, M.; Boettcher, E.; Chu, E.; Shi, C.

2016-11-01

The forming limit behaviour of AA6013-T6 aluminium alloy sheet was characterized under isothermal conditions at room temperature (RT) and 250°C using limiting dome height (LDH) tests. Full field strain measurements were acquired throughout testing using in situ stereoscopic digital image correlation (DIC) techniques. Limit strain data was generated from the resulting full field strain measurements using two localized necking criteria: ISO12004- 2:2008 and a time and position dependent criterion, termed the “Necking Zone” (NZ) approach in this paper, introduced by Martinez-Donaire et al. (2014). The limit strains resulting from the two localization detection schemes were compared. It was found that the ISO and NZ limit strains at RT are similar on the draw-side of the FLD, while the NZ approach yields a biaxial major limit strain 14.8% greater than the ISO generated major limit strain. At 250°C, the NZ generated major limit strains are 31-34% greater than the ISO generated major limit strains for near uniaxial, plane strain and biaxial loading conditions, respectively. The significant variance in limit strains between the two methodologies at 250°C highlights the need for a validation study regarding warm FLC determination.

The influence of cladding on fission gas release from irradiated U-Mo monolithic fuel

NASA Astrophysics Data System (ADS)

Burkes, Douglas E.; Casella, Amanda J.; Casella, Andrew M.

2017-04-01

The monolithic uranium-molybdenum (U-Mo) alloy has been proposed as a fuel design capable of converting the world's highest power research reactors from use of high enriched uranium to low enriched uranium. However, a zirconium (Zr) diffusion barrier must be used to eliminate interactions that form between the U-Mo monolith and aluminum alloy 6061 (AA6061) cladding during fabrication and are enhanced during irradiation. One aspect of fuel development and qualification is to demonstrate an appropriate understanding of the extent of fission product release from the fuel under anticipated service environments. An exothermic reaction has previously been observed between the AA6061 cladding and Zr diffusion layer. In this paper, two fuel segments with different irradiation history were subjected to specified thermal profiles under a controlled atmosphere using a thermogravimetric/differential thermal analyzer coupled with a mass spectrometer inside a hot cell. Samples from each segment were tested with cladding and without cladding to investigate the effect, if any, that the exothermic reaction has on fission gas release mechanisms. Measurements revealed there is an instantaneous effect of the cladding/Zr exothermic reaction, but not necessarily a cumulative effect above approximately 973 K (700 °C). The mechanisms responsible for fission gas release events are discussed.

On Using Homogeneous Polynomials To Design Anisotropic Yield Functions With Tension/Compression Symmetry/Assymetry

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

Soare, S.; Cazacu, O.; Yoon, J. W.

With few exceptions, non-quadratic homogeneous polynomials have received little attention as possible candidates for yield functions. One reason might be that not every such polynomial is a convex function. In this paper we show that homogeneous polynomials can be used to develop powerful anisotropic yield criteria, and that imposing simple constraints on the identification process leads, aposteriori, to the desired convexity property. It is shown that combinations of such polynomials allow for modeling yielding properties of metallic materials with any crystal structure, i.e. both cubic and hexagonal which display strength differential effects. Extensions of the proposed criteria to 3D stressmore » states are also presented. We apply these criteria to the description of the aluminum alloy AA2090T3. We prove that a sixth order orthotropic homogeneous polynomial is capable of a satisfactory description of this alloy. Next, applications to the deep drawing of a cylindrical cup are presented. The newly proposed criteria were implemented as UMAT subroutines into the commercial FE code ABAQUS. We were able to predict six ears on the AA2090T3 cup's profile. Finally, we show that a tension/compression asymmetry in yielding can have an important effect on the earing profile.« less

The influence of cladding on fission gas release from irradiated U-Mo monolithic fuel

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

Burkes, Douglas E.; Casella, Amanda J.; Casella, Andrew M.

2017-04-01

The monolithic uranium-molybdenum (U-Mo) alloy has been proposed as a fuel design capable of converting the world’s highest power research reactors from use of high enriched uranium to low enriched uranium. However, a zirconium (Zr) diffusion barrier must be used to eliminate interactions that form during fabrication and are enhanced during irradiation between the U-Mo monolith and aluminum alloy 6061 (AA6061) cladding. One aspect of fuel development and qualification is to demonstrate appropriate understanding of the extent of fission product release from the fuel under anticipated service environments. An exothermic reaction has previously been observed between the AA6061 cladding andmore » Zr diffusion layer. In this paper, two fuel segments with different irradiation history were subjected to specified thermal profiles under a controlled atmosphere using a thermogravimetric/differential thermal analyzer coupled with a mass spectrometer inside a hot cell. Samples from each segment were tested with cladding and without cladding to investigate the effect, if any, that the exothermic reaction has on fission gas release mechanisms. Measurements revealed there is an instantaneous effect of the cladding/Zr exothermic reaction, but not necessarily a cumulative effect above approximately 973 K (700 oC). The mechanisms responsible for fission gas release events are discussed.« less

A dynamic inert metal anode.

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

Hryn, J. N.

1998-11-09

A new concept for a stable anode for aluminum electrowinning is described. The anode consists of a cup-shaped metal alloy container filled with a molten salt that contains dissolved aluminum. The metal alloy can be any of a number of alloys, but it must contain aluminum as a secondary alloying metal. A possible alloy composition is copper with 5 to 15 weight percent aluminum. In the presence of oxygen, aluminum on the metal anode's exterior surface forms a continuous alumina film that is thick enough to protect the anode from chemical attack by cryolite during electrolysis and thin enough tomore » maintain electrical conductivity. However, the alumina film is soluble in cryolite, so it must be regenerated in situ. Film regeneration is achieved by the transport of aluminum metal from the anode's molten salt interior through the metal wall to the anode's exterior surface, where the transported aluminum oxidizes to alumina in the presence of evolving oxygen to maintain the protective alumina film. Periodic addition of aluminum metal to the anode's interior keeps the aluminum activity in the molten salt at the desired level. This concept for an inert anode is viable as long as the amount of aluminum produced at the cathode greatly exceeds the amount of aluminum required to maintain the anode's protective film.« less

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

NASA Astrophysics Data System (ADS)

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

2015-12-01

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

Evaluation of AA5052 alloy anode in alkaline electrolyte with organic rare-earth complex additives for aluminium-air batteries

NASA Astrophysics Data System (ADS)

Wang, Dapeng; Li, Heshun; Liu, Jie; Zhang, Daquan; Gao, Lixin; Tong, Lin

2015-10-01

Behaviours of the AA5052 aluminium alloy anode of the alkaline aluminium-air battery are studied by the hydrogen evolution test, the electrochemical measurements and the surface analysis method. The combination of amino-acid and rare earth as electrolyte additives effectively retards the self-corrosion of AA5052 aluminium alloy in 4 M NaOH solution. It shows that the combination of L-cysteine and cerium nitrate has a synergistic effect owing to the formation of a complex film on AA5052 alloy surface. The organic rare-earth complex can decrease the anodic polarisation, suppress the hydrogen evolution and increase the anodic utilization rate.

High Strength and Wear Resistant Aluminum Alloy for High Temperature Applications

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.; Munafo, Paul M. (Technical Monitor)

2002-01-01

In this paper, a new high strength and wear resistant aluminum cast alloy invented by NASA-MSFC for high temperature applications will be presented. Developed to meet U.S. automotive legislation requiring low-exhaust emission, the novel NASA 398 aluminum-silicon alloy offers dramatic improvement in tensile and fatigue strengths at elevated temperatures (500 F-800 F), enabling new pistons to utilize less material, which can lead to reducing part weight and cost as well as improving performance. NASA 398 alloy also offers greater wear resistance, surface hardness, dimensional stability, and lower thermal expansion compared to conventional aluminum alloys for several commercial and automotive applications. The new alloy can be produced economically using permanent steel molds from conventional gravity casting or sand casting. The technology was developed to stimulate the development of commercial aluminum casting products from NASA-developed technology by offering companies the opportunity to license this technology.

Beryllium-aluminum alloys for investment castings

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

Nachtrab, W.T.; Levoy, N.

1997-05-01

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

NASA-427: A New Aluminum Alloy

NASA Technical Reports Server (NTRS)

Nabors, Sammy A.

2015-01-01

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

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

Development of 1100 °C Capable Alumina-Forming Austenitic Alloys

DOE PAGES

Brady, M. P.; Muralidharan, G.; Yamamoto, Y.; ...

2016-11-18

Recently dalumina-forming austenitic (AFA) alloys based on ~12–32 weight % (wt%) Ni have been developed and offer an attractive combination of oxidation resistance and creep resistance at relatively low alloy cost. But, they exhibit a transition to internal oxidation and nitridation of Al above ~750–950 °C depending on composition and exposure environment. In order to identify AFA compositions capable of higher-temperature operation for applications such as ethylene cracking, the oxidation behavior of a series of developmental, as-cast nominal Fe–(25–45)Ni–(10–25)Cr–(4–5)Al–1Si–0.15Hf–0.07Y–0.01B wt% base alloys with and without Nb, Ti, and C additions was evaluated at 1100 °C in air with 10% watermore » vapor. Furthermore, we observed protective alumina scale formation at levels of 35Ni, 25Cr, and 4Al with additions of Nb and C, indicating promise for 1100°C capable cast AFA alloys.« less

Gas-tungsten arc welding of aluminum alloys

DOEpatents

Frye, L.D.

1982-03-25

The present invention is directed to a gas-tungsten arc welding method for joining together structures formed of aluminum alloy with these structures disposed contiguously to a heat-damagable substrate of a metal dissimilar to the aluminum alloy. The method of the present invention is practiced by diamond machining the fay surfaces of the aluminum alloy structures to profice a mirror finish thereon having a surface roughness in the order of about one microinch. The fay surface are aligned and heated sufficiently by the tungsten electrode to fuse the aluminum alloy continguous to the fay surfaces to effect the weld joint. The heat input used to provide an oxide-free weld is significantly less than that required if the fay surfaces were prepared by using conventional chemical and mechanical practices.

Ultrafine nanoporous palladium-aluminum film fabricated by citric acid-assisted hot-water-treatment of aluminum-palladium alloy film

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

Harumoto, Takashi; Tamura, Yohei; Ishiguro, Takashi, E-mail: ishiguro@rs.noda.tus.ac.jp

Hot-water-treatment has been adapted to fabricate ultrafine nanoporous palladium-aluminum film from aluminum-palladium alloy film. Using citric acid as a chelating agent, a precipitation of boehmite (aluminum oxide hydroxide, AlOOH) on the nanoporous palladium-aluminum film was suppressed. According to cross-sectional scanning transmission electron microscopy observations, the ligament/pore sizes of the prepared nanoporous film were considerably small (on the order of 10 nm). Since this fabrication method only requires aluminum alloy film and hot-water with chelating agent, the ultrafine nanoporous film can be prepared simply and environmentally friendly.

The effect of hydrogen embrittlement on the localized plastic deformation of aluminum alloy

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

Bochkareva, Anna, E-mail: avb@ispms.tsc.ru; Lunev, Aleksey, E-mail: agl@ispms.tsc.ru; National Research Tomsk Polytechnic University, Tomsk, 634050

2015-10-27

The effect of hydrogen embrittlement on the localized plastic deformation of aluminum alloy D1 was investigated. The studies were performed for the test samples of aluminum alloy subjected to electrolytic hydrogenation. It is found that the mechanical properties and localized plastic deformation parameters of aluminum alloy are affected adversely by hydrogen embrittlement. The hydrogenated counterpart of alloy has a lower degree of ductility relative to the original alloy; however, the plastic flow behavior of material remains virtually unaffected. Using scanning electron and atomic force microscopy methods, the changes in the fracture surface were investigated. The deformation diagrams were examined formore » the deformed samples of aluminum alloy. These are found to show all the plastic flow stages: the linear, parabolic and pre-failure stages would occur for the respective values of the exponent n from the Ludwik-Holomon equation. Using digital speckle image technique, the local strain patterns were being registered for the original alloy D1 and the counterpart subjected to electrolytic hydrogenation for 100 h.« less

Investigation of americium-241 metal alloys for target applications. [Alloys with cerium

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

Conner, W.V.

1980-01-01

Several americium-241 metal alloys have been investigated for possible use in the Lawrence Livermore National Laboratory Radiochemical Diagnostic Tracer Program. Alloys investigated have included uranium-americium, aluminum-americium, and cerium-americium. Uranium-americium alloys with the desired properties proved to be difficult to prepare, and work with this alloy was discontinued. Aluminum-americium alloys were much easier to prepare, but the alloy consisted of an aluminum-americium intermetallic compound (AmAl/sub 4/) in an aluminum matrix. This alloy could be cast and formed into shapes, but the low density of aluminum, and other problems; made the alloy unsuitable for the intended application. Americium metal was found tomore » have a high solid solubility in cerium and alloys prepared from these two elements exhibited all of the properties desired for the tracer program application. Cerium-americium alloys containing up to 34 wt % americium have been prepared using both comelting and coreduction techniques. The latter technique involves coreduction of Ce F/sub 4/ and AmF/sub 4/ with calcium metal in a sealed reduction vessel. Casting techniques have been developed for preparing up to eight 0.87 inch (2.2 cm) diameter disks in a single casting, and cerium-americium metal alloy disks containing from 10 to 25 wt % americium-241 have been prepared using these techniques.« less

The Inhibition of Aluminum Corrosion in Sulfuric Acid by Poly(1-vinyl-3-alkyl-imidazolium Hexafluorophosphate)

PubMed Central

Arellanes-Lozada, Paulina; Olivares-Xometl, Octavio; Guzmán-Lucero, Diego; Likhanova, Natalya V.; Domínguez-Aguilar, Marco A.; Lijanova, Irina V.; Arce-Estrada, Elsa

2014-01-01

Compounds of poly(ionic liquid)s (PILs), derived from imidazole with different alkylic chain lengths located in the third position of the imidazolium ring (poly(1-vinyl-3-dodecyl-imidazolium) (PImC12), poly(1-vinyl-3-octylimidazolium) (PImC8) and poly(1-vinyl-3-butylimidazolium) (PImC4) hexafluorophosphate) were synthesized. These compounds were tested as corrosion inhibitors on aluminum alloy AA6061 in diluted sulfuric acid (0.1–1 M H2SO4) by weight loss tests, polarization resistance measurements and inductively coupled plasma optical emission spectroscopy. Langmuir’s isotherms suggested film formation on bare alloy while standard free energy indicated inhibition by a physisorption process. However, compound efficiencies as inhibitors ranked low (PImC12 > PImC8 > PImC4) to reach 61% for PImC12 in highly diluted acidic solution. Apparently, the high mobility of sulfates favored their adsorption in comparison to PILs. The surface film displayed general corrosion, and pitting occurred as a consequence of PILs’ partial inhibition along with a continuous dissolution of defective patchy film on formation. A slight improvement in efficiency was displayed by compounds having high molecular weight and a long alkyl chain, as a consequence of steric hindrance and PIL interactions. PMID:28788156

Modeling the microstructural changes during hot tandem rolling of AA5 XXX aluminum alloys: Part II. Textural evolution

NASA Astrophysics Data System (ADS)

Wells, M. A.; Samarasekera, I. V.; Brimacombe, J. K.; Hawbolt, E. B.; Lloyd, D. J.

1998-06-01

In Part II of this article, the experimental work undertaken to measure the effect of deformation parameters (temperature, strain, and strain rate) on the texture formation during hot deformation and the evolution during subsequent recrystallization is described. In addition, the isothermal kinetics of development of individual texture components were also determined. A neutron diffractometer was used to measure the texture in the as-hot-deformed aluminum samples, and the samples were then heat treated in a 400 °C salt bath for various lengths of time, with the texture being remeasured at various stages in the recrystallization process. Using data from the experimental program, the texture evolution during recrystallization was modeled by applying a modified form of the Avrami equation. Results indicated that, of the deformation parameters studied, textural development was most sensitive to the deformation temperature for both alloys. In addition, modeling results revealed that the Cu component ({112} <111>) was the first to recrystallize, typically followed by the S ({123} <634>) and Bs ({110} <112>) components. This is in agreement with earlier work which indicated that the Bs component was the hardest to recrystallize, possibly because it is able to deform on very few slip systems and, hence, the dislocation interaction may be low.

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

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.

2009-01-01

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

Fatigue crack propagation in aluminum-lithium alloys

NASA Technical Reports Server (NTRS)

Rao, K. T. V.; Ritchie, R. O.; Piascik, R. S.; Gangloff, R. P.

1989-01-01

The principal mechanisms which govern the fatigue crack propagation resistance of aluminum-lithium alloys are investigated, with emphasis on their behavior in controlled gaseous and aqueous environments. Extensive data describe the growth kinetics of fatigue cracks in ingot metallurgy Al-Li alloys 2090, 2091, 8090, and 8091 and in powder metallurgy alloys exposed to moist air. Results are compared with data for traditional aluminum alloys 2024, 2124, 2618, 7075, and 7150. Crack growth is found to be dominated by shielding from tortuous crack paths and resultant asperity wedging. Beneficial shielding is minimized for small cracks, for high stress ratios, and for certain loading spectra. While water vapor and aqueous chloride environments enhance crack propagation, Al-Li-Cu alloys behave similarly to 2000-series aluminum alloys. Cracking in water vapor is controlled by hydrogen embrittlement, with surface films having little influence on cyclic plasticity.

Effects of silicon, copper and iron on static and dynamic properties of alloy 206 (aluminum-copper) in semi-solids produced by the SEED process

NASA Astrophysics Data System (ADS)

Lemieux, Alain

The advantages of producing metal parts by rheocasting are generally recognised for common foundry alloys of Al-Si. However, other more performing alloys in terms of mechanical properties could have a great interest in specialized applications in the automotive industry, while remaining competitive in the forming. Indeed, the growing demand for more competitive products requires the development of new alloys better suited to semi-solid processes. Among others, Al-Cu alloys of the 2XX series are known for their superior mechanical strength. However, in the past, 2XX alloys were never candidates for pressure die casting. The main reason is their propensity to hot tearing. Semi-solid processes provide better conditions for molding with the rheological behavior of dough and molding temperatures lower reducing this type of defect. In the initial phase, this research has studied factors that reduce hot tearing susceptibility of castings produced by semi-solid SEED of alloy 206. Subsequently, a comparative study on the tensile properties and fatigue was performed on four variants of the alloy 206. The results of tensile strength and fatigue were compared with the specifications for applications in the automotive industry and also to other competing processes and alloys. During this study, several metallurgical aspects were analyzed. The following main points have been validated: i) the main effects of compositional variations of silicon, iron and copper alloy Al-Cu (206) on the mechanical properties, and ii) certain relationships between the mechanism of hot cracking and the solidification rate in semi-solid. Parts produced from the semi-solid paste coming from the SEED process combined with modified 206 alloys have been successfully molded and achieved superior mechanical properties than the requirements of the automotive industry. The fatigue properties of the two best modified 206 alloys were higher than those of A357 alloy castings and are close to those of the wrought alloy AA6061. At present, there is simply no known application for pressure die-cast alloy with 206 (Liquid Die-casting). This is mainly due to the high propensity to hot cracking and limitations facing the part geometry and the subsequent assembly. This study demonstrated that in addition to pieces produced by semi-solid die-casting using large variations in chemical composition, the SEED process allows obtaining spare sound (sound part) and more complex geometry. Moreover, as the semi-solid parts have less porosity, they can also be machined and welded for some applications. The conclusions of this study demonstrate significant progress in identifying the main issues related to the feasibility of die-casting good parts with high performance using the modified 206 alloy combined with SEED process. This work is therefore a baseline work in the development of new Al-Cu alloys for industries of semi-solid and, at the same time, for the expansion of aluminum for high performance applications in the industry. N.B. This thesis is part of a research project developed by the NSERC / Rio Tinto Akan Industrial Research Chair in Metallurgy of Innovative Aluminum Transformation (CIMTAL).

Biaxial Testing of 2195 Aluminum Lithium Alloy Using Cruciform Specimens

NASA Technical Reports Server (NTRS)

Johnston, W. M.; Pollock, W. D.; Dawicke, D. S.; Wagner, John A. (Technical Monitor)

2002-01-01

A cruciform biaxial test specimen was used to test the effect of biaxial load on the yield of aluminum-lithium alloy 2195. Fifteen cruciform specimens were tested from 2 thicknesses of 2195-T8 plate, 0.45 in. and 1.75 in. These results were compared to the results from uniaxial tensile tests of the same alloy, and cruciform biaxial tests of aluminum alloy 2219-T87.

High-temperature, low-cycle fatigue behavior of an Al-Mg-Si based heat-resistant aluminum alloy

NASA Astrophysics Data System (ADS)

Kim, Kyu-Sik; Sung, Si-Young; Han, Bum-Suck; Park, Joong-Cheol; Lee, Kee-Ahn

2015-11-01

High-temperature, low-cycle fatigue behavior of the new heat-resistant aluminum alloy was investigated in this study. The aluminum alloy consists of aluminum matrix and small amount of precipitated Mg2Si and (Co, Ni)3Al4 strengthening particles. At room temperature and 523 K, the yield and tensile strengths of Al-Mg-Si-(Co, Ni) the aluminum alloy were maintained with no significant decrease, and elongation increased slightly. Low-cycle fatigue tests controlled by total strain were performed with strain ratio (R) = -1, strain rate = 2×10-3 s-1 at 523 K. The fatigue limit of the low-cycle fatigue of this alloy showed plastic strain amplitude (Δ ɛ pa) of 0.22% at 103 cycles. This value was superior to that of conventional aluminum alloy such as A319. The results of the fractographical observation showed that second phases, especially (Co, Ni)3Al4 particles, affected fatigue behavior. This study also attempted to clarify the mechanism of high-temperature, low-cycle fatigue deformation of Al-Mg-Si-(Co, Ni) alloy in relation to its microstructure and energy dissipation analysis.

Precision forging technology for aluminum alloy

NASA Astrophysics Data System (ADS)

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

2018-03-01

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

A Fatigue Model for Discontinuous Particulate-Reinforced Aluminum Alloy Composite: Influence of Microstructure

NASA Astrophysics Data System (ADS)

McCullough, R. R.; Jordon, J. B.; Brammer, A. T.; Manigandan, K.; Srivatsan, T. S.; Allison, P. G.; Rushing, T. W.

2014-01-01

In this paper, the use of a microstructure-sensitive fatigue model is put forth for the analysis of discontinuously reinforced aluminum alloy metal matrix composite. The fatigue model was used for a ceramic particle-reinforced aluminum alloy deformed under conditions of fully reversed strain control. Experimental results revealed the aluminum alloy to be strongly influenced by volume fraction of the particulate reinforcement phase under conditions of strain-controlled fatigue. The model safely characterizes the evolution of fatigue damage in this aluminum alloy composite into the distinct stages of crack initiation and crack growth culminating in failure. The model is able to capture the specific influence of particle volume fraction, particle size, and nearest neighbor distance in quantifying fatigue life. The model yields good results for correlation of the predicted results with the experimental test results on the fatigue behavior of the chosen aluminum alloy for two different percentages of the ceramic particle reinforcement. Further, the model illustrates that both particle size and volume fraction are key factors that govern fatigue lifetime. This conclusion is well supported by fractographic observations of the cyclically deformed and failed specimens.

Applications of high-temperature powder metal aluminum alloys to small gas turbines

NASA Technical Reports Server (NTRS)

Millan, P. P., Jr.

1982-01-01

A program aimed at the development of advanced powder-metallurgy (PM) aluminum alloys for high-temperature applications up to 650 F using the concepts of rapid solidification and mechanical alloying is discussed. In particular, application of rapidly solidified PM aluminum alloys to centrifugal compressor impellers, currently used in auxiliary power units for both military and commercial aircraft and potentially for advanced automotive gas turbine engines, is examined. It is shown that substitution of high-temperature aluminum for titanium alloy impellers operating in the 360-650 F range provides significant savings in material and machining costs and results in reduced component weight, and consequently, reduced rotating group inertia requirements.

Electrodeposition of magnesium and magnesium/aluminum alloys

DOEpatents

Mayer, Anton

1988-01-01

Electrolytes and plating solutions for use in processes for electroplating and electroforming pure magnesium and alloys of aluminum and magnesium and also electrodeposition processes. An electrolyte of this invention is comprised of an alkali metal fluoride or a quaternary ammonium halide, dimethyl magnesium and/or diethyl magnesium, and triethyl aluminum and/or triisobutyl aluminum. An electrolyte may be dissolved in an aromatic hydrocarbon solvent to form a plating solution. The proportions of the component compounds in the electrolyte are varied to produce essentially pure magnesium or magnesium/aluminum alloys having varying selected compositions.

Electrodeposition of magnesium and magnesium/aluminum alloys

DOEpatents

Mayer, A.

1988-01-21

Electrolytes and plating solutions for use in processes for electroplating and electroforming pure magnesium and alloys of aluminum and magnesium and also electrodeposition processes. An electrolyte of this invention is comprised of an alkali metal fluoride or a quaternary ammonium halide, dimethyl magnesium and/or diethyl magnesium, and triethyl aluminum and/or triisobutyl aluminum. An electrolyte may be dissolved in an aromatic hydrocarbon solvent to form a plating solution. The proportions of the component compounds in the electrolyte are varied to produce essentially pure magnesium or magnesium/aluminum alloys having varying selected compositions.

The hydrogen diffusion in liquid aluminum alloys from ab initio molecular dynamics

NASA Astrophysics Data System (ADS)

Jakse, N.; Pasturel, A.

2014-09-01

We study the hydrogen diffusion in liquid aluminum alloys through extensive ab initio molecular dynamics simulations. At the microscopic scale, we show that the hydrogen motion is characterized by a broad distribution of spatial jumps that does not correspond to a Brownian motion. To determine the self-diffusion coefficient of hydrogen in liquid aluminum alloys, we use a generalized continuous time random walk model recently developed to describe the hydrogen diffusion in pure aluminum. In particular, we show that the model successfully accounts the effects of alloying elements on the hydrogen diffusion in agreement with experimental features.

Strengthening Aluminum Alloys for High Temperature Applications Using Nanoparticles of Al203 and Al3-X Compounds (X= Ti, V, Zr)

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.

2007-01-01

In this paper the effect of nanoparticles A12O3 and A13-X compounds (X= Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their chemical stability and low diffusions rates in aluminum matrix at high temperatures. The strengthening mechanism for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. Samples were prepared from A12O3 nanoparticle preforms, which were produced using ceramic injection molding process and pressure infiltrated by molten aluminum. A12O3 nanoparticles can also be homogeneously mixed with aluminum powder and consolidated into samples through hot pressing and sintering. On the other hand, the Al3-X nanoparticles are produced as precipitates via in situ reactions with molten aluminum alloys using conventional casting techniques. The degree of alloy strengthening using nanoparticles will depend on the materials, particle size, shape, volume fraction, and mean inter-particle spacing.

Advanced powder metallurgy aluminum alloys and composites

NASA Technical Reports Server (NTRS)

Lisagor, W. B.; Stein, B. A.

1982-01-01

The differences between powder and ingot metallurgy processing of aluminum alloys are outlined. The potential payoff in the use of advanced powder metallurgy (PM) aluminum alloys in future transport aircraft is indicated. The national program to bring this technology to commercial fruition and the NASA Langley Research Center role in this program are briefly outlined. Some initial results of research in 2000-series PM alloys and composites that highlight the property improvements possible are given.

Interactive effects of aging parameters of AA6056

NASA Astrophysics Data System (ADS)

Dehghani, Kamran; Nekahi, Atiye

2012-10-01

The effect of thermomechanical treatment on the aging behavior of AA6056 aluminum alloy was modeled using response surface methodology (RSM). Two models were developed to predict the final yield stress (FYS) and elongation amounts as well as the optimum conditions of aging process. These were done based on the interactive effects of applied thermomechanical parameters. The optimum condition predicted by the model to attain the maximum strength was pre-aging at 80 °C for 15 h, followed by 70% cold work and subsequent final aging at 165 °C for 4 h, which resulted in the FYS of about 480 MPa. As for the elongation, the optimum condition was pre-aging at 80 °C for 15 h, followed by 30% cold work and final-aging at 165 °C for 4 h, which led to 21% elongation. To verify the suggested optimum conditions, the tests were carried out confirming the high accuracy (above 94%) of the RSM technique as well as the developed models. It is shown that the RSM can be used successfully to optimize the aging process, to determine the significance of aging parameters and to model the combination effect of process variables on the aging behavior of AA6056.

Construction of vacuum system for Tristan accumulation ring

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

Ishimaru, H.; Horikoshi, G.; Kobayashi, M.

1983-08-01

An all aluminum-alloy vacuum system for the TRISTAN accumulation ring is now under construction. Aluminum and aluminum alloys are preferred materials for ultrahigh vacuum systems of large electron storage rings because of their good thermal conductivity, extremely low outgassing rate, and low residual radioactivity. Vacuum beam chambers for the dipole and quadrupole magnets are extruded using porthole dies. The aluminum alloy 6063-T6 provides superior performance in extrusion. For ultrahigh vacuum performance, a special extrusion technique is applied which, along with the outgassing procedure used, is described in detail. Aluminum alloy 3004 seamless elliptical bellows are inserted between the dipole andmore » quadrupole magnet chambers. These bellows are produced by the hydraulic forming of a seamless tube. The seamless bellows and the beam chambers are joined by fully automatic welding. The ceramic chambers for the kicker magnets, the fast bump magnets, and the slow beam intensity monitor are inserted in the aluminum alloy beam chambers. The ceramic chamber (98% alumina) and elliptical bellows are brazed with brazing sheets (4003-3003-4003) in a vacuum furnace. The brazing technique is described. The inner surface of the ceramic chamber is coated with a TiMo alloy by vacuum evaporation to permit a smooth flow of the RF wall current. Other suitable aluminum alloy components, including fittings, feedthroughs, gauges, optical windows, sputter ion pumps, turbomolecular pumps, and valves have been developed; their fabrication is described.« less

High-Strength Aluminum Casting Alloy for High-Temperature Applications (MSFC Center Director's Discretionary Fund Final Project No. 97-10)

NASA Technical Reports Server (NTRS)

Lee, J. A.

1998-01-01

A new aluminum-silicon alloy has been successfully developed at Marshall Space Flight Center that has a significant improvement in tensile strength at elevated temperatures (550 to 700 F). For instance, the new alloy shows in average tensile strength of at least 90 percent higher than the current 390 aluminum piston alloy tested at 500 F. Compared to conventional aluminum alloys, automotive engines using the new piston alloy will have improved gas mileage, and may produce less air pollution in order to meet the future U.S. automotive legislative requirements for low hydrocarbon emissions. The projected cost for this alloy is less than $0.95/lb, and it readily allows the automotive components to be cast at a high production volume with a low, fully accounted cost. It is economically produced by pouring molten metal directly into conventional permanent steel molds or die casting.

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.

Negative electrode composition

DOEpatents

Kaun, Thomas D.; Chilenskas, Albert A.

1982-01-01

A secondary electrochemical cell and a negative electrode composition for use therewith comprising a positive electrode containing an active material of a chalcogen or a transiton metal chalcogenide, a negative electrode containing a lithium-aluminum alloy and an amount of a ternary alloy sufficient to provide at least about 5 percent overcharge capacity relative to a negative electrode solely of the lithium-aluminum alloy, the ternary alloy comprising lithium, aluminum, and iron or cobalt, and an electrolyte containing lithium ions in contact with both of the positive and the negative electrodes. The ternary alloy is present in the electrode in the range of from about 5 percent to about 50 percent by weight of the electrode composition and may include lithium-aluminum-nickel alloy in combination with either the ternary iron or cobalt alloys. A plurality of series connected cells having overcharge capacity can be equalized on the discharge side without expensive electrical equipment.

Study of tapping process of carbon fiber reinforced plastic composites/AA7075 stacks

NASA Astrophysics Data System (ADS)

D'Orazio, Alessio; Mehtedi, Mohamad El; Forcellese, Archimede; Nardinocchi, Alessia; Simoncini, Michela

2018-05-01

The present investigation aims at studying the tapping process of a three-layer stack constituted by two CFRP layers and a core plate in AA7075 aluminum alloy. The CFRP laminates were obtained by a pre-impregnated woven sample made up of T700 carbon fibers and a thermoset epoxy matrix. Tapping experiments were performed on a 5-axis machining center instrumented with a dynamometer to measure thrust force generated during process. A high-speed steel tool, coated with nanocomposite TiAlN, was used. According to the tool manufacturer recommendations, rotational speed and feed rate were 800 rpm and 1000 mm/min, respectively. Similar thrust force time history responses were obtained by tapping different holes, even though the vertical force increases with number of threaded holes. Furthermore, a quantitative evaluation of delamination at the periphery of entry holes was carried out. The delamination at the entry hole strongly increases with number of threaded holes.

The Cryogenic Tensile Properties of an Extruded Aluminum-Beryllium Alloy

NASA Technical Reports Server (NTRS)

Gamwell, W. R.

2002-01-01

Basic mechanical properties; i.e., ultimate tensile strength, yield strength, percent elongation, and elastic modulus, were obtained for the aluminum-beryllium alloy, AlBeMet162, at cryogenic (-195.5 C (-320 F) and -252.8 C (-423 F)) temperatures. The material evaluated was purchased to the requirements of SAE-AMS7912, "Aluminum-Beryllium Alloy, Extrusions."

The application of water coupled nonlinear ultrasonics to quantify the dislocation density in aluminum 1100

NASA Astrophysics Data System (ADS)

Mostavi, Amir; Tehrani, N.; Kamali, N.; Ozevin, D.; Chi, S. W.; Indacochea, J. E.

2017-02-01

This article investigates water coupled nonlinear ultrasonic method to measure the dislocation density in aluminum 1100 specimens. The different levels of dislocation densities are introduced to the samples by applying different levels of plastic strains by tensile loading. The ultrasonic testing includes 2.25 MHz transducer as transmitter and 5.0 MHz transducer as receiver in an immersion tank. The results of immersion experiments are compared with oil-coupled experiments. While water has significant nonlinearity within itself, the immersion ultrasound results agree with the literature of oil coupled ultrasound results of the specimens that the nonlinearity coefficient increases with the increase of dislocation density in aluminum.

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.

Degradation Mechanisms in Aluminum Matrix Composites: Alumina/Aluminum and Boron/Aluminum. Ph.D. Thesis - North Carolina State Univ. at Raleigh

NASA Technical Reports Server (NTRS)

Olsen, G. C.

1981-01-01

The effects of fabrication and long term thermal exposure (up to 10,000 hours at 590 K) on two types of aluminum matrix composites were examined. An alumina/aluminum composite, was made of continuous alpha Al2O3 fibers in a matrix of commercially pure aluminum alloyed with 2.8% lithium. The mechanical properties of the material, the effect of isothermal exposure, cyclic thermal exposure, and fatigue are presented. Two degradation mechanisms are identified. One was caused by formation of a nonstoichiometric alumina during fabrication, the other by a loss of lithium to a surface reaction during long term thermal exposure. The other composite, boron/aluminum, made of boron fibers in an aluminum matrix, was investigated using five different aluminum alloys for the matrices. The mechanical properties of each material and the effect of isothermal and cyclic thermal exposure are presented. The effects of each alloy constituent on the degradation mechanisms are discussed. The effects of several reactions between alloy constituents and boron fibers on the composite properties are discussed.

Effect of fiber diameter and matrix alloys on impact-resistant boron/aluminum composites

NASA Technical Reports Server (NTRS)

Mcdanels, D. L.; Signorelli, R. A.

1976-01-01

Efforts to improve the impact resistance of B/Al are reviewed and analyzed. Nonstandard thin-sheet charpy and Izod impact tests and standard full-size Charpy impact tests were conducted on composites containing unidirectional 0.10mm, 0.14mm, and 0.20mm diameter boron fibers in 1100, 2024, 5052, and 6061 Al matrices. Impact failure modes of B/Al are proposed in an attempt to describe the mechanisms involved and to provide insight for maximizing impact resistance. The impact strength of B/Al was significantly increased by proper selection of materials and processing. The use of a ductile matrix and large diameter boron fibers gave the highest impact strengths. This combination resulted in improved energy absorption through matrix shear deformation and multiple fiber breakage.

An Investigation on Axial Deformation Behavior of Thin-Wall Unfilled and Filled Tube with Aluminum Alloy (Al-Si7Mg) Foam Reinforced with SiC Particles

NASA Astrophysics Data System (ADS)

Kumaraswamidhas, L. A.; Rajak, Dipen Kumar; Das, S.

2016-08-01

The objective of this research is to produce superior quality aluminum alloy foam with low relative density and higher resistance against compression deformation. This investigation has studied crash energy capacities of unfilled and filled aluminum alloy foams in mild steel tubes. The foam has been prepared by the melt route process with an addition of 5wt.% silicon carbide particles. The fabricated aluminum alloy foams were characterized by field emission scanning electron microscopy, x-ray diffraction, Fourier transform infrared spectroscopy, and Material Pro analyzer. It was observed that the foam-filled tubes could absorb more energy as compared to the unfilled tubes before reaching the complete densification point. Also, the aluminum alloy foams had better energy absorption capacity during the crash or impact loading. This article demonstrates the excellent ability of aluminum alloy foam application in the field where there is a need to absorb crash energy. It is to be noted that the amount of energy absorption will be greater for low-density foam filled in thin-wall rectangular section tubes. We have seen an increasing trend in the application of aluminum foams inside the thin-wall mild steel tubes for maximum energy absorption.

Electrochemical study of aluminum corrosion in boiling high purity water

NASA Technical Reports Server (NTRS)

Draley, J. E.; Legault, R. A.

1969-01-01

Electrochemical study of aluminum corrosion in boiling high-purity water includes an equation relating current and electrochemical potential derived on the basis of a physical model of the corrosion process. The work involved an examination of the cathodic polarization behavior of 1100 aluminum during aqueous oxidation.

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST). Supplement: Research on Materials for the High Speed Civil Transport

NASA Technical Reports Server (NTRS)

Gangloff, Richard P.; Starke, Edgar A., Jr.

1997-01-01

This report documents the progress achieved over the past 6 to 12 months on four graduate student projects conducted within the NASA-UVA Light Aerospace Alloy and Structures Technology Program. These studies were aimed specifically at light metallic alloy issues relevant to the High Speed Civil Transport. Research on Hydrogen-Enhanced Fracture of High-Strength Titanium Alloy Sheet refined successfully the high resolution R-curve method necessary to characterize initiation and growth fracture toughnesses. For solution treated and aged Low Cost Beta without hydrogen precharging, fracture is by ductile transgranular processes at 25 C, but standardized initiation toughnesses are somewhat low and crack extension is resolved at still lower K-levels. This fracture resistance is degraded substantially, by between 700 and 1000 wppm of dissolved hydrogen, and a fracture mode change is affected. The surface oxide on P-titanium alloys hinders hydrogen uptake and complicates the electrochemical introduction of low hydrogen concentrations that are critical to applications of these alloys. Ti-15-3 sheet was obtained for study during the next reporting period. Research on Mechanisms of deformation and Fracture in High-Strength Titanium Alloys is examining the microstructure and fatigue resistance of very thin sheet. Aging experiments on 0. 14 mm thick (0.0055 inch) foil show microstructural agility that may be used to enhance fatigue performance. Fatigue testing of Ti-15-3 sheet has begun. The effects of various thermo-mechanical processing regimens on mechanical properties will be examined and deformation modes identified. Research on the Effect of Texture and Precipitates on Mechanical Property Anisotropy of Al-Cu-Mg-X and Al-Cu alloys demonstrated that models predict a minor influence of stress-induced alignment of Phi, caused by the application of a tensile stress during aging, on the yield stress anisotropy of both modified AA2519 and a model Al-Cu binary alloy. This project is no longer included in the NASA-UVA LAST program. Research on the Creep Behavior and Microstructural stability of Al-Cu-Mg-Ag and Al-Cu-Li-Mg-Ag showed that the creep resistance of three candidate aluminum alloys (C415, C416 and ML377) was much superior compared to that of the current Concorde alloy, AA2618. Creep induced change in precipitates at grain boundaries was observed in the alloy which exhibits the highest creep strain of the three examined. The other two alloys developed no detectable microstructural changes at grain boundaries under the creep conditions tested.

Preparation of aluminum-magnesium alloy from magnesium oxide in RECl3-KCl-MgCl2 electrolyte by molten salts electrolysis method

NASA Astrophysics Data System (ADS)

Yang, Shaohua; Wu, Lin; Yang, Fengli; Li, Mingzhou; Hu, Xianwei; Wang, Zhaowen; Shi, Zhongning; Gao, Bingliang

Aluminum-magnesium alloys were prepared from magnesium oxide by molten salt electrolysis method. 10w%RECl3-63.5w%KCl-23.5w%MgCl2-3w%MgO was taken as electrolyte. The results showed that RE could be attained in aluminum-magnesium alloy, and it was proved that the RE was reduced directly by aluminum. Magnesium in the alloy was produced by electrolysis on cathode. The content of RE in the alloy was about 0.8wt %-1.2wt%, and the content of Mg in the alloy was lwt%˜6wt% with electrolytic times. The highest current efficiency was 81.3% with 0.8A/cm2 current density. The process of electrolysis was controlled together by electrochemical polarization and concentration polarization.

On the Prediction of Hot Tearing in Al-to-Steel Welding by Friction Melt Bonding

NASA Astrophysics Data System (ADS)

Jimenez-Mena, N.; Jacques, P. J.; Drezet, J. M.; Simar, A.

2018-07-01

Aluminum alloy AA6061 was welded to dual-phase steel 980 (DP980) by the friction melt bonding (FMB) process. Hot tears have been suppressed by controlling the thermomechanical cycle. In particular, the welding speed and the thermal conductivity of the backing plate have been optimized. A finite-element thermomechanical model coupled with the Rappaz-Drezet-Gremaud (RDG) criterion has been used to explain these experimental observations. The hot tear susceptibility has been reduced with large thermal gradients and with the formation of a cellular microstructure. Both effects are favored by a backing plate made of a material with high thermal conductivity, such as copper.

On the Prediction of Hot Tearing in Al-to-Steel Welding by Friction Melt Bonding

NASA Astrophysics Data System (ADS)

Jimenez-Mena, N.; Jacques, P. J.; Drezet, J. M.; Simar, A.

2018-04-01

Aluminum alloy AA6061 was welded to dual-phase steel 980 (DP980) by the friction melt bonding (FMB) process. Hot tears have been suppressed by controlling the thermomechanical cycle. In particular, the welding speed and the thermal conductivity of the backing plate have been optimized. A finite-element thermomechanical model coupled with the Rappaz-Drezet-Gremaud (RDG) criterion has been used to explain these experimental observations. The hot tear susceptibility has been reduced with large thermal gradients and with the formation of a cellular microstructure. Both effects are favored by a backing plate made of a material with high thermal conductivity, such as copper.

Effect of Copper and Silicon on Al-5%Zn Alloy as a Candidate Low Voltage Sacrificial Anode

NASA Astrophysics Data System (ADS)

Pratesa, Yudha; Ferdian, Deni; Togina, Inez

2017-05-01

One common method used for corrosion protection is a sacrificial anode. Sacrificial anodes that usually employed in the marine environment are an aluminum alloy sacrificial anode, especially Al-Zn-In. However, the electronegativity of these alloys can cause corrosion overprotection and stress cracking (SCC) on a high-strength steel. Therefore, there is a development of the sacrificial anode aluminum low voltage to reduce the risk of overprotection. The addition of alloying elements such as Cu, Si, and Ge will minimize the possibility of overprotection. This study was conducted to analyze the effect of silicon and copper addition in Al-5Zn. The experiment started from casting the sacrificial anode aluminum uses electrical resistance furnace in a graphite crucible in 800°C. The results alloy was analyzed using Optical emission spectroscopy (OES), Differential scanning calorimetry, electrochemical impedance spectroscopy, and metallography. Aluminum alloy with the addition of a copper alloy is the most suitable and efficient to serve as a low-voltage sacrificial anode aluminum. Charge transfer resistivity of copper is smaller than silicon which indicates that the charge transfer between the metal and the electrolyte is easier t to occur. Also, the current potential values in coupling with steel are also in the criteria range of low-voltage aluminum sacrificial anodes.

Particulate and gaseous emissions when welding aluminum alloys.

PubMed

Cole, Homer; Epstein, Seymour; Peace, Jon

2007-09-01

Fabrication and repair of aluminum components and structures commonly involves the use of electric arc welding. The interaction of the arc and the metal being welded generates ultraviolet radiation, metallic oxides, fumes, and gases. Aluminum is seldom used as the pure metal but is often alloyed with other metals to improve strength and other physical properties. Therefore, the exact composition of any emissions will depend on the welding process and the particular aluminum alloy being welded. To quantify such emissions, The Aluminum Association sponsored several studies to characterize arc welding emissions by the gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) processes for various combinations of base and filler alloys. In all cases, the tests were conducted under conditions that could be found in a production weld shop without forced ventilation. The concentrations of each analyte that a welder could be exposed to were greatly affected by the welding process, the composition of the base and filler alloys, the position of the welder, and the welding helmet. The results obtained can be used by employers to identify and control potential hazards associated with the welding of aluminum alloys and can provide the basis for hazard communication to employees involved in the welding of these alloys.

The effect of cerium oxide argon-annealed coatings on the high temperature oxidation of a FeCrAl alloy

NASA Astrophysics Data System (ADS)

Nguyen, C. T.; Buscail, H.; Cueff, R.; Issartel, C.; Riffard, F.; Perrier, S.; Poble, O.

2009-09-01

Ceria coatings were applied in order to improve the adherence of alumina scales developed on a model Fe-20Cr-5Al alloy during oxidation at high temperature. These coatings were performed by argon annealing of a ceria sol-gel coating at temperatures ranging between 600 and 1000 °C. The influence of these coatings on the alloy oxidation behaviour was studied at 1100 °C. In situ X-ray diffraction (XRD) was performed to characterize the coating crystallographic nature after annealing and during the oxidation process. The alumina scale morphologies were studied by means of scanning electron microscopy (SEM) coupled with energy dispersive X-ray spectroscopy (EDS). The present work shows that the alumina scale morphology observed on cerium sol-gel coated alloy was very convoluted. On the cerium sol-gel coated alloy, argon annealing results in an increase of the oxidation rate in air, at 1100 °C. The 600 °C argon annealing temperature results in a good alumina scale adherence under thermal cycling conditions at 1100 °C.

Filler wire for aluminum alloys and method of welding

NASA Technical Reports Server (NTRS)

Bjorkman, Jr., Gerald W. O. (Inventor); Cho, Alex (Inventor); Russell, Carolyn K. (Inventor)

2003-01-01

A weld filler wire chemistry has been developed for fusion welding 2195 aluminum-lithium. The weld filler wire chemistry is an aluminum-copper based alloy containing high additions of titanium and zirconium. The additions of titanium and zirconium reduce the crack susceptibility of aluminum alloy welds while producing good weld mechanical properties. The addition of silver further improves the weld properties of the weld filler wire. The reduced weld crack susceptibility enhances the repair weldability, including when planishing is required.

Isothermal and cyclic oxidation at 1000 and 1100 deg C of four nickel-base alloys: NASA-TRW VIA, B-1900, 713C, and 738X

NASA Technical Reports Server (NTRS)

Barrett, C. A.; Santoro, G. J.; Lowell, C. E.

1973-01-01

The isothermal and cyclic oxidation resistance of four cast Ni-base gamma + gamma prime alloys, NASA-TRW Via, B-1900, 713C, and 738X, was determined in still air at 1000 and 1100 C. The oxidation process was evaluated by specific sample weight change with time, sample thickness change, X-ray diffraction of the scales, and sample metallography. The behavior is discussed in terms of the Cr, Al, and refractory metal contents of the alloys.

High Strength Discontinuously Reinforced Aluminum For Rocket Applications

NASA Technical Reports Server (NTRS)

Pandey, A. B.; Shah, S. R.; Shadoan, M.

2003-01-01

This study presents results on the development of a new aluminum alloy with very high strength and ductility. Five compositions of Al-Mg-Sc-Gd-Zr alloy were selected for this purpose. These alloys were also reinforced with 15 volume percent silicon-carbide and boron-carbide particles to produce Discontinuously Reinforced Aluminum (DRA) materials. Matrix alloys and DRA were processed using a powder metallurgy process. The helium gas atomization produced very fine powder with cellular-dentritic microstructure. The microstructure of matrix alloys showed fine Al3Sc based precipitate which provides significant strengthening in these alloys. DRA showed uniform distribution of reinforcement in aluminum matrix. DRA materials were tested at -320 F, 75 F in air and 7S F in gaseous hydrogen environments and matrix alloys were tested at 75 F in air. DRA showed high strengths in the range of 89-111 ksi (614-697 MPa) depending on alloy compositions and test environments. Matrix alloys had a good combination of strength, 84-89 ksi (579-621 MPa) and ductility, 4.5-6.5%. The properties of these materials can further be improved by proper control of processing parameters.

Interlocked by nanoscale sculpturing: pure aluminum copper contacts (Conference Presentation)

NASA Astrophysics Data System (ADS)

Gerngross-Baytekin, Melike; Gerngross, Mark Daniel; Carstensen, Jürgen; Adelung, Rainer

2017-06-01

Connecting metals reliable with different corrosion potential is a well-known challenge. An extreme example are copper aluminum contacts. Galvanic corrosion occurs if the two different metals are in contact with each other and an electrolyte, the aluminum becomes susceptible to corrosion under current flow. Usually, antioxidant pastes containing metals are employed but create difficulties e.g. for fatigue resistant power electronic connections. The recently described process of nanoscale sculpturing [1] offers an alternative. Usually, if the surface of metals like aluminium are prepared they are just arbitrary cuts through the bulk. There is no optimization of the surface grain structure towards stability at all. Neither the crystalline facets in the grains are in their most stable orientation nor is the protective oxide shell the most stable one. The nanoscale sculpturing approach is carving out the most stable grains and planes by chemical or electrochemical treatment. The decisive trick is that the chemistry is targeting towards the instable oxide and not the metal. Aluminium sample surfaces including alloys like AA575 exhibit afterwards single crystalline surface facets covered with nanoscale stable oxide films. Galvanically deposited copper forms extremely reliable interlocked connections on top, even allowing for soldering on top of their surface.

Finite element analysis of the upsetting of a 5056 aluminum alloy sample with consideration of its microstructure

NASA Astrophysics Data System (ADS)

Voronin, S. V.; Chaplygin, K. K.

2017-12-01

Computer simulation of upsetting the finite element models (FEMs) of an isotropic 5056 aluminum alloy sample and a 5056 aluminum alloy sample with consideration of microstructure is carried out. The stress and strain distribution patterns at different process stages are obtained. The strain required for the deformation of the FEMs of 5056 alloy samples is determined. The influence of the material microstructure on the stress-strain behavior and technological parameters are demonstrated.

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.

Reinforcement with alumina particles at the interface region of AA6101-T6 and AA1350 alloys during friction stir welding

NASA Astrophysics Data System (ADS)

Ashok Kumar, R.; Thansekhar, M. R.

2018-04-01

This paper deals the combinational effect of friction stir welding and friction stir processing on dissimilar AA6101-T6 and AA1350 aluminium alloys. For that, alumina particles are reinforced at interface region of AA6101-T6 and AA1350 aluminium alloys. Friction Stir Welding and Friction Stir Processing are done simultaneously for various sizes of groove. To analyze the welding quality and surface modifications, mechanical, wear and microstructural tests are carried out. Among these, smallest groove of 0.5 mm width and 1 mm depth reveals highest tensile and bending strengths and largest groove of 2 mm width and 3 mm depth gives maximum hardness and wear resistance. Taguchi technique shows that groove width is most influencing parameter. Developed second order models with interaction predict the responses with minimum error.

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

Influence of alloying elements on friction and wear of copper

NASA Technical Reports Server (NTRS)

Buckley, D. H.

1972-01-01

The friction and wear characteristics were determined for copper binary alloys containing 10 atomic percent aluminum, silicon, indium, and tin. A ternary alloy containing 10 atomic percent aluminum and 5 atomic percent silicon was also examined. The effectiveness of each of the alloying elements aluminum and silicon were very effective in reducing friction. Silicon, however, also reduced wear appreciably. With lubrication, silicon, indium, and tin were all effective alloying elements in reducing friction and wear from values obtained for copper. Silicon was the most effective single element in reducing friction and wear in dry sliding and with lubrication.

Structure of a bimetallic strip produced by plasma spraying of a TiAl powder on a niobium sheet

NASA Astrophysics Data System (ADS)

Povarova, K. B.; Antonova, A. V.; Burmistrov, V. I.; Safronov, B. V.; Perfilov, L. S.; Chukanov, A. P.

2007-10-01

Ti-48 at % Al alloy granules produced by centrifugal spraying are milled into a powder with a particle size of 40 100 μm, and are applied onto a niobium foil using plasma spraying in an argon atmosphere. The fabricated TiAl/Nb bimetallic strip consists of a 100-μm-thick niobium layer and a porous 300-to 400-μm-thick TiAl layer formed by flattened particles. Directly after the preparation of the bimetallic strip, the surface of the TiAl porous layer is rough. Vacuum annealing at 1000, 1100, and 1200°C for 0.5 1.5 h leads to intense pore healing. After deposition and annealing, the interlayer adhesion is strong. The preparation of TiAl granules and spraying of the powder is accompanied by aluminum depletion of the Ti-48 at % Al alloy to 42 45 at % and an increase in the fraction of the α2-Ti3Al phase in the deposited layer. The prepared material has a duplex structure. An intermediate diffuse layer characterized by a variable composition and thickness is formed at the interface. This layer consists of two solid solutions; one of them, which is formed at the TiAl layer, is an α2-Ti3Al-based solid solution of niobium and the other, which is formed at the niobium foil, is a niobium-based solid solution of titanium and aluminum.

Aluminum battery alloys

DOEpatents

Thompson, David S.; Scott, Darwin H.

1985-01-01

Aluminum alloys suitable for use as anode structures in electrochemical cs are disclosed. These alloys include iron levels higher than previously felt possible, due to the presence of controlled amounts of manganese, with possible additions of magnesium and controlled amounts of gallium.

Aluminum battery alloys

DOEpatents

Thompson, D.S.; Scott, D.H.

1984-09-28

Aluminum alloys suitable for use as anode structures in electrochemical cells are disclosed. These alloys include iron levels higher than previously felt possible, due to the presence of controlled amounts of manganese, with possible additions of magnesium and controlled amounts of gallium.

Study of localized corrosion in aluminum alloys by the scanning reference electrode technique

NASA Technical Reports Server (NTRS)

Danford, M. D.

1995-01-01

Localized corrosion in 2219-T87 aluminum (Al) alloy, 2195 aluminum-lithium (Al-Li) alloy, and welded 2195 Al-Li alloy (4043 filler) have been investigated using the relatively new scanning reference electrode technique (SRET). Anodic sites are more frequent and of greater strength in the 2195 Al-Li alloy than in the 2219-T87 Al alloy, indicating a greater tendency toward pitting for the latter. However, the overall corrosion rates are about the same for these two alloys, as determined using the polarization resistance technique. In the welded 2195 Al-Li alloy, the weld bean is entirely cathodic, with rather strongly anodic heat affected zones (HAZ) bordering both sides, indicating a high probability of corrosion in the HAZ parallel to the weld bead.

Commercialization of NASA's High Strength Cast Aluminum Alloy for High Temperature Applications

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.

2003-01-01

In this paper, the commercialization of a new high strength cast aluminum alloy, invented by NASA-Marshall Space Flight Center, for high temperature applications will be presented. Originally developed to meet U.S. automotive legislation requiring low- exhaust emission, the novel NASA aluminum alloy offers dramatic improvement in tensile and fatigue strengths at elevated temperatures (450 F-750 F), which can lead to reducing part weight and cost as well as improving performance for automotive engine applications. It is an ideal low cost material for cast components such as pistons, cylinder heads, cylinder liners, connecting rods, turbo chargers, impellers, actuators, brake calipers and rotors. NASA alloy also offers greater wear resistance, dimensional stability, and lower thermal expansion compared to conventional aluminum alloys, and the new alloy can be produced economically from sand, permanent mold and investment casting. Since 2001, this technology was licensed to several companies for automotive and marine internal combustion engines applications.

PLURAL METALLIC COATINGS ON URANIUM AND METHOD OF APPLYING SAME

DOEpatents

Gray, A.G.

1958-09-16

A method is described of applying protective coatings to uranlum articles. It consists in applying chromium plating to such uranium articles by electrolysis in a chromic acid bath and subsequently applying, to this minum containing alloy. This aluminum contalning alloy (for example one of aluminum and silicon) may then be used as a bonding alloy between the chromized surface and an aluminum can.

Effect of Intensive Plastic Deformation on Microstructure and Mechanical Properties of Aluminum Alloys

NASA Astrophysics Data System (ADS)

Rakhadilov, Bauyrzhan; Uazyrkhanova, Gulzhaz; Myakinin, Alexandr; Uazyrkhanova, Zhuldyz

2016-08-01

In work it was studied the influence of intensive plastic deformation on structure and mechanical properties of aluminum alloys. Intensive plastic deformation was carried out by using equal-channel angular extrusion. It is shown that the most efficient angle of intersection of the channels is the angle of Φ=120°, which ensures defect-free parts at the highest possible level of accumulated strain (e=8). It is established that the intensive milling grain structures in aluminum alloys AMG6 and AMC occurs at ECAE-12 passes, while the intersection angle of the channels of 120°. After ECAE-12 in aluminum alloys the grain refinement reaches to the size of ∼⃒1.0-1.5 gm. It is determined that as a result of equal channel angular pressing, the microhardness of alloy AMG6 increases almost 4 times in comparison with the initial state, the microhardness of alloy AMC increases by almost 4.5 times in comparison with the initial state. It is shown that ECAE-12 mass loss is reduced to 5.4 and 5.6 mg, which shows an increase in wear-resistance of aluminum alloys AMG6 and AMC 13-14 %.

Environment assisted degradation mechanisms in aluminum-lithium alloys

NASA Technical Reports Server (NTRS)

Gangloff, Richard P.; Stoner, Glenn E.; Swanson, Robert E.

1988-01-01

Section 1 of this report records the progress achieved on NASA-LaRC Grant NAG-1-745 (Environment Assisted Degradation Mechanisms in Al-Li Alloys), and is based on research conducted during the period April 1 to November 30, 1987. A discussion of work proposed for the project's second year is included. Section 2 provides an overview of the need for research on the mechanisms of environmental-mechanical degradation of advanced aerospace alloys based on aluminum and lithium. This research is to provide NASA with the basis necessary to permit metallurgical optimization of alloy performance and engineering design with respect to damage tolerance, long term durability and reliability. Section 3 reports on damage localization mechanisms in aqueous chloride corrosion fatigue of aluminum-lithium alloys. Section 4 reports on progress made on measurements and mechanisms of localized aqueous corrosion in aluminum-lithium alloys. Section 5 provides a detailed technical proposal for research on environmental degradation of Al-Li alloys, and the effect of hydrogen in this.

Cathode Formed by Thermal Evaporation of Ba:Al Alloy and Estimations of Barrier Height in an Organic LED

NASA Astrophysics Data System (ADS)

Ding, Lei; Zhang, Fang-Hui

2011-06-01

It is demonstrated that barium and aluminum alloy synthesized by melting in a glass tube under low vacuum is applicable for organic laser emitting diodes (LEDs) as a thin film cathode. The alloy film obtained by the thermal evaporation of pre-synthesized alloy is used in a single-boat organic LED device with the structure: indium tin oxide (ITO)/4,4'-bis[N-(1-naphthyl)-N-phenylamino]biphenyl(NPB)/tris-(8-hydroxyquinoline) aluminum(Alq3)/barium:aluminum alloy. The experimental results show that devices with this alloy film cathode exhibit better current density-voltage-luminance characteristics than those with a conventional pure Al cathode, and more weight of barium in aluminum leads to better performance of the devices. Characteristics of current density versus voltage for the electron-only devices are fitted by the Richardson—Schottky emission model, indicating that the electron injection barrier has a decrease of about 0.3 eV by this alloy cathode.

An investigation on capability of hybrid Nd:YAG laser-TIG welding technology for AA2198 Al-Li alloy

NASA Astrophysics Data System (ADS)

Faraji, Amir Hosein; Moradi, Mahmoud; Goodarzi, Massoud; Colucci, Pietro; Maletta, Carmine

2017-09-01

This paper surveys the capability of the hybrid laser-arc welding in comparison with lone laser welding for AA2198 aluminum alloy experimentally. In the present research, a continuous Nd:YAG laser with a maximum power of 2000 W and a 350 A electric arc were used as two combined welding heat sources. In addition to the lone laser welding experiments, two strategies were examined for hybrid welding; the first one was low laser power (100 W) accompanied by high arc energy, and the second one was high laser power (2000 W) with low arc energy. Welding speed and arc current varied in the experiments. The influence of heat input on weld pool geometry was surveyed. The macrosection, microhardness profile and microstructure of the welded joints were studied and compared. The results indicated that in lone laser welding, conduction mode occurred and keyhole was not formed even in low welding speeds and thus the penetration depth was so low. It was also found that the second approach (high laser power accompanied with low arc energy) is superior to the first one (low laser power accompanied with high arc energy) in hybrid laser-arc welding of Al2198, since lower heat input was needed for full penetration weld and as a result a smaller HAZ was created.

Effects of Stress Relaxation Aging with Electrical Pulses on Microstructures and Properties of 2219 Aluminum Alloy

PubMed Central

Tan, Jingsheng; Zhan, Lihua; Zhang, Jiao; Yang, Zhan; Ma, Ziyao

2016-01-01

To realize the high-efficiency and high-performance manufacture of complex high-web panels, this paper introduced electric pulse current (EPC) into the stress relaxation aging forming process of 2219 aluminum alloy and systematically studied the effects of EPC, stress, and aging time upon the microstructure and properties of 2219 aluminum alloy. It is discovered that: (a) EPC greatly enhanced the mechanical properties after stress relaxation aging and reduced the sensitivity of the yield strength for the initial stress under the aging system of 165 °C/11 h; (b) compared with general aging, stress relaxation aging instead delayed the aging process of 2219 aluminum alloy and greatly increased the peak strength value; (c) EPC accelerated the aging precipitation behavior of 2219 aluminum alloy and reduced transgranular and grain-boundary energy difference, thus leading to a more diffused distribution of the transgranular precipitated phase and the absence of a significant precipitation-free zone (PFZ) and grain-boundary stable phase in the grain boundary, further improving the mechanical properties of the alloy. PMID:28773660

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.

Anodized aluminum pressure sensitive paint for unsteady aerodynamic applications

NASA Astrophysics Data System (ADS)

Sakaue, Hirotaka

2003-06-01

A comprehensive study of anodized aluminum pressure sensitive paint (AA-PSP) is documented. The study consisted of the development of AA-PSP and its application to unsteady aerodynamic fields at atmospheric conditions. Luminophore application mechanism and two-component application on anodized aluminum was studied for the development. Two-component application includes hydrophobic-coated AA-PSP and bi-luminophore system. It was found that the polarity of solvents and the surface charge of anodized aluminum determine the optimized luminophore application. As a result, a wide variation of luminophore can be applied on anodized aluminum. To apply both components on anodized aluminum, optimum solvent polarities for each component should match. AA-PSP performances, such as pressure sensitivity, temperature dependency, signal level, and aging were improved by the luminophore application mechanism and two-component application. AA-PSPs demonstrate the capability of measuring surface pressures on unsteady aerodynamic fields. For an application to the Purdue Mach 4 Quiet Flow Ludwieg Tube, surface pressures on the order of a hundred Pascals were measured for approximately 200ms. The measurement uncertainty of the pressure was on the order of 5%. The main uncertainty source comes from fitting the adsorption control model to calibration points. The results compared qualitatively well to CFD calculations. A miniature fluidic oscillator was used to demonstrate the capability of measuring oscillating unsteady aerodynamic fields with 6.4kHz primary frequency. Flow oscillation images as well as pressure maps of various phases were captured by AA-PSP with PtTFPP as a luminophore (AA-PSPPtTFPP ). Main uncertainty source comes from fitting the adsorption control model to calibration points and from the pulse width of illumination. The measurement uncertainty of the pressure was 4.68%. AA-PSPPtTFPP was applied to a high-amplified acoustic fielding in a standing wave tube. The maximum pressure change created was 171dB (1.04psi). Sinusoidal pressure wave images inside a standing wave tube were captured at various phases. From these images, the integrated pressure map was obtained. In this case, measurement uncertainty was 3.64% and was due mainly to the pulse width and from fitting of the adsorption controlled model. Comparison with theoretical model is necessary to validate the integrated map as a streaming pattern.

A novel sandwich Fe-Mn damping alloy with ferrite shell prepared by vacuum annealing

NASA Astrophysics Data System (ADS)

Qian, Bingnan; Peng, Huabei; Wen, Yuhua

2018-04-01

To improve the corrosion resistance of high strength Fe-Mn damping alloys, we fabricated a novel sandwich Fe-17.5Mn damping alloy with Mn-depleted ferrite shell by vacuum annealing at 1100 °C. The formation behavior of the ferrite shell obeys the parabolic law for the vacuum annealed Fe-17.5Mn alloy at 1100 °C. The sandwich Fe-17.5Mn alloy with ferrite shell exhibits not only better corrosion resistance but also higher damping capacity than the conventional annealed Fe-17.5Mn alloy under argon atmosphere. The existence of only ferrite shell on the surface accounts for the better corrosion in the sandwich Fe-17.5Mn alloy. The better damping capacity in the sandwich Fe-17.5Mn alloy is owed to more stacking faults inside both ɛ martensite and γ austenite induced by the stress from ferrite shell. Vacuum annealing is a new way to improve the corrosion resistance and damping capacity of Fe-Mn damping alloys.

Effect of Iron Impurity on the Phase Composition, Structure and Properties of Magnesium Alloys Containing Manganese and Aluminum

NASA Astrophysics Data System (ADS)

Volkova, E. F.

2017-07-01

Results of a study of the interaction between iron impurity and manganese and aluminum alloying elements during formation of phase composition in alloys of the Mg - Mn, Mg - Al, Mg - Al - Mn, and Mg - Al - Zn - Mn systems are presented. It is proved that this interaction results in introduction of Fe into the intermetallic phase. The phase compositions of model magnesium alloys and commercial alloys MA2-1 and MA5 are studied. It is shown that both manganese and aluminum may bind the iron impurity into phases. Composite Fe-containing intermetallic phases of different compositions influence differently the corrosion resistance of magnesium alloys.

Water-soluble metal working fluids additives derived from the esters of acid anhydrides with higher alcohols for aluminum alloy materials.

PubMed

Yamamoto, Syutaro; Tomoda, Hideyuki; Watanabe, Shoji

2007-01-01

Water-soluble metal working fluids are used for processing of aluminum alloy materials. This short article describes properties of new additives in water-soluble metal working fluids for aluminum alloy materials. Many half esters or diesters were prepared from the reactions of higher alcohols with acid anhydrides. Interestingly, diesters of PTMG (tetrahydrofuran oligomer, MW = 650 and 1000) and polybutylene oxide (MW = 650) with maleic anhydride and succinic anhydride showed both of an excellent anti-corrosion property for aluminum alloy and a good hard water tolerance. The industrial soluble type processing oils including these additives also showed anti-corrosion property and hard water tolerance.

Characterization of Infrastructure Materials using Nonlinear Ultrasonics

NASA Astrophysics Data System (ADS)

Liu, Minghe

In order to improve the safety, reliability, cost, and performance of civil and mechanical structures/components, it is necessary to develop techniques that are capable of characterizing and quantifying the amount of distributed damage in engineering materials before any detectable discontinuities (cracks, delaminations, voids, etc.) appear. In this dissertation, novel nonlinear ultrasonic NDE methods are developed and applied to characterize cumulative damage such as fatigue damage in metallic materials and degradation of cement-based materials due to chemical reactions. First, nonlinear Rayleigh surface waves are used to measure the near-surface residual stresses in shot-peened aluminum alloy (AA 7075) samples. Results show that the nonlinear Rayleigh wave is very sensitive to near-surface residual stresses, and has the potential to quantitatively detect them. Second, a novel two-wave mixing method is theoretically developed and numerically verified. This method is then successfully applied to detect the fatigue damage in aluminum alloy (AA 6061) samples subjected to monotonic compression. In addition to its high sensitivity to fatigue damage, this collinear wave mixing method allows the measurement over a specific region of interest in the specimen, and this capability makes it possible to obtain spatial distribution of fatigue damage through the thickness direction of the sample by simply timing the transducers. Third, the nonlinear wave mixing method is used to characterize the degradation of cement-based materials caused by alkali-silica reaction (ASR). It is found that the nonlinear ultrasonic method is sensitive to detect ASR damage at very early stage, and has the potential to identify the different damage stages. Finally, a micromechanics-based chemo-mechanical model is developed which relates the acoustic nonlinearity parameter to ASR damage. This model provides a way to quantitatively predict the changes in the acoustic nonlinearity parameter due to ASR damage, which can be used to guide experimental measurements for nondestructive evaluation of ASR damage.

Fabrication of the micro/nano-structure superhydrophobic surface on aluminum alloy by sulfuric acid anodizing and polypropylene coating.

PubMed

Wu, Ruomei; Liang, Shuquan; Liu, Jun; Pan, Anqiang; Yu, Y; Tang, Yan

2013-03-01

The preparation of the superhydrophobic surface on aluminum alloy by anodizing and polypropylene (PP) coating was reported. Both the different anodizing process and different PP coatings of aluminum alloy were investigated. The effects of different anodizing conditions, such as electrolyte concentration, anodization time and current on the superhydrophobic surface were discussed. By PP coating after anodizing, a good superhydrophobic surface was facilely fabricated. The optimum conditions for anodizing were determined by orthogonal experiments. After the aluminium-alloy was grinded with 600# sandpaper, pretreated by 73 g/L hydrochloric acid solution at 1 min, when the concentration of sulfuric acid was 180 g/L, the concentration of oxalic acid was 5 g/L, the concentration of potassium dichromate was 10 g/L, the concentration of chloride sodium was 50 g/L and 63 g/L of glycerol, anodization time was 20 min, and anodization current was 1.2 A/dm2, anodization temperature was 30-35 degrees C, the best micro-nanostructure aluminum alloy films was obtained. On the other hand, the PP with different concentrations was used to the PP with different concentrations was used to coat the aluminum alloy surface after anodizing. The results showed that the best superhydrophobicity was achieved by coating PP, and the duration of the superhydrophobic surface was improved by modifying the coat the aluminum alloy surface after anodizing. The results showed that the best superhydrophobicity was surface with high concentration PP. The morphologies of micro/nano-structure superhydrophobic surface were further confirmed by scanning electron microscope (SEM). The material of PP with the low surface free energy combined with the micro/nano-structures of the surface resulted in the superhydrophobicity of the aluminum alloy surface.

[Microbiological corrosion of aluminum alloys].

PubMed

Smirnov, V F; Belov, D V; Sokolova, T N; Kuzina, O V; Kartashov, V R

2008-01-01

Biological corrosion of ADO quality aluminum and aluminum-based construction materials (alloys V65, D16, and D16T) was studied. Thirteen microscopic fungus species and six bacterial species proved to be able to attack aluminum and its alloys. It was found that biocorrosion of metals by microscopic fungi and bacteria was mediated by certain exometabolites. Experiments on biocorrosion of the materials by the microscopic fungus Alternaria alternata, the most active biodegrader, demonstrated that the micromycete attack started with the appearance of exudate with pH 8-9 on end faces of the samples.

Oxidation and corrosion resistance of candidate Stirling engine heater-head-tube alloys

NASA Technical Reports Server (NTRS)

Stephens, J. R.; Barrett, C. A.

1984-01-01

Sixteen candidate iron base Stirling engine heater head tube alloys are evaluated in a diesel fuel fired simulator materials test rig to determine their oxidation and corrosion resistance. Sheet specimens are tested at 820 C for 3500 hr in 5 hr heating cycles. Specific weight change data and an attack parameter are used to categorize the alloys into four groups; 10 alloys show excellent for good oxidation and corrosion resistance and six alloys exhibit poor or catastrophic resistance. Metallographic, X-ray, and electron microprobe analyses aid in further characterizing the oxidation and corrosion behavior of the alloys. Alloy compositions, expecially the reactive elements aluminum, titanium, and chromium, play a major role in the excellent oxidation and corrosion behavior of the alloys. The best oxidation resistance is associated with the formation of an iron nickel aluminum outer oxide scale, an intermediate oxide scale rich in chromium and titanium, and an aluminum outer oxide scale adjacent to the metallic substrate, which exhibits a zone of internal oxidation of aluminum and to some extent titanium.

Carbothermic reduction and prereduced charge for producing aluminum-silicon alloys

DOEpatents

Stevenson, David T.; Troup, Robert L.

1985-01-01

Disclosed is a method for the carbothermic reduction of aluminum oxide to form an aluminum alloy including producing silicon carbide by heating a first mix of carbon and silicon oxide in a combustion reactor to an elevated temperature sufficient to produce silicon carbide at an accelerated rate, the heating being provided by an in situ combustion with oxygen gas, and then admixing the silicon carbide with carbon and aluminum oxide to form a second mix and heating the second mix in a second reactor to an elevated metal-forming temperature sufficient to produce aluminum-silicon alloy. The prereduction step includes holding aluminum oxide substantially absent from the combustion reactor. The metal-forming step includes feeding silicon oxide in a preferred ratio with silicon carbide.

Aluminum alloy material structure impact localization by using FBG sensors

NASA Astrophysics Data System (ADS)

Zhu, Xiubin

2014-12-01

The aluminum alloy structure impact localization system by using fiber Bragg grating (FBG) sensors and impact localization algorithm was investigated. A four-FBG sensing network was established. And the power intensity demodulation method was initialized employing the narrow-band tunable laser. The wavelet transform was used to weaken the impact signal noise. And the impact signal time difference was extracted to build the time difference localization algorithm. At last, a fiber Bragg grating impact localization system was established and experimentally verified. The experimental results showed that in the aluminum alloy plate with the 500 mm*500 mm*2 mm test area, the maximum and average impact abscissa localization errors were 11 mm and 6.25 mm, and the maximum and average impact ordinate localization errors were 9 mm and 4.25 mm, respectively. The fiber Bragg grating sensors and demodulation system are feasible to realize the aviation aluminum alloy material structure impact localization. The research results provide a reliable method for the aluminum alloy material structure impact localization.

In vitro and in vivo corrosion evaluation of nickel-chromium- and copper-aluminum-based alloys.

PubMed

Benatti, O F; Miranda, W G; Muench, A

2000-09-01

The low resistance to corrosion is the major problem related to the use of copper-aluminum alloys. This in vitro and in vivo study evaluated the corrosion of 2 copper-aluminum alloys (Cu-Al and Cu-Al-Zn) compared with a nickel-chromium alloy. For the in vitro test, specimens were immersed in the following 3 corrosion solutions: artificial saliva, 0.9% sodium chloride, and 1.0% sodium sulfide. For the in vivo test, specimens were embedded in complete dentures, so that one surface was left exposed. The 3 testing sites were (1) close to the oral mucosa (partial self-cleaning site), (2) surface exposed to the oral cavity (self-cleaning site), and (3) specimen bottom surface exposed to the saliva by means of a tunnel-shaped perforation (non-self-cleaning site). Almost no corrosion occurred with the nickel-chromium alloy, for either the in vitro or in vivo test. On the other hand, the 2 copper-aluminum-based alloys exhibited high corrosion in the sulfide solution. These same alloys also underwent high corrosion in non-self-cleaning sites for the in vivo test, although minimal attack was observed in self-cleaning sites. The nickel-chromium alloy presented high resistance to corrosion. Both copper-aluminum alloys showed considerable corrosion in the sulfide solution and clinically in the non-self-cleaning site. However, in self-cleaning sites these 2 alloys did not show substantial corrosion.

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

Effectiveness of silica-lasing method on the bond strength of composite resin repair to Ni-Cr alloy.

PubMed

Madani, Azam S; Astaneh, Pedram Ansari; Nakhaei, Mohammadreza; Bagheri, Hossein G; Moosavi, Horieh; Alavi, Samin; Najjaran, Niloufar Tayarani

2015-04-01

The aim of this study was to evaluate the effectiveness of silica-lasing method for improving the composite resin repair of metal ceramic restorations. Sixty Ni-Cr cylindrical specimens were fabricated. The bonding surface of all specimens was airborne-particle abraded using 50 μm aluminum oxide particles. Specimens were divided into six groups that received the following surface treatments: group 1-airborne-particle abrasion alone (AA); group 2-Nd:YAG laser irradiation (LA); group 3-silica coating (Si-CO); group 4-silica-lasing (metal surface was coated with slurry of opaque porcelain and irradiated by Nd:YAG laser) (Si-LA); group 5-silica-lasing plus etching with HF acid (Si-LA-HF); group 6-CoJet sand lased (CJ-LA). Composite resin was applied on metal surfaces. Specimens were thermocycled and tested in shear mode in a universal testing machine. The shear bond strength values were analyzed using ANOVA and Tukey's tests (α = 0.05). The mode of failure was determined, and two specimens in each group were examined by scanning electron microscopy and wavelength dispersive X-ray spectroscopy. Si-CO showed significantly higher shear bond strength in comparison to other groups (p < 0.001). The shear bond strength values of the LA group were significantly higher than those of the AA group (p < 0.05). No significant difference was found among lased groups (LA, Si-LA, Si-LA-HF, CJ-LA; p > 0.05). The failure mode was 100% adhesive for AA, Si-LA, Si-LA-HF, and CJ-LA. LA and Si-CO groups showed 37.5% and 87.5% cohesive failure, respectively. Silica coating of Ni-Cr alloy resulted in higher shear bond strength than those of other surface treatments. © 2014 by the American College of Prosthodontists.

Preparation of nanostructured materials having improved ductility

DOEpatents

Zhao, Yonghao; Zhu, Yuntian T.

2010-04-20

A method for preparing a nanostructured aluminum alloy involves heating an aluminum alloy workpiece at temperature sufficient to produce a single phase coarse grained aluminum alloy, then refining the grain size of the workpiece at a temperature at or below room temperature, and then aging the workpiece to precipitate second phase particles in the nanosized grains of the workpiece that increase the ductility without decreasing the strength of the workpiece.

REGENERATION OF REACTOR FUEL ELEMENTS

DOEpatents

Roake, W.E.; Lyon, W.L.

1960-03-29

A process of concentrating by electrolysis the uraatum and/or plutonium of an aluminum alloy containing these actinides after the actinide has been partially consumed by neutron bombardment in a reactor is given. The alloy is made the anode in a system having an aluminum cathode and a cryolite electrolyte. Electrolysis from 22 to 28 ampere-hours removes a sufficient quantity of aluminum from the alloy to make it suitable for reuse.

Stress-corrosion characteristics of aluminum casting alloy M-45

NASA Technical Reports Server (NTRS)

Lovoy, C. V.

1968-01-01

Evaluation of the stress-corrosion characteristics of aluminum alloy M-45 shows that the most favorable artificial aging cycle for this alloy, with regard to optimum strength and stress-corrosion resistance, appears to be 400 degrees F for 12 hours.

Microstructural features of friction stir welded dissimilar Aluminium alloys AA2219-AA7475

NASA Astrophysics Data System (ADS)

Zaman Khan, Noor; Ubaid, Mohammed; Siddiquee, Arshad Noor; Khan, Zahid A.; Al-Ahmari, Abdulrahman; Chen, Xizhang; Haider Abidi, Mustufa

2018-05-01

High strength, good corrosion resistance, light weight make aluminium alloys a material of choice in many industrial sectors like aerospace, marine etc. Problems associated with welding of these alloys by fusion welding processes restricted their use in various industries. Friction stir welding (FSW), a clean solid-state joining process, easily overcomes various difficulties encountered during conventional fusion welding processes. In the present work, the effect of rotational speed (710 rpm, 900 rpm and 1120 rpm) on micro-hardness distribution and microstructure of FSWed dissimilar aluminium alloy joints were analyzed. Plates of AA7475-T761 and AA2219-O having thickness of 2.5 mm were welded by fixing AA7475 on retreating side (RS) and AA2219 on advancing side (AS). Welded joints were characterized by Vickers micro-hardness testing, scanning electron microscopy (SEM) and optical microscopy (OM). Results revealed that rotational speed significantly affects the micro-hardness due to increase in grain size, coarsening and dissolution of strengthening precipitates and re-precipitation. Higher micro-hardness values were observed in stir zone due to grain refinement and re-precipitation. Minimum micro-hardness value was observed at the TMAZ/HAZ of advancing side due to thermal softening.

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

NASA Astrophysics Data System (ADS)

Dou, Ruifeng; Phillion, A. B.

2016-08-01

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

Fluxing agent for metal cast joining

DOEpatents

Gunkel, Ronald W.; Podey, Larry L.; Meyer, Thomas N.

2002-11-05

A method of joining an aluminum cast member to an aluminum component. The method includes the steps of coating a surface of an aluminum component with flux comprising cesium fluoride, placing the flux coated component in a mold, filling the mold with molten aluminum alloy, and allowing the molten aluminum alloy to solidify thereby joining a cast member to the aluminum component. The flux preferably includes aluminum fluoride and alumina. A particularly preferred flux includes about 60 wt. % CsF, about 30 wt. % AlF.sub.3, and about 10 wt. % Al.sub.2 O.sub.3.

REGENERATION OF REACTOR FUEL ELEMENTS

DOEpatents

Lyon, W.L.

1960-04-01

A process is described for concentrating uranium and/or plutonium metal in aluminum alloys in which the actinide content was partially consumed by neutron bombardinent. Two embodiments are claimed: Either the alloy is heated, together with zinc chloride to at least 1000 deg C whereby some aluminum, in the form of aluminum chloride, and any zinc formed volatilize; or else aluminum fluoride is added and reacted at 800 to 1000 deg O and substmospheric pressure whereby pant of the aluminum volatilizes and aluminum subfluoride.

Development of ultrafine-grained microstructure in Al-Cu-Mg alloy through equal-channel angular pressing

NASA Astrophysics Data System (ADS)

Sai Anuhya, Danam; Gupta, Ashutosh; Nayan, Niraj; Narayana Murty, S. V. S.; Manna, R.; Sastry, G. V. S.

2014-08-01

Al-Cu-Mg alloys are extensively used for riveting applications in aerospace industries due to their relatively high shear strength coupled with high plasticity. The significant advantage of using V65 aluminum alloy ((Al-4Cu-0.2Mg) for rivet application also stems from its significantly slower natural aging kinetics, which gives operational flexibility to carryout riveting operation even after 4 days of solution heat treatment, in contrast to its equivalent alloy AA2024.Rivets are usually made by cold heading of wire rods. In order to form a defect free rivet head, grain size control in wire rods is essential at each and every stage of processing right from casting onwards upto the final wire drawing stage. Wire drawing is carried out at room temperature to reduce diameter as well as impart good surface finish. In the present study, different microstructures in V65 alloy bars were produced by rolling at different temperatures (room temperature to 523K) and subsequently deformed by equal channel angular pressing (ECAP) at 423K upto an equivalent strain of 7. ECAP was carried out to study the effect of initial microstructure on grain refinement and degree of deformation on the evolution of ultrafine grain structure. The refinement of V65 alloy by ECAP is significantly influenced by Initial microstructure but amount of deformation strongly affects the evolution processes as revealed by optical microscopy and transmission electron microscopy.

Surface segregation in HAYNES 230 alloy

NASA Astrophysics Data System (ADS)

Pop, D.; Wolski, K.

2006-12-01

The surface segregation in the Ni-based alloy HAYNES 230 was studied by Auger Electron Spectroscopy and X-ray Photoelectron Spectroscopy between 400 and 1100 °C. The qualitative variations of the surface contents of S, P, W, Mo, N, Si, and Mn were determined as a function of annealing temperature and time. It was found that at 925 °C the maximum coverage of sulphur at the alloy surface is in the range 0.06-0.15 monolayers. Chromium evaporation from the HAYNES 230 surface under UHV conditions is clearly evidenced for annealing at 1100 °C.

Dissolution Mechanism for High Melting Point Transition Elements in Aluminum Melt

NASA Astrophysics Data System (ADS)

Lee, Young E.; Houser, Stephen L.

When added cold in aluminum melt, the alloying process for compacts of transition metal elements such as Mn, Fe, Cr, Ni, Ti, Cu, and Zn takes a sequence of incubation, exothermic reactions to form intermetallic compounds, and dispersion of the alloying elements into aluminum melt. The experiments with Cr compacts show that the incubation period is affected by the content of ingredient Al and size of compacts and by size of Cr particles. Incubation period becomes longer as the content of ingredient aluminum in compact decreases, and this prolonged incubation period negatively impacts the dissolution of the alloying elements in aluminum. Once liquid aluminum forms at reaction sites, the exothermic reaction takes place quickly and significantly raises the temperature of the compacts. As the result of it, the compacts swell in volume with a sponge like structure. Such porous structure encourages the penetration of liquid aluminum from the melt. The compacts become weak mechanically, and the alloying elements are dispersed and entrained in aluminum melt as discrete and small sized units. When Cr compacts are deficient in aluminum, the unreacted Cr particles are encased by the intermetallic compounds in the dispersed particles. They are carried in the melt flow and continue the dissolution reaction in aluminum. The entire dissolution process of Cr compacts completes within 10 to 15 minutes with a full recovery when the aluminum content is 10 to 20% in compacts.

Effect of oxide layer formation on deformation of aluminum alloys under fire conditions

DOE PAGES

Yilmaz, Nadir; Vigil, Francisco M.; Tolendino, Greg; ...

2015-05-14

The purpose of this study is to investigate the structural behavior of aluminum alloys used in the aerospace industry when exposed to conditions similar to those of an accident scenario, such as a fuel fire. This study focuses on the role that the aluminum oxide layer plays in the deformation and the strength of the alloy above melting temperature. To replicate some of the thermal and atmospheric conditions that the alloys might experience in an accident scenario, aluminum rod specimens were subjected to temperatures near to or above their melting temperature in air, nitrogen, and vacuum environments. The characteristics ofmore » their deformation, such as geometry and rate of deformation, were observed. Tests were conducted by suspending aluminum rods vertically from an enclosure. This type of experiment was performed in two different environments: air and nitrogen. The change in environments allowed the effects of the oxide layer on the material strength to be analyzed by inhibiting the growth of the oxide layer. Observations were reported from imaging taken during the experiment showing creep behavior of aluminum alloys at elevated temperatures and time to failure. In addition, an example of tensile load–displacement data obtained in air and vacuum was reported to understand the effect of oxide layer on aluminum deformation and strength.« less

Aluminum Alloy and Article Cast Therefrom

NASA Technical Reports Server (NTRS)

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

2003-01-01

A cast article from an aluminum alloy, which has improved mechanical properties at elevated temperatures, has the following composition in weight percent: Silicon 14 - 25.0, Copper 5.5 - 8.0, Iron 0.05 - 1.2, Magnesium 0.5 - 1.5, Nickel 0.05 - 0.9, Manganese 0.05 - 1.0, Titanium 0.05 - 1.2, Zirconium 0.05 - 1.2, Vanadium 0.05 - 1.2, Zinc 0.05 - 0.9, Phosphorus 0.001 - 0.1, and the balance is Aluminum, wherein the silicon-to-magnesium ratio is 10 - 25, and the copper-to-magnesium ratio is 4 - 15. The aluminum alloy contains a simultaneous dispersion of three types of Al3X compound particles (X=Ti, V, Zr) having a LI2, crystal structure, and their lattice parameters are coherent to the aluminum matrix lattice. A process for producing this cast article is also disclosed, as well as a metal matrix composite, which includes the aluminum alloy serving as a matrix and containing up to about 60% by volume of a secondary filler material.

Synthesis of aluminum-based scandium-yttrium master alloys

NASA Astrophysics Data System (ADS)

Bazhin, V. Yu.; Kosov, Ya. I.; Lobacheva, O. L.; Dzhevaga, N. V.

2015-07-01

The preparation technology for an Al-2% Sc-0.5% Y master alloy using aluminum-manganese alloys has been developed and tested. The microstructure of the prepared master alloy is studied and the compositions of intermetallics is determined. The efficient technological parameters of the synthesis are determined. It is shown that varying the compositions of starting reagents and alloying additions and optimizing the process conditions (temperature, mixing, etc.) allow us to forecast the manufacturing and operating characteristics of aluminum-based master alloys. Joint additions of scandium and yttrium oxides to a charge favor a substantial decrease in the grain size of the formed intermetallics; this effect appears to the utmost in the case of microallying with yttrium up to 0.5 wt %.

Development and Evaluation of Wide Clearance Braze Joints in Gamma Prime Alloys.

DTIC Science & Technology

1982-03-01

from nickel base superalloys which contain significant amounts of aluminum and/or titanium . * These latter two elements, while imparting good hiqh...thermally induced tensile stress fatigue, their surfaces become covered with oxides (and sulfides) of the aluminum and titanium used to strengthen the alloys...process, it also cleans crack surfaces, and this opens a way to repair the very costly parts. Since the alloys contain aluminum and titanium , post- weld

The effect of aluminum alloying on strength properties and deformation mechanisms of the <123> Hadfield steel single crystals

NASA Astrophysics Data System (ADS)

Astafurova, E. G.; Tukeev, M. S.; Chumlyakov, Yu. I.

2007-10-01

The role of aluminum alloying on strength properties and deformation mechanisms (slip, twinning) of <123> single crystals of Hadfield steel under tensile loading at T = 300 K is demonstrated. It is found out that aluminum alloying suppresses twinning deformation in the <123> single crystals and, during slip, results in a dislocation structure change from a uniform dislocation distribution to a planar dislocation structure.

The effect of surface oxide layer on the rate of hydrogen emission from aluminum and its alloys in a high vacuum

NASA Technical Reports Server (NTRS)

Makarova, V. I.; Zyabrev, A. A.

1979-01-01

The influence of surface oxide layers on the kinetics of hydrogen emission at the high vacuum of 10 to the minus 8th power torr was investigated at temperatures from 20 to 450 C using samples of pure AB00 aluminum and the cast alloy AMg. Cast and deformed samples of AMts alloy were used to study the effect of oxide film thickness on the rate of hydrogen emission. Thermodynamic calculations of the reactions of the generation and dissociation of aluminum oxide show that degasification at elevated temperatures (up to 600 C) and high vacuum will not reduce the thickness of artificially-generated surface oxide layers on aluminum and its alloys.

Advanced powder metallurgy aluminum alloys via rapid solidification technology, phase 2

NASA Technical Reports Server (NTRS)

Ray, Ranjan; Jha, Sunil C.

1987-01-01

Marko's rapid solidification technology was applied to processing high strength aluminum alloys. Four classes of alloys, namely, Al-Li based (class 1), 2124 type (class 2), high temperature Al-Fe-Mo (class 3), and PM X7091 type (class 4) alloy, were produced as melt-spun ribbons. The ribbons were pulverized, cold compacted, hot-degassed, and consolidated through single or double stage extrusion. The mechanical properties of all four classes of alloys were measured at room and elevated temperatures and their microstructures were investigated optically and through electron microscopy. The microstructure of class 1 Al-Li-Mg alloy was predominantly unrecrystallized due to Zr addition. Yield strengths to the order of 50 Ksi were obtained, but tensile elongation in most cases remained below 2 percent. The class 2 alloys were modified composition of 2124 aluminum alloy, through addition of 0.6 weight percent Zr and 1 weight percent Ni. Nickel addition gave rise to a fine dispersion of intermetallic particles resisting coarsening during elevated temperature exposure. The class 2 alloy showed good combination of tensile strength and ductility and retained high strength after 1000 hour exposure at 177 C. The class 3 Al-Fe-Mo alloy showed high strength and good ductility both at room and high temperatures. The yield and tensile strength of class 4 alloy exceeded those of the commercial 7075 aluminum alloy.

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

NASA Astrophysics Data System (ADS)

McNamara, Cameron T.

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

Zinc alloy enhances strength and creep resistance

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

Machler, M.

1996-10-01

A family of high-performance ternary zinc-copper-aluminum alloys has been developed that provides higher strength, hardness, and creep resistance than the traditional zinc-aluminum alloys Zamak 3, Zamak 5, and ZA-8. Designated ACuZinc, mechanical properties comparable to those of more expensive materials make it suitable for high-load applications and those at elevated temperatures. This article describes the alloy`s composition, properties, and historical development.

Carbothermic reduction and prereduced charge for producing aluminum-silicon alloys

DOEpatents

Stevenson, D.T.; Troup, R.L.

1985-01-01

Disclosed is a method for the carbothermic reduction of aluminum oxide to form an aluminum alloy including producing silicon carbide by heating a first mix of carbon and silicon oxide in a combustion reactor to an elevated temperature sufficient to produce silicon carbide at an accelerated rate, the heating being provided by an in situ combustion with oxygen gas, and then admixing the silicon carbide with carbon and aluminum oxide to form a second mix and heating the second mix in a second reactor to an elevated metal-forming temperature sufficient to produce aluminum-silicon alloy. The prereduction step includes holding aluminum oxide substantially absent from the combustion reactor. The metal-forming step includes feeding silicon oxide in a preferred ratio with silicon carbide. 1 fig.

Study of constitution diagram aluminum-tantalum

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

Glazov, V.M.; Mal'tsev, M.V.; Chistyakov, Y.D.

1988-10-20

Alloys of aluminum with tantalum were for the first time obtained by aluminothermic method in 1868 by Moriniak. Later these alloys were studied in the works of Schirmeister (1915) and Brouwer (1938), moreover Brouwer established that tantalum with aluminum forms the chemical compound TaA1, which has tetragonal crystal lattice with parameters a=5.422 angstroms and c=8.536 angstroms (1). However despite the fact that alloys of aluminum with tantalum long ago are obtained already, constitution diagram of this system is not studied until recently. In connection with the application of tantalum as the modifying additive in aluminum alloys an emergency in themore » construction of this diagram, without the knowledge by which it is not possible to give the correct explanation of the mechanism of the very process of the modification of primary grain. For this purpose was undertaken this work. Russian translations.« less

Seacoast stress corrosion cracking of aluminum alloys

NASA Technical Reports Server (NTRS)

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

1981-01-01

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

Thermal Pyrolytic Graphite Enhanced Components

NASA Technical Reports Server (NTRS)

Hardesty, Robert E. (Inventor)

2015-01-01

A thermally conductive composite material, a thermal transfer device made of the material, and a method for making the material are disclosed. Apertures or depressions are formed in aluminum or aluminum alloy. Plugs are formed of thermal pyrolytic graphite. An amount of silicon sufficient for liquid interface diffusion bonding is applied, for example by vapor deposition or use of aluminum silicon alloy foil. The plugs are inserted in the apertures or depressions. Bonding energy is applied, for example by applying pressure and heat using a hot isostatic press. The thermal pyrolytic graphite, aluminum or aluminum alloy and silicon form a eutectic alloy. As a result, the plugs are bonded into the apertures or depressions. The composite material can be machined to produce finished devices such as the thermal transfer device. Thermally conductive planes of the thermal pyrolytic graphite plugs may be aligned in parallel to present a thermal conduction path.

PRODUCTION OF PLUTONIUM METAL

DOEpatents

Lyon, W.L.; Moore, R.H.

1961-01-17

A process is given for producing plutonium metal by the reduction of plutonium chloride, dissolved in alkali metal chloride plus or minus aluminum chloride, with magnesium or a magnesium-aluminum alloy at between 700 and 800 deg C and separating the plutonium or plutonium-aluminum alloy formed from the salt.

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.

Materials data handbook: Aluminum alloy 2219

NASA Technical Reports Server (NTRS)

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

1972-01-01

A summary of the materials property information for aluminum 2219 alloy is presented. The scope of the information includes physical and mechanical properties at cryogenic, ambient, and elevated temperatures. Information on material procurement, metallurgy of the alloy, corrosion, environmental effects, fabrication, and joining techniques is developed.

Materials data handbook: Aluminum alloy 7075

NASA Technical Reports Server (NTRS)

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

1972-01-01

A summary of the materials property information on aluminum alloy 7075 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.

Materials data handbook: Aluminum alloy 5456

NASA Technical Reports Server (NTRS)

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

1972-01-01

A summary of the materials property information for aluminum alloy 5456 is presented. The scope of the information includes physical and mechanical property data at cryogenic, ambient, and elevated temperatures. Information on material procurement, metallurgy of the alloy, corrosion, environmental effects, fabrication, and joining techniques is developed.

Aluminum and its light alloys

NASA Technical Reports Server (NTRS)

Merica, Paul D

1920-01-01

Report is a summary of research work which has been done here and abroad on the constitution and mechanical properties of the various alloy systems with aluminum. The mechanical properties and compositions of commercial light alloys for casting, forging, or rolling, obtainable in this country are described.

NASA-UVa light aerospace alloy and structure technology program supplement: Aluminum-based materials for high speed aircraft

NASA Technical Reports Server (NTRS)

Starke, E. A., Jr.

1993-01-01

This report on the NASA-UVa Light Aerospace Alloy and Structure Technology Program Supplement: Aluminum-Based Materials for High Speed Aircraft covers the period from January 1, 1992 to June 30, 1992. The objective of the research is to develop aluminum alloys and aluminum matrix composites for the airframe which can efficiently perform in the HSCT environment for periods as long as 60,000 hours (certification for 120,000 hours) and, at the same time, meet the cost and weight requirements for an economically viable aircraft. Current industry baselines focus on flight at Mach 2.4. The research covers four major materials systems: (1) ingot metallurgy 2XXX, 6XXX, and 8XXX alloys, (2) powder metallurgy 2XXX alloys, (3) rapidly solidified, dispersion strengthened Al-Fe-X alloys, and (4) discontinuously reinforced metal matrix composites. There are ten major tasks in the program which also include evaluation and trade-off studies by Boeing and Douglas aircraft companies.

NASA-UVa light aerospace alloy and structures technology program supplement: Aluminum-based materials for high speed aircraft

NASA Technical Reports Server (NTRS)

Starke, E. A., Jr. (Editor)

1995-01-01

This report on the NASA-UVa light aerospace alloy and structure technology program supplement: Aluminum-Based Materials for High Speed Aircraft covers the period from July 1, 1992. The objective of the research is to develop aluminum alloys and aluminum matrix composites for the airframe which can efficiently perform in the HSCT environment for periods as long as 60,000 hours (certification for 120,000 hours) and, at the same time, meet the cost and weight requirements for an economically viable aircraft. Current industry baselines focus on flight at Mach 2.4. The research covers four major materials systems: (1) Ingot metallurgy 2XXX, 6XXX, and 8XXX alloys, (2) Powder metallurgy 2XXX alloys, (3) Rapidly solidified, dispersion strengthened Al-Fe-X alloys, and (4) Discontinuously reinforced metal matrix composites. There are ten major tasks in the program which also include evaluation and trade-off studies by Boeing and Douglas aircraft companies.

Evaluation of Stress Corrosion Cracking Susceptibility Using Fracture Mechanics Techniques, Part 1. [environmental tests of aluminum alloys, stainless steels, and titanium alloys

NASA Technical Reports Server (NTRS)

Sprowls, D. O.; Shumaker, M. B.; Walsh, J. D.; Coursen, J. W.

1973-01-01

Stress corrosion cracking (SSC) tests were performed on 13 aluminum alloys, 13 precipitation hardening stainless steels, and two titanium 6Al-4V alloy forgings to compare fracture mechanics techniques with the conventional smooth specimen procedures. Commercially fabricated plate and rolled or forged bars 2 to 2.5-in. thick were tested. Exposures were conducted outdoors in a seacoast atmosphere and in an inland industrial atmosphere to relate the accelerated tests with service type environments. With the fracture mechanics technique tests were made chiefly on bolt loaded fatigue precracked compact tension specimens of the type used for plane-strain fracture toughness tests. Additional tests of the aluminum alloy were performed on ring loaded compact tension specimens and on bolt loaded double cantilever beams. For the smooth specimen procedure 0.125-in. dia. tensile specimens were loaded axially in constant deformation type frames. For both aluminum and steel alloys comparative SCC growth rates obtained from tests of precracked specimens provide an additional useful characterization of the SCC behavior of an alloy.

The Effect of Alloying Elements on Thermal Conductivity and Casting Characteristic in High Pressure Die Casting of Aluminum Alloy

NASA Astrophysics Data System (ADS)

Kim, Cheol-Woo; Cho, Jae-Ik; Choi, Se-Weon; Kim, Young-Chan; Kang, Chang-Seog

Recently, demand of aluminum alloys for use in high thermal conductivity application is increases but the most aluminum die casting alloys exhibit very lower thermal properties because of their high concentrations of alloying elements. However, those alloying elements are essential to obtain sufficient fluidity and mechanical strength. Therefore, the purpose of this study is to analyze the effect of alloying elements in die casting alloys, Si, Cu, Mg, Fe and Mn, in thermal conductivity, die casting characteristics and mechanical properties and find out the appropriate amount of each alloying element for development of heat sink component. The results showed that Mn had the most deleterious effect in thermal conductivity and Si and Fe contents were important to improve strength and limit casting defects, such as hot tearing and die soldering. The alloy with 0.2 1.0wt%Cu, 0.3 0.6wt%Fe and 1.0 2.0wt%Si showed very good combination of high thermal conductivity and good casting characteristics.

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

NASA Technical Reports Server (NTRS)

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

2007-01-01

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

Multi-channel Spiral Twist Extrusion (MCSTE): A Novel Severe Plastic Deformation Technique for Grain Refinement

NASA Astrophysics Data System (ADS)

El-Garaihy, W. H.; Fouad, D. M.; Salem, H. G.

2018-07-01

Multi-channel Spiral Twist Extrusion (MCSTE) is introduced as a novel severe plastic deformation (SPD) technique for producing superior mechanical properties associated with ultrafine grained structure in bulk metals and alloys. The MCSTE design is based on inserting a uniform square cross-sectioned billet within stacked disks that guarantee shear strain accumulation. In an attempt to validate the technique and evaluate its plastic deformation characteristics, a series of experiments were conducted. The influence of the number of MCSTE passes on the mechanical properties and microstructural evolution of AA1100 alloy were investigated. Four passes of MCSTE, at a relatively low twisting angle of 30 deg, resulted in increasing the strength and hardness coupled with retention of ductility. Metallographic observations indicated a significant grain size reduction of 72 pct after 4 passes of MCSTE compared with the as-received (AR) condition. Moreover, the structural uniformity increased with the number of passes, which was reflected in the hardness distribution from the peripheries to the center of the extrudates. The current study showed that the MCSTE technique could be an effective, adaptable SPD die design with a promising potential for industrial applications compared to its counterparts.

Multi-channel Spiral Twist Extrusion (MCSTE): A Novel Severe Plastic Deformation Technique for Grain Refinement

NASA Astrophysics Data System (ADS)

El-Garaihy, W. H.; Fouad, D. M.; Salem, H. G.

2018-04-01

Multi-channel Spiral Twist Extrusion (MCSTE) is introduced as a novel severe plastic deformation (SPD) technique for producing superior mechanical properties associated with ultrafine grained structure in bulk metals and alloys. The MCSTE design is based on inserting a uniform square cross-sectioned billet within stacked disks that guarantee shear strain accumulation. In an attempt to validate the technique and evaluate its plastic deformation characteristics, a series of experiments were conducted. The influence of the number of MCSTE passes on the mechanical properties and microstructural evolution of AA1100 alloy were investigated. Four passes of MCSTE, at a relatively low twisting angle of 30 deg, resulted in increasing the strength and hardness coupled with retention of ductility. Metallographic observations indicated a significant grain size reduction of 72 pct after 4 passes of MCSTE compared with the as-received (AR) condition. Moreover, the structural uniformity increased with the number of passes, which was reflected in the hardness distribution from the peripheries to the center of the extrudates. The current study showed that the MCSTE technique could be an effective, adaptable SPD die design with a promising potential for industrial applications compared to its counterparts.

Effect of equal-channel angular pressing and aging on the microstructure and mechanical properties of an Al-Cu-Mg-Si alloy

NASA Astrophysics Data System (ADS)

Gazizov, M. R.; Dubina, A. V.; Zhemchuzhnikova, D. A.; Kaibyshev, R. O.

2015-07-01

The effect of intermediate equal-channel angular pressing (ECAP) and final aging at 170°C on the mechanical properties and microstructure of aluminum alloy belonging to Al-Cu-Mg-Si system stress with a Cu/Mg ratio (AA2014) is considered. After quenching and aging (treatment T6), the yield stress (σ0.2) and ultimate tensile strength (σu) are ˜415 and ˜450 MPa, respectively; the elongation to fracture (δ) is 4.2%. The precipitation strengthening is reached due to the precipitation of θ″-, θ'-, β″-, and Q'/ C-phase particles. After intermediate ECAP and subsequent aging for 0.5 h, σ0.2 and σu increase to 470 and 535 MPa, respectively; δ increases to ˜9.5%. The plastic deformation leads to the formation of a microstructure that consists of deformation bands characterized by a high density of dislocations. During aging for 0.5 h, the partial decomposition of supersaturated solid solution and formation of segregations within grains and at dislocations and precipitation of the Guinier-Preston zones and β″ phase also occur; all of this ensure the maximum increase in the strength of the AA2014 alloy. As the aging time increases to 8 h, the slight decrease in both σ0.2 and σu to 465 and 515 MPa and δ to ˜6% takes place. It has been shown that the intermediate ECAP does not affect the sequence of the precipitation of main strengthening θ″ and θ' phases during aging. However, in this case, the volume fraction of strengthening particles decreases significantly and their dispersivity increases.

Iron-aluminum alloys having high room-temperature and method for making same

DOEpatents

Sikka, V.K.; McKamey, C.G.

1993-08-24

A wrought and annealed iron-aluminum alloy is described consisting essentially of 8 to 9.5% aluminum, an effective amount of chromium sufficient to promote resistance to aqueous corrosion of the alloy, and an alloying constituent selected from the group of elements consisting of an effective amount of molybdenum sufficient to promote solution hardening of the alloy and resistance of the alloy to pitting when exposed to solutions containing chloride, up to about 0.05% carbon with up to about 0.5% of a carbide former which combines with the carbon to form carbides for controlling grain growth at elevated temperatures, and mixtures thereof, and the balance iron, wherein said alloy has a single disordered [alpha] phase crystal structure, is substantially non-susceptible to hydrogen embrittlement, and has a room-temperature ductility of greater than 20%.

Synthesis of Aluminum-Aluminum Nitride Nanocomposites by a Gas-Liquid Reaction II. Microstructure and Mechanical Properties

NASA Astrophysics Data System (ADS)

Borgonovo, Cecilia; Makhlouf, Makhlouf M.

2016-04-01

In situ fabrication of the reinforcing particles in the metal matrix is an answer to many of the challenges encountered in manufacturing aluminum matrix nanocomposites. In this method, the nanoparticles are formed directly within the melt by means of a chemical reaction between a specially designed aluminum alloy and a gas. In this publication, we describe a process for synthesizing aluminum-aluminum nitride nanocomposites by reacting a nitrogen-containing gas with a molten aluminum-lithium alloy. We quantify the effect of the process parameters on the average particle size and particle distribution, as well as on the tendency of the particles to cluster in the alloy matrix, is quantified. Also in this publication, we present the measured room temperature and elevated temperature tensile properties of the nanocomposite material as well as its measured room temperature impact toughness.

Inhibition of Tryptophan on AA 2024 in Chloride-Containing Solutions

NASA Astrophysics Data System (ADS)

Li, Xing; Xiang, Bin; Zuo, Xiu-Li; Wang, Qin; Wei, Zi-Dong

2011-03-01

The inhibitory effects of tryptophan on the corrosion of AA 2024 in 1 M HCl, 20% (wt.%) CaCl2, and 3.5% (wt.%) NaCl solutions were investigated via polarization techniques, electrochemical impedance spectroscopy, and weight loss methods. The scanning electron microscope technique was employed to observe corrosion morphology. The results suggest that AA 2024 was corroded in these three corrosive media to some extent and that tryptophan can significantly inhibit the corrosion of aluminum alloys. The inhibition efficiency (η) increased with increasing concentrations of tryptophan, and the best inhibition efficiency exhibited was about 87% in 1 M HCl solution with 0.008 M tryptophan. Tryptophan acted as a cathodic corrosion inhibitor and affected the hydrogen evolution reaction, which was the main electrode reaction in the 1 M HCl solution. In solutions with 20% CaCl2 and 3.5% NaCl, tryptophan was adsorbed onto anodic areas, thus increasing the activation energy of the interface reaction as an anodic corrosion inhibitor. The Dmol3 program of Material Studio 4.0 was used to obtain the optimized geometry of the tryptophan inhibitor and some quantum-chemical parameters. Front orbital distributions and Fukui indices indicate that the molecular active reaction zones were located in the indole ring of tryptophan.

Synthesizing Aluminum alloys by double mechanical alloying

NASA Astrophysics Data System (ADS)

Froyen, L.; Delaey, L.; Niu, X. P.; Le Brun, P.; Peytour, C.

1995-03-01

A new synthesis technique, namely double mechanical alloying (dMA), has been developed to fabricate aluminum alloys containing the finely distributed intermetallic compounds and inert dispersoids Al4C3 and Al2O3 The technique consists mainly of three steps: a primary milling stage of elemental powders (MAI) followed by a heat treatment to promote the formation of intermetallic phases, a secondary milling stage (MA2) to refine the microstructure, and consolidation of the produced powders. The results of mechanical and tribological properties of the resulting materials indicate that the dMA is a promising technique for the fabrication of aluminum alloys for applications requiring wear resistance and high-temperature performance.

High gas velocity oxidation and hot corrosion testing of oxide dispersion-strengthened nickel-base alloys

NASA Technical Reports Server (NTRS)

Deadmore, D. L.; Lowell, C. E.

1975-01-01

Several oxide dispersion strengthened (ODS) nickel-base alloys were tested in high velocity gases for cyclic oxidation resistance at temperatures to 1200 C and times to 500 hours and for hot corrosion resistance at 900 C for 200 hours. Nickel-chromium-aluminum ODS alloys were found to have superior resistance to oxidation and hot corrosion when compared to bare and coated nickel-chromium ODS alloys. The best of the alloys tested had compositions of nickel - 15.5 to 16 weight percent chromium with aluminum weight percents between 4.5 and 5.0. All of the nickel-chromium-aluminum ODS materials experienced small weight losses (less than 16 mg/sq cm).

Fretting of Nickel-Chromium-Aluminum Alloys at Temperatures to 816 C

NASA Technical Reports Server (NTRS)

Bill, R. C.

1974-01-01

A series of four nickel-based alloys containing 10 percent and 20 percent chromium in combination with 2 percent and 5 percent aluminum were fretted in dry air at temperatures to 816 C. At all temperatures, the alloys showed far less fretting wear than did high-purity nickel. This was attributed to the formation of protective oxide films on the alloys, the result of the selective oxidation of the alloy constituents. Increasing the aluminum concentration reduced fretting wear at all temperatures. Increasing the chromium concentration from 10 percent to 20 percent resulted in decreased fretting wear at 23 and 540 C, but increased fretting wear at 650 and 816 C.

Evaluation of Sc-Bearing Aluminum Alloy C557 for Aerospace Applications

NASA Technical Reports Server (NTRS)

Domack, Marcia S.; Dicus, Dennis L.

2002-01-01

The performance of the Al-Mg-Sc alloy C557 was evaluated to assess its potential for a broad range of aerospace applications, including airframe and launch vehicle structures. Of specific interest were mechanical properties at anticipated service temperatures and thermal stability of the alloy. Performance was compared with conventional airframe aluminum alloys and with other emerging aluminum alloys developed for specific service environments. Mechanical properties and metallurgical structure were evaluated for commercially rolled sheet in the as-received H116 condition and after thermal exposures at 107 C. Metallurgical analyses were performed to de.ne grain morphology and texture, strengthening precipitates, and to assess the effect of thermal exposure.

Thermodynamics of Titanium-Aluminum-Oxygen Alloys Studied

NASA Technical Reports Server (NTRS)

Copland, Evan H.; Jacobson, Nathan S.

2001-01-01

Titanium-aluminum alloys are promising intermediate-temperature alloys for possible compressor applications in gas-turbine engines. These materials are based on the a2-Ti3Al + g-TiAl phases. The major issue with these materials is high oxygen solubility in a2-Ti3Al, and oxidation of unsaturated alloys generally leads to mixed non-protective TiO2+Al2O3 scales. From phase diagram studies, oxygen saturated a2-Ti3Al(O) is in equilibrium with Al2O3; however, oxygen dissolution has a detrimental effect on mechanical properties and cannot be accepted. To better understand the effect of oxygen dissolution, we examined the thermodynamics of titanium-aluminum-oxygen alloys.

Observations of Static Strain-Aging in Polycrystalline NiAl

NASA Technical Reports Server (NTRS)

Weaver, M. L.; Noebe, R. D.; Lewandowski, J. J.; Oliver, B. F.; Kaufman, M. J.

1996-01-01

Static strain-aging has been investigated in eight polycrystalline NiAl alloys. After annealing at 1100 K for 7200 s followed by furnace cooling, high-purity, nitrogen-doped, and titanium-doped alloys exhibited continuous yielding, while conventional-purity and carbon-doped alloys exhibited distinct upper yield points and Luders strains. Either water quenching from 1100 K or prestraining via hydrostatic pressurization suppressed the yield points in the latter alloys, but they could be reintroduced by further annealing treatments. Yield points could be reintroduced more rapidly if the specimens were prestrained uniaxially rather than hydrostatically, owing to the arrangement of dislocations into cell structures during uniaxial deformation. Chemical analysis suggests that the species responsible for strain-aging is interstitial carbon.

Scaling of the Propulsive Capability of Aluminized Gelled Nitromethane

NASA Astrophysics Data System (ADS)

Loiseau, Jason; Higgins, Andrew; Frost, David; Zhang, Fan

2017-06-01

It is well accepted that small mass fractions (<20%) of micron-scale aluminum particles added to a high explosive can react quickly and with sufficient exothermicity to improve metal-acceleration ability (AA) relative to an equal volume of only the base explosive. In order for the aluminum to increase AA, exothermicity must more than offset losses in gas-production and from heating and accelerating the solid particle in the flow. Furthermore, particles must react promptly to deliver this energy prior to loss in driving pressure with product expansion or acoustic decoupling from the driven material. For these reasons many aluminized formulations exhibit slight or no increase in AA ability. Furthermore, AA ability is typically studied using the cylinder test, which specifies a fixed, heavy copper wall. In the present study the authors have used symmetric sandwiches of flyer plates of varying thicknesses to examine how charge scaling and plate acceleration timescales influence the enhancement in AA for different mass fractions and sizes of aluminum particles. Nitromethane gelled with 4% Poly(methyl methacrylate) by mass was used as the base explosive. 3M K1 microballoons were added at a mass fraction of 0.5% to sensitize the mixture. Mass fraction of aluminum was varied between 10% and 40% and particle size was varied from 2 μm to 100 μm. For small mass fractions of alumimum, an enhancement in AA was observed for all particle sizes and flyer configurations and indicated an onset of reaction very close to the sonic plane of the detonation wave.

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

Development of Weldable Superplastic Forming Aluminum Alloy Sheet Final Report CRADA No. TC-1086-95

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

Lesuer, D.; Sun, T. C.

Numerous applications could exist for superplastic formable, weldable aluminum alloys in the automotive, aerospace, architectural, and construction industries. In this project, LLNL and Kaiser worked with the Institute for Metals Superplasticity Problems to develop and evaluate weldable superplastic alloys.

Steam Oxidation Behavior of Alloy 617 at 900 °C to 1100 °C

NASA Astrophysics Data System (ADS)

Liang, Zhiyuan; Wang, Yungang; Zhao, Qinxin

2018-07-01

The steam oxidation behavior of solid solution strengthened alloy 617 at 900 °C-1100 °C was investigated. The oxidation products were characterized by scanning electron microscopy, X-ray diffraction, and energy-dispersive spectroscopy. The results show that the oxidation kinetics of alloy 617 in steam followed the parabolic oxidation law. The calculated activity energy of alloy 617 was 223.47 kJ/mol. The oxidation products were mainly composed of external and internal scales and prior oxides at grain boundaries. External oxide scales were MnCr2O4, TiO2, and Cr2O3. Internal oxidation scales and prior oxides were Al2O3 and some Cr2O3 dissolved into Al2O3. The growth mechanism of oxide scales on alloy 617 is proposed.

Steam Oxidation Behavior of Alloy 617 at 900 °C to 1100 °C

NASA Astrophysics Data System (ADS)

Liang, Zhiyuan; Wang, Yungang; Zhao, Qinxin

2018-05-01

The steam oxidation behavior of solid solution strengthened alloy 617 at 900 °C-1100 °C was investigated. The oxidation products were characterized by scanning electron microscopy, X-ray diffraction, and energy-dispersive spectroscopy. The results show that the oxidation kinetics of alloy 617 in steam followed the parabolic oxidation law. The calculated activity energy of alloy 617 was 223.47 kJ/mol. The oxidation products were mainly composed of external and internal scales and prior oxides at grain boundaries. External oxide scales were MnCr2O4, TiO2, and Cr2O3. Internal oxidation scales and prior oxides were Al2O3 and some Cr2O3 dissolved into Al2O3. The growth mechanism of oxide scales on alloy 617 is proposed.

Analysis of Widespread Fatigue Damage in Aerospace Structures

DTIC Science & Technology

1999-02-01

Fatigue in 2024 - T351 Aluminum Alloy ," Wear, 221(1), pp 24-36 (1998). 20. T.N. Farris, M.P. Szolwinski and G...Fretting Fatigue in 2024 - T351 Aluminum Alloy ," Wear, 221(1), pp 24-36 (1998). Hsing-Ling Wang1, and Alten F. Grandt, Jr.2 FATIGUE ANALYSIS OF MULTIPLE...34 Effect of Prior Corrosion on the S/N Fatigue Performance of Aluminum Sheet Alloys 2024 -T3 and 2524-T3, Effects of the

A STATE-VARIABLE APPROACH FOR PREDICTING THE TIME REQUIRED FOR 50% RECRYSTALLIZATION

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

M. STOUT; ET AL

2000-08-01

It is important to be able to model the recrystallization kinetics in aluminum alloys during hot deformation. The industrial relevant process of hot rolling is an example of where the knowledge of whether or not a material recrystallizes is critical to making a product with the correct properties. Classically, the equations that describe the kinetics of recrystallization predict the time to 50% recrystallization. These equations are largely empirical; they are based on the free energy for recrystallization, a Zener-Holloman parameter, and have several adjustable exponents to fit the equation to engineering data. We have modified this form of classical theorymore » replacing the Zener-Hollomon parameter with a deformation energy increment, a free energy available to drive recrystallization. The advantage of this formulation is that the deformation energy increment is calculated based on the previously determined temperature and strain-rate sensitivity of the constitutive response. We modeled the constitutive response of the AA5182 aluminum using a state variable approach, the value of the state variable is a function of the temperature and strain-rate history of deformation. Thus, the recrystallization kinetics is a function of only the state variable and free energy for recrystallization. There are no adjustable exponents as in classical theory. Using this approach combined with engineering recrystallization data we have been able to predict the kinetics of recrystallization in AA5182 as a function of deformation strain rate and temperature.« less

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

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

PubMed Central

Sillapasa, Kittima; Mutoh, Yoshiharu; Miyashita, Yukio; Seo, Nobushiro

2017-01-01

Overall fatigue strengths and hardness distributions of the aluminum alloy similar and dissimilar friction stir welding (FSW) joints were determined. The local fatigue strengths as well as local tensile strengths were also obtained by using small round bar specimens extracted from specific locations, such as the stir zone, heat affected zone, and base metal. It was found from the results that fatigue fracture of the FSW joint plate specimen occurred at the location of the lowest local fatigue strength as well as the lowest hardness, regardless of microstructural evolution. To estimate the fatigue strengths of aluminum alloy FSW joints from the hardness measurements, the relationship between fatigue strength and hardness for aluminum alloys was investigated based on the present experimental results and the available wide range of data from the references. It was found as: σa (R = −1) = 1.68 HV (σa is in MPa and HV has no unit). It was also confirmed that the estimated fatigue strengths were in good agreement with the experimental results for aluminum alloy FSW joints. PMID:28772543

A study of aluminum-lithium alloy solidification using acoustic emission techniques. Ph.D. Thesis, 1991

NASA Technical Reports Server (NTRS)

Henkel, Daniel P.

1992-01-01

Physical phenomena associated with the solidification of an aluminum lithium alloy was characterized using acoustic emission (AE) techniques. It is shown that repeatable patterns of AE activity may be correlated to microstructural changes that occur during solidification. The influence of the experimental system on generated signals was examined in the time and frequency domains. The analysis was used to show how an AE signal from solidifying aluminum is changed by each component in the detection system to produce a complex waveform. Conventional AE analysis has shown that a period of high AE activity occurs in pure aluminum, an Al-Cu alloy, and the Al-Li alloy, as the last fraction of solid forms. A model attributes this to the internal stresses of grain boundary formation. An additional period of activity occurs as the last fraction of solid forms, but only in the two alloys. A model attributes this to the formation of interdendritic porosity which was not present in the pure aluminum. The AE waveforms were dominated by resonant effects of the waveguide and the transducer.

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

PubMed

Sillapasa, Kittima; Mutoh, Yoshiharu; Miyashita, Yukio; Seo, Nobushiro

2017-02-15

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

Perforation of Thin Aluminum Alloy Plates by Blunt Projectiles - Experimental and Numerical Investigation

NASA Astrophysics Data System (ADS)

Wei, Gang; Zhang, Wei; Xiao, Xinke; Guo, Zitao

2011-06-01

Reducing the armor weight has become a research focus in terms of armored material with the increasing requirement of the mobility and flexibility of tanks and armored vehicles in modern local wars. Due to high strength-to-density ratio, aluminum alloy has become a potential light armored material. In this study, both lab-scale ballistic test and finite element simulation were adopted to examine the ballistic resistance of aluminum alloy targets. Blunt high strength steel projectiles with 12.7 mm diameter were launched by light gas gun against 3.3 mm thick aluminum alloy plates at velocity of 90 ~170 m/s. The ballistic limit velocity was obtained. Plugging failure and obvious structure deformation of targets were observed, and with the impact velocity increasing, the target structure deformation decrease gradually. Corresponding 2D finite element simulations were conducted by ABAQUS/EXPLICIT combined with material performance testing. Good agreement between the numerical simulations and the experimental results was found. Detailed computational results were provided to understand the deformation and failure mechanisms of the aluminum alloy plates.

The role of hydrogen in hot-salt stress corrosion cracking of titanium-aluminum alloys

NASA Technical Reports Server (NTRS)

Ondrejcin, R. S.

1971-01-01

Additional support is presented for the previously proposed role of hydrogen as an embrittling agent in hot-salt stress corrosion cracking of titanium-aluminum alloys. The main source of hydrogen formed during the reactions of titanium alloys with hot salt was identified as water associated with the salt. Hydrogen is produced by the reaction of an intermediate (hydrogen halide) with the alloy rather than from metal-water reactions. The fracture mode of precracked tensile specimens was ductile when the specimens were tested in air, and brittle when tests were made in high-pressure hydrogen. Stressed titanium-aluminum alloys also were cracked by bombardment with hydrogen ions produced in a proton accelerator. The approximate concentrations of the hydrogen ions in the alloys were calculated.

Roll Casting of Aluminum Alloy Clad Strip

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

Nakamura, R.; Tsuge, H.; Haga, T.

2011-01-17

Casting of aluminum alloy three layers of clad strip was tried using the two sets of twin roll casters, and effects of the casting parameters on the cladding conditions were investigated. One twin roll caster was mounted on the other twin roll caster. Base strip was 8079 aluminum alloy and overlay strips were 6022 aluminum alloy. Effects of roll-load of upper and lower casters and melt temperature of the lower caster were investigated. When the roll-load of the upper and lower caster was large enough, the overlay strip could be solidified and be connected. The overlay strip could be connectedmore » when the melt of the overlay strip cast by the lower caster was low enough. Sound three layers of clad strip could be cast by proper conditions.« less

Effect of Aluminum Coating on the Surface Properties of Ti-(~49 at. pct) Ni Alloy

NASA Astrophysics Data System (ADS)

Sinha, Arijit; Khan, Gobinda Gopal; Mondal, Bholanath; Majumdar, Jyotsna Dutta; Chattopadhyay, Partha Protim

2015-08-01

Stable porous layer of mixed Al2O3 and TiO2 has been formed on the Ti-(~49 at. pct) Ni alloy surface with an aim to suppress leaching of Ni from the alloy surface in contact with bio-fluid and to enhance the process of osseointegration. Aluminum coating on the Ni-Ti alloy surface prior to the anodization treatment has resulted in enhancement of depth and uniformity of pores. Thermal oxidation of the anodized aluminum-coated Ni-Ti samples has exhibited the formation of Al2O3 and TiO2 phases with dense porous structure. The nanoindentation and nanoscratch measurements have indicated a remarkable improvement in the hardness, wear resistance, and adhesiveness of the porous aluminum-coated Ni-Ti sample after thermal oxidation.

Carbide coated fibers in graphite-aluminum composites

NASA Technical Reports Server (NTRS)

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

1975-01-01

Thin, uniform coats of titanium carbide, deposited on graphite fibers by chemical vapor deposition with thicknesses up to approximately 0.1 microns were shown to improve fiber strength significantly. For greater thicknesses, strength was degraded. The coats promote wetting of the fibers and infiltration of the fiber yarns with aluminum alloys, and act as protective barriers to inhibit reaction between the fibers and the alloys. Chemical vapor deposition was used to produce silicon carbide coats on graphite fibers. In general, the coats were nonuniform and were characterized by numerous surface irregularities. Despite these irregularities, infiltration of these fibers with aluminum alloys was good. Small graphite-aluminum composite samples were produced by vacuum hot-pressing of aluminum-infiltrated graphite yarn at temperatures above the metal liquidus.

Corrosion protection of aluminum alloys in contact with other metals

NASA Technical Reports Server (NTRS)

Kuster, C. A.

1969-01-01

Study establishes the quality of chemical and galvanized protection afforded by anodized and aldozided coatings applied to test panels of various aluminum alloys. The test panels, placed in firm contact with panels of titanium alloys, were subjected to salt spray tests and visually examined for corrosion effect.

New weldable high strength aluminum alloy developed for cryogenic service

NASA Technical Reports Server (NTRS)

1966-01-01

Wrought aluminum alloy has improved low temperature notch toughness and weldability. This alloy can be mill-fabricated to plate and sheet without difficulty. Post-weld aging improves weld ductility and strength properties. A typical treatment is 8 hours at 225 deg F plus 16 hours at 300 deg F.

Laser Surface Alloying of Copper, Manganese, and Magnesium with Pure Aluminum Substrate

NASA Astrophysics Data System (ADS)

Jiru, Woldetinsay G.; Sankar, M. Ravi; Dixit, Uday S.

2016-03-01

Laser surface alloying is one of the recent technologies used in the manufacturing sector for improving the surface properties of the metals. Light weight materials like aluminum alloys, titanium alloys, and magnesium alloys are used in the locomotive, aerospace, and structural applications. In the present work, an experimental study was conducted to improve the surface hardness of commercially pure aluminum plate. CO2 laser is used to melt pre-placed powders of pure copper, manganese, and magnesium. Microstructure of alloyed surface was analyzed using optical microscope. The best surface alloying was obtained at the optimum values of laser parameters, viz., laser power, scan speed, and laser beam diameter. In the alloyed region, microhardness increased from 30 HV0.5 to 430 HV0.5, while it was 60 HV0.5 in the heat-affected region. Tensile tests revealed some reduction in the strength and total elongation due to alloying. On the other hand, corrosion resistance improved.

Modification of Sr on 4004 Aluminum Alloy

NASA Astrophysics Data System (ADS)

Guo, Erjun; Cao, Guojian; Feng, Yicheng; Wang, Liping; Wang, Guojun; Lv, Xinyu

2013-05-01

As a brazing foil, 4004 Al alloy has good welding performance. However, the high Si content decreases the plasticity of the alloy. To improve the plasticity of 4004 Al alloy and subsequently improve the productivity of 4004 Al foil or 434 composite foil, 4004 Al alloy was modified by Al-10%Sr master alloy. Modification effects of an additional amount of Sr, modification temperature, and holding time on 4004 aluminum alloy were studied by orthogonal design. The results showed that the greatest impact parameter of 4004 aluminum alloy modification was the additional amount of Sr, followed by holding time and modification temperature. The optimum modification parameters obtained by orthogonal design were as follows: Sr addition of 0.04%, holding time of 60 min, and modification temperature of 760°C. The effect of Sr addition on modification was analyzed in detail based on orthogonal results. With increasing of Sr addition, elongation of 4004 alloy increased at first, and decreased after reaching the maximum value.

ALLOY COATINGS AND METHOD OF APPLYING

DOEpatents

Eubank, L.D.; Boller, E.R.

1958-08-26

A method for providing uranium articles with a pro tective coating by a single dip coating process is presented. The uranium article is dipped into a molten zinc bath containing a small percentage of aluminum. The resultant product is a uranium article covered with a thin undercoat consisting of a uranium-aluminum alloy with a small amount of zinc, and an outer layer consisting of zinc and aluminum. The article may be used as is, or aluminum sheathing may then be bonded to the aluminum zinc outer layer.

[The Research on Optic Fiber FBG Corrosion Sensor Based on the Analysis of the Spectral Characteristics].

PubMed

Zhang, Jun; Zeng, Jie; Wang, Bo; Wang, Wen-juan; Liang, Da-kai; Liu, Xiao-ying

2016-03-01

Aiming at meeting the need of aluminum corrosion monitoring in aerospace field, a pre-load type fiber grating corrosion sensor based on an aluminum thin tube structure is proposed. The corrosion sensor of aluminum alloy structure in-service monitoring mechanism is studied, a theoretical model about the relation of FBG reflection spectral characteristics and aluminum thickness variation is also obtained. Optical fiber grating corrosion monitoring test system based on the capillary structure of aluminum alloy is constructed by acid-base environment. The problem of cross sensitivity of temperature and strain is solved by configuring an optical fiber grating which is not affected by strain and only sensitive to temperature inside the aluminum alloy tube. The results shows that he aluminum tube packaging design not only can sense the effects of corrosion on the mechanical properties, but also can interference shielding effect of corrosion on the tube optical fiber sensing device. With the deepening of the metal tube corrosion and aluminum alloy tube thickness gradually thinning, fiber grating reflective spectrum gradually shift to the short wavelength and the wall thickness and the grating center wavelength offset has a good monotonic relation. These characteristics can provide useful help to further research corrosion online monitoring based on optic fiber sensor.

A Survey of Fastening Techniques for Shipbuilding

DTIC Science & Technology

1973-09-01

many alloys ranging from aluminum to titanium, and with several types of corrosion-preventive coatings or electrodepositions that can be applied to... effective returns. The quest for increased customer acceptance emerged in one form as extended- life airframe warranties ( fatigue -rated structure). These... Aluminum Characteristics alloy Shear and tension rated NAS1436-42 Steel alloy Fatigue rated NAS1456-62 Titanium alloy , Fluid-tight bolts and collars

Sensitization of Naturally Aged Aluminum 5083 Armor Plate

DTIC Science & Technology

2015-07-29

susceptibility to intergranular corrosion of 5XXX series aluminum alloys by mass loss after exposure to nitric acid (NAMLT Test)”, ASTM G-67-04. [6...67 nitric acid mass-loss values were 19 to 25 mg/cm2. The transmission electron microscopy microstructure of the sample was found to be consistent...5XXX Series Aluminum Alloys by Mass Loss after Exposure to Nitric Acid “ was used as an assessment of the degree of sensitization (DOS) of the alloy.[5

Minutes of the Conference on the International Committee on Aeronautical Fatigue (10th) Held in Melbourne, Australia on May 1967

DTIC Science & Technology

1968-02-01

Effects A room temperature, axial-loading low-cycle fatigue investigation on 2024 -T4 and 7075--T6 aluminum alloys ...Hudson, C. Michael: Investigation of the Effect of Stress Ratio on Fatigue Crack Growth in 7075-T6 Aluminum Alloy . To be presented at Symposium on...Stress Ratio on Fatigue Crack Growth and Mode of Fracture in 2024 -T4 and 7075-T6 Aluminum Alloys in the Low-Cycle Range. Air Force Materials Laboratory

Quick Reaction Evaluation of Materials for Systems Applications.

DTIC Science & Technology

1980-04-01

The six slack-quenched aluminum alloy plates used in this program were: (1) 2024 -T851; 2.75 inches (60 mm) thick, (2) 2024 - T351 ; 2.00 inches (51 mm...compact (CT) specimen machined from aluminum alloys 7075-T6 and 2024 - T351 , titanium 6A1-4V, and 4340 steel. Deviation between the two curves is small...1.6 Complete Fatigue Crack Growth Rate Curves for Aluminum Alloy 2124-T851 Including Crack Growth Modeling 44 1.7 Crack Length Determination for the

Assessment of Damage Tolerance Requirements and Analysis. Volume 4. Raw Test Data

DTIC Science & Technology

1986-03-31

T3XX aluminum alloy . Four (4) product forms were selected: MATERIAL PRODUCT FORM THICKNESS (IN) 2024-T3 Sheet 0.090, 0.190 2024-T351 Plate 0.250 2024...T3511 Extruded Tee 0.190 2024-T3511 Extruded Angle 0.250 The material selected to represent bomber/transport/cargo aircraft is 7075- T6XX aluminum alloy ...aluminum alloys , respectively. The raw test data were processed in accordance with ASTM Standard E-8. All the tensile properties, except those marked

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.

Preparations and properties of anti-corrosion additives of water-soluble metal working fluids for aluminum alloy materials.

PubMed

Watanabe, Shoji

2008-01-01

This short review describes various types of anti-corrosion additives of water-soluble metal working fluids for aluminum alloy materials. It is concerned with synthetic additives classified according to their functional groups; silicone compounds, carboxylic acids and dibasic acids, esters, Diels-Alder adducts, various polymers, nitrogen compounds, phosphoric esters, phosphonic acids, and others. Testing methods for water-soluble metal working fluids for aluminum alloy materials are described for a practical application in a laboratory.

Oxidation of nickel-aluminum and iron-aluminum alloys

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

Cathcart, J.V.

1985-01-01

The high-temperature oxidation behavior of several ordered alloys in the Ni-Al and Fe-Al systems is reviewed with special emphasis on Ni/sub 3/Al and NiAl. Ordering influences oxidation through its effect on the activities of the alloy components and by changing the point defect concentration in an alloy. Three categories of Ni-Al alloys are distinguished based on Al content and oxidation behavior. A characteristic feature of the oxidation of high-aluminum Ni-Al and Fe-Al alloys is the formation of voids in the substrate at the oxidate-metal interface. The mechanism of void formation and its suppression by minor additions of oxygen-active elements ismore » discussed. A brief description of the effect of preoxidation on the reactions of Ni/sub 3/Al-base alloys in SO/sub 2//O/sub 2/ environments is also included. 51 references, 14 figures, 1 table.« less

Oxidation of nickel-aluminum and iron-aluminum alloys

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

Cathcart, J.V.

1984-01-01

The high-temperature oxidation behavior of several ordered alloys in the Ni-Al and Fe-Al systems is reviewed with special emphasis on Ni/sub 3/Al and NiAl. Ordering influences oxidation through its effect on the activities of the alloy components and by changing the point defect concentration in an alloy. Three categories of Ni-Al alloys are distinguished based on Al content and oxidation behavior. A characteristic feature of the oxidation of high-aluminum Ni-Al and Fe-Al alloys is the formation of voids in the substrate at the oxide-metal interface. The mechanism of void formation and its suppression by minor additions of oxygen-active elements aremore » discussed. A brief description of the effect of pre-oxidation on the reactions of Ni/sub 3/Al-base alloys in SO/sub 2//O/sub 2/ environments is also included.« less

High performance aluminum–cerium alloys for high-temperature applications

DOE PAGES

Sims, Zachary C.; Rios, Orlando R.; Weiss, David; ...

2017-08-01

Light-weight high-temperature alloys are important to the transportation industry where weight, cost, and operating temperature are major factors in the design of energy efficient vehicles. Aluminum alloys fill this gap economically but lack high-temperature mechanical performance. Alloying aluminum with cerium creates a highly castable alloy, compatible with traditional aluminum alloy additions, that exhibits dramatically improved high-temperature performance. These compositions display a room temperature ultimate tensile strength of 400 MPa and yield strength of 320 MPa, with 80% mechanical property retention at 240 °C. A mechanism is identified that addresses the mechanical property stability of the Al-alloys to at least 300more » °C and their microstructural stability to above 500 °C which may enable applications without the need for heat treatment. Lastly, neutron diffraction under load provides insight into the unusual mechanisms driving the mechanical strength.« less

Computational modeling of heat transfer and visco-plastic flow in friction stir welding

NASA Astrophysics Data System (ADS)

Nandan, Rituraj

With a focus to develop a quantitative understanding of the FSW process, a comprehensive three dimensional heat transfer and plastic flow model is developed. The model can predict variables such as temperature and velocity fields and torque based on the given welding parameters like weld velocity, tool rotational speed and axial pressure. It considers tool design dependent spatially variable heat generation rates, deformational work, non-Newtonian viscosity as a function of local strain rate, temperature and the nature of the material and temperature dependent thermal conductivity, specific heat capacity and yield stress. It is shown that the temperature fields, cooling rates, the plastic flow fields and the geometry of the thermo-mechanically affected zone (TMAZ) can be adequately described by solving the equations of conservation of mass, momentum and energy in three dimensions with appropriate boundary conditions and constitutive equations for viscosity. The model is tested for four different alloys: (1) AA 6061-T6, (2) 1018 Mn steel, (3) 304L stainless steel and (4) Ti-6Al-4V which have widely different thermophysical and rheological properties. Numerically computed temperature fields, variations of peak temperatures with FSW variables and TMAZ geometry were compared with the experimental results. Currently, due to unknown parameters in existing transport phenomena based models, the computed temperature and velocity fields and torque may not always agree with the corresponding experimentally determined values and may not show the same trend as experimental results for a range of welding variables. Here, it is shown that this problem can be solved by combining the rigorous phenomenological process sub-model with a multivariable optimization scheme called Differential Evolution. The values of the uncertain model input parameters from a limited volume of independent experimental data which includes temperature measurements obtained using thermocouples and torque measured using dynamometers. This approach resulted in agreement between the phenomenological model and the experimental results with a greater degree of certainty. It is tested for FSW of: (1) dissimilar AA 6061-T6 to AA 1200, (2) 1018 Mn steel and (3) Ti-6Al-4V. Independent thermocouple and dynamometer measurements are also used for validation and verification of results. Improvement in the reliability of the numerical model is an important first step towards increasing its practical usefulness. Also, one of the reasons why current models do not find extensive applications is because they cannot be used to tailor weld attributes. The aim of the present research is to develop a reliable bi-directional model which can find wide use in manufacturing and process control. It is shown that by coupling a reliable model with an evolutionary search algorithm, we can find multiple sets of welding parameters to achieve a target peak temperature and cooling rate in welds. The model is tested for dissimilar welds of AA 6351 and AA 1200. FSW is being increasingly used for dissimilar metal joining. Models are needed to calculate the redistribution of alloying elements when two alloys with dissimilar alloying element contents are joined. The transport and mixing of magnesium from Mg-rich AA 6061 alloy into a commercially pure aluminum AA 1200 was examined experimentally and numerically at various locations in the welded workpiece. The concentration of the solute is measured in transverse cross-sections across the weld-center line at various depths from the top surface of the workpiece. The measurement was done using electron probe micro-analysis (EPMA) of polished transverse-cut friction-stir welded samples. The comparison of the experimental and computed concentration profiles of magnesium shows imperfect mixing of the plasticized alloys during FSW. The plasticized material seem to move in layers without significant diffusive interlayer mixing. A comprehensive model for FSW is developed with capability of calculating temperature fields, material flow patterns and concentration fields in both similar and dissimilar welds in three dimensions. The model is tested for the FSW of alloys with widely different thermophysical properties. A mechanism for improving reliability and ability to provide guidance to tailor weld attributes is incorporated into the model to increase its practical usefulness. This is done by by combining the transport phenomena based model with Differential Evolution algorithm to minimize the objective function based on limited volume of experimental thermal cycles and torque measurements. (Abstract shortened by UMI.)

46 CFR 119.730 - Nonferrous metallic piping materials.

Code of Federal Regulations, 2011 CFR

2011-10-01

...) Provisions must be made to protect piping systems using aluminum alloys in high risk fire areas due to the... galvanic corrosion due to the relative solution potentials of copper, aluminum, and alloys of copper and... suitable thread compound must be used in making up threaded joints in aluminum pipe to prevent seizing...

46 CFR 182.730 - Nonferrous metallic piping materials.

Code of Federal Regulations, 2011 CFR

2011-10-01

... protect piping systems using aluminum alloys in high risk fire areas due to the low melting point of aluminum alloys; (2) Provisions must be made to prevent or mitigate the effect of galvanic corrosion due to... compound must be used in making up threaded joints in aluminum pipe to prevent seizing. Pipe in the...

An improved stress corrosion test medium for aluminum alloys

NASA Technical Reports Server (NTRS)

Humphries, T. S.; Coston, J. E.

1981-01-01

A laboratory test method that is only mildly corrosive to aluminum and discriminating for use in classifying the stress corrosion cracking resistance of aluminum alloys is presented along with the method used in evaluating the media selected for testing. The proposed medium is easier to prepare and less expensive than substitute ocean water.

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.

THE ACCURATE DETERMINATION OF MICROGRAM AMOUNTS OF BORON IN ALUMINUM AND ALUMINUM-URANIUM ALLOYS BY THE METHYL BORATE-CURCUMIN-OXALIC ACID METHOD

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

Crocker, I.H.

1958-10-01

A method was developed for the deternninntion of boron in aluminum and aluminum--uranium alloys in which the boron concentration is 30 ppm or more. Boron is separated by distillation as methyl borate from a hydrochloric acid solution of the alloy and is determined spectrophotometrically by the boric acid-- curcumin-oxalic acid color reaction. A precision of plus or minus 2% is attain able when the determination is penformed with the utmost care. The accuracy is such that no bias need be given when a calibration curve is used. (auth)

Process for producing a high emittance coating and resulting article

NASA Technical Reports Server (NTRS)

Le, Huong G. (Inventor); O'Brien, Dudley L. (Inventor)

1993-01-01

Process for anodizing aluminum or its alloys to obtain a surface particularly having high infrared emittance by anodizing an aluminum or aluminum alloy substrate surface in an aqueous sulfuric acid solution at elevated temperature and by a step-wise current density procedure, followed by sealing the resulting anodized surface. In a preferred embodiment the aluminum or aluminum alloy substrate is first alkaline cleaned and then chemically brightened in an acid bath The resulting cleaned substrate is anodized in a 15% by weight sulfuric acid bath maintained at a temperature of 30.degree. C. Anodizing is carried out by a step-wise current density procedure at 19 amperes per square ft. (ASF) for 20 minutes, 15 ASF for 20 minutes and 10 ASF for 20 minutes. After anodizing the sample is sealed by immersion in water at 200.degree. F. and then air dried. The resulting coating has a high infrared emissivity of about 0.92 and a solar absorptivity of about 0.2, for a 5657 aluminum alloy, and a relatively thick anodic coating of about 1 mil.

The structure and mechanical properties of AlMg5Si2Mn alloy after surface alloying by the use of fiber laser

NASA Astrophysics Data System (ADS)

Pakieła, Wojciech; Tanski, Tomasz; Pawlyta, Mirosława; Pakieła, Katarzyna; Brytan, Zbigniew; Sroka, Marek

2018-03-01

Laser surface treatment is successfully applied to increase hardness as well as corrosion and wear resistance in light alloys such as aluminum or magnesium. The laser surface remelting also can be used to repair superficial cracks, voids or porosity caused by the mechanical impact, metallurgical process as well as the corrosive environment on the surface of the aluminum alloy. The purpose of this paper was to investigate the influence of a fiber laser surface treatment on the structure and properties of the EN AC AlMg5Si2Mn alloy. The goal of this investigation was to increase the hardness and improve tribological properties of the aluminum alloy surface as a result of the conducted laser surface treatment. During laser processing, the top surface of the aluminum alloy was enriched with Cr and Ni particles. The grain size of the applied particles was approximately about 60-130 m. The Cr-Ni powder has been introduced in the molten pool using vacuum feeder at a constant rate of 4.5 g/min. For surface remelting we used square laser beam at a size 3 × 3 mm and with the power of 3.0 kW. The linear laser scan rate of the beam was set at 0.5 m/min. Argon was used to protect the liquid metal alloy during surface treatment. Application of the laser treatment on aluminum alloy has enabled to obtain much harder as well as better wear resistant material compared to the untreated EN AC AlMg5Si2Mn.

Ductile metal alloys, method for making ductile metal alloys

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

Cockeram, Brian V.

A ductile alloy is provided comprising molybdenum, chromium and aluminum, wherein the alloy has a ductile to brittle transition temperature of about 300 C after radiation exposure. The invention also provides a method for producing a ductile alloy, the method comprising purifying a base metal defining a lattice; and combining the base metal with chromium and aluminum, whereas the weight percent of chromium is sufficient to provide solute sites within the lattice for point defect annihilation.

Violent oxidation of lithium-containing aluminum alloys in liquid oxygen

NASA Astrophysics Data System (ADS)

Dalins, Ilmars; Karimi, Majid; Ila, Daryush

1991-06-01

A strong exothermic and quite well known thermite reaction involving aluminum, oxygen and transition metals (Fe, Cr, Ni, etc.) has apparently been initiated during impact testing of Alcoa aluminum alloy #2090 in liquid oxygen at NASA-MSFC. In some instances, this reaction, essentially an oxidation process, has been so intense that the Inconel 718 cup containing the aluminum alloy disk and associated impacter has melted raising certain safety concerns in the use of this alloy. Reaction products as well as the test specimen surfaces have been studied with surface science techniques like XPS/ESCA, SIMS and AES. Typically, in order to initiate the thermite reaction a temperature of approximately 1000°C is necessary. The mechanism responsible for this oxidation is of great interest. The analysis of the reaction products together with a theoretical analysis, including digital modeling has been pursued. There is strong evidence that the large relaxation energy of the aluminum oxide coating, formed during the aluminum alloy cleaning process, is causing a highly localized energy release during fracture or lattice deformation which is enhancing the oxidation process to a runaway condition. The presence of alkali atoms (Li) enhances the likelihood and intensity of the oxidation reaction. The details of the surface studies will be discussed.