Science.gov

Sample records for processed 6061-t6 aluminum

  1. Angular distortion and through-thickness residual stress distribution in the friction-stir processed 6061-T6 aluminum alloy

    SciTech Connect

    Woo, Wan Chuck; Choo, Hahn; Brown, D. W.; Feng, Zhili; Liaw, Peter K; Hubbard, Camden R

    2006-01-01

    Residual stresses were measured through the thickness of friction-stir processed (FSP) 6061-T6 aluminum-alloy plates using neutron diffraction. Two different specimens were prepared to study the relationship between residual stress distributions through the thickness of the plate and angular distortion: (Case 1) a plate processed with both stirring pin and tool shoulder, i.e., a typical FSP plate subjected to both plastic deformation and frictional heat, and (Case 2) a plate processed only with the tool shoulder, i.e., subjected mainly to the frictional heating. The measured residual stress profiles show relatively small through-thickness residual stress variations in Case 1, while there is a significant through-thickness residual stress variations in Case 2. The main cause of the geometric angular distortion could be related to the non-uniform distribution of the frictional heat generated by the tool shoulder leading to the asymmetric distributions of the residual stress through the thickness of the FSP plate.

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

    SciTech Connect

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

    2008-12-01

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

  3. Fatigue design curves for 6061-T6 aluminum

    SciTech Connect

    Yahr, G.T.

    1993-06-01

    A request has been made to the ASME Boiler and Pressure Vessel Committee that 6061-T6 aluminum be approved for use in the construction of Class 1 welded nuclear vessels so it can be used for the pressure vessel of the Advanced Neutron Source research reactor. Fatigue design curves with and without mean stress effects have been proposed. A knock-down factor of two is applied to the design curve for evaluation of welds. The basis of the curves is explained. The fatigue design curves are compared to fatigue data from base metal and weldments.

  4. Fatigue design curves for 6061-T6 aluminum

    SciTech Connect

    Yahr, G.T.

    1993-01-01

    A request has been made to the ASME Boiler and Pressure Vessel Committee that 6061-T6 aluminum be approved for use in the construction of Class 1 welded nuclear vessels so it can be used for the pressure vessel of the Advanced Neutron Source research reactor. Fatigue design curves with and without mean stress effects have been proposed. A knock-down factor of two is applied to the design curve for evaluation of welds. The basis of the curves is explained. The fatigue design curves are compared to fatigue data from base metal and weldments.

  5. Corrosion of type 6061-T6 aluminum in mercury and mercury vapor

    NASA Astrophysics Data System (ADS)

    Pawel, S. J.; Manneschmidt, E. T.

    2003-05-01

    To examine potential corrosion of aluminum maintenance equipment in environments periodically containing mercury vapor and droplets of liquid mercury, c-rings of 6061-T6 aluminum have been exposed to a series of screening tests. The tests included vapor phase exposures as well as immersion of stressed and unstressed c-rings in the as-received condition and with chemical treatments to modify the passive film. Test conditions included the temperature range 0-160 °C, times of 3-30 days and, in addition to liquid Hg, various Hg vapor environments including residual air, residual helium and condensing conditions. The results indicate 6061-T6 is quite susceptible to pitting and cracking when immersed in Hg for even a brief time, but at least one chemical treatment was shown to improve corrosion resistance under immersion conditions. Type 6061-T6 was found to be essentially immune to vapor phase corrosion for the conditions examined, with only very minor development of pits or pit precursors.

  6. Thermal-mechanical modeling and experimental validation of weld solidification cracking in 6061-T6 aluminum

    SciTech Connect

    Dike, J.J.; Brooks, J.A.; Bammann, D.J.; Li, M.

    1997-12-31

    Finite element simulation using an internal state variable constitutive model coupled with a void growth and damage model are used to study weld solidification cracking of 6061-T6 aluminum. Calculated results are compared with data from an experimental program determining the locations of failure as a function of weld process parameters and specimen geometry. Two types of weld solidification cracking specimen were studied. One specimen, in which cracking did not occur, was used to evaluate finite element simulations of the thermal response and calculations of average strain across the weld. The other specimen type was used to determine the location of crack initiation as a function of weld process parameters. This information was used to evaluate the finite element simulations of weld solidification cracking. A solidification model which includes dendrite tip and eutectic undercooling was used in both thermal and mechanical finite element analyses. A strain rate and temperature history dependent constitutive model is coupled with a ductile void growth damage model in the mechanical analyses. Stresses near the weld pool are examined to explain results obtained in the finite element analyses and correlated with experimental observations. Good agreement is obtained between simulation and experiment for locations of crack initiation and extent of cracking. Some effects of uncertainties in material parameters are discussed.

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

    NASA Astrophysics Data System (ADS)

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

    1997-12-01

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

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

    NASA Astrophysics Data System (ADS)

    Gencalp Irizalp, Simge; Saklakoglu, Nursen

    2016-02-01

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

  9. Prevention of non-ductile fracture in 6061-T6 aluminum nuclear pressure vessels

    SciTech Connect

    Yahr, G.T.

    1995-06-01

    The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Committee has approved rules for the use of 6061-T6 and 6061-T651 aluminum for the construction of Class 1 welded nuclear pressure vessels for temperatures not exceeding 149 C (300 F). Nuclear Code Case N-519 allows the use of this aluminum in the construction of low temperature research reactors such as the Advanced Neutron Source. The rules for protection against non-ductile fracture are discussed. The basis for a value of 25.3 MPa {radical}m (23 ksi {radical}in.) for the critical or reference stress intensity factor for use in the fracture analysis is presented. Requirements for consideration of the effects of neutron irradiation on the fracture toughness are discussed.

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

    NASA Technical Reports Server (NTRS)

    Danford, M. D.

    1990-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    1983-01-01

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

  12. Vertical Compensation Friction Stir Welding of 6061-T6 Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Ji, Shude; Meng, Xiangchen; Xing, Jingwei; Ma, Lin; Gao, Shuangsheng

    2016-09-01

    Vertical compensation friction stir welding (VCFSW) was proposed in order to solve the adverse effect caused by a big gap at the interface between two welded workpieces. VCFSW was successfully applied to weld 6061-T6 aluminum alloy with the thickness of 4 mm, while 2024-T4 aluminum alloy was selected as a rational compensation material. The results show that VCFSW is difficult to get a sound joint when the width of strip is no less than 1.5 mm. Decreasing the welding speed is beneficial to break compensation strip into pieces and then get higher quality joint. When the width of strip is 1 mm, the tensile strength and elongation of joint at the welding speed of 50 mm/min and rotational velocity of 1,800 rpm reach the maximum values of 203 MPa and 5.2%, respectively. Moreover, the addition of 2024-T4 alloy plays a strengthening effect on weld zone (WZ) of VCFSW joint. The fracture surface morphology of joint consisting of amounts of dimples exhibits ductile fracture.

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

    NASA Astrophysics Data System (ADS)

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

    2016-03-01

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

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

    NASA Technical Reports Server (NTRS)

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

    1985-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-07-01

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

  16. Effect of laser shot peening on precipitation hardened aluminum alloy 6061-T6 using low energy laser

    NASA Astrophysics Data System (ADS)

    Sathyajith, S.; Kalainathan, S.

    2012-03-01

    Mechanical properties of engineering material can be improved by introducing compressive residual stress on the material surface and refinement of their microstructure. Variety of mechanical process such as shot peening, water jet peening, ultrasonic peening, laser shot peening were developed in the last decades on this contrast. Among these, lasers shot peening emerged as a novel industrial treatment to improve the crack resistance of turbine blades and the stress corrosion cracking (SCC) of austenic stainless steel in power plants. In this study we successfully performed laser shot peening on precipitation hardened aluminum alloy 6061-T6 with low energy (300 mJ, 1064 nm) Nd:YAG laser using different pulse densities of 22 pulses/mm 2 and 32 pulses/mm 2. Residual stress evaluation based on X-ray diffraction sin 2 ψ method indicates a maximum of 190% percentage increase on surface compressive stress. Depth profile of micro-hardness shows the impact of laser generated shock wave up to 1.2 mm from the surface. Apart from that, the crystalline size and micro-strain on the laser shot peened surfaces have been investigated and compared with the unpeened surface using X-ray diffraction in conjunction with line broadening analysis through the Williamson-Hall plot.

  17. Shock-loading response of 6061-T6 aluminum metal-matrix composites

    SciTech Connect

    Vecchio, K.S.; Gray, G.T. III

    1995-10-01

    The purpose of this research was to systematically study the influence of peak-shock pressure and second-phase reinforcement on the structure/property response of shock-loaded 6061-T6 Al, used as a baseline for comparison, showed no increased shock hardening compared to the unshocked material deformed to an equivalent strain. The reload stress-strain response of the shock-loaded 6061-T6 Al-alumina composites exhibit a lower reload yield strength than the flow stress of the starting composites. The degrees of strength loss was found to increase with increasing shock pressure. Wavespeed measurements of shock-prestrained specimens showed no degradation compared to unshocked specimens, indicating that particle cracking had not occurred under shock. This result was supported by optical metallography, which did not reveal cracked particles or particle decohesion in the shock-prestrained samples. The reload stress-strain response of the shock-prestrained composites, after resolutionizing and T6 reaging, showed that the composites recovered their full as-received preshock stress-strain responses. This result supports the finding that degradation in reload strength was attributable to matrix microstructural changes resulting from the shock. Transmission electron microscopy (TEM) examination of the shock-loaded microstructures revealed that the matrix regions adjacent to the particle/matrix interface had undergone significant recovery and partial recrystallization resulting from the shock. This type of near-interface substructure is in stark contrast to the heavily dislocated near-interface dislocation substructure of the as-received composites. The loss of dislocation density (i.e., strain hardening) in the near-interface matrix region, resulting from the shock, highlights the importance of the thermally introduced dislocation substructure changes in establishing the strength of metal-matrix composites (MMCs).

  18. 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.

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

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

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

    NASA Astrophysics Data System (ADS)

    Odoh, Daniel Oghenekewhe Oluwatobi

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

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

    SciTech Connect

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

    2000-08-08

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

  2. Ultrasonic Fatigue Endurance of Aluminum Alloy AISI 6061-T6 on Pre-corroded and Non-corroded Specimens

    NASA Astrophysics Data System (ADS)

    Domínguez Almaraz, Gonzalo M.; Dueñas Aburto, Antonio; Correa Gómez, Erasmo

    2014-01-01

    Ultrasonic fatigue tests are carried out on aluminum alloy 6061-T6 in order to analyze the fatigue endurance behavior under artificial pre-corrosion attack by hydrochloric acid for the pH concentrations of 0.47 and 0.80. The pre-corrosion attack is used to simulate the long-time environmental effect and the corresponding decay of fatigue life in regard to non-corroded specimens. Experimental results show that ultrasonic fatigue endurance under these two degrees of pre-corrosion attack decreases dramatically. Furthermore, it is observed that crack initiation is frequently associated with one or several pre-corrosion pitting holes at the specimen surface. Pitting holes are assumed to be semi-hemispherical and the stress concentration factors are evaluated taking into account the size and proximity of two crack initiation pitting holes. The crack growth rates are obtained for the pre-corroded specimens and compared to the non-corroded specimen. Finally, conclusions are listed concerning ultrasonic fatigue endurance of testing specimens, together with the fracture surfaces, crack paths, and crack growth rates.

  3. Characterization of mechanical shock waves in aluminum 6061-T6 using a high power laser pulse

    NASA Astrophysics Data System (ADS)

    Gonzalez Romero, J. R.; García-Torales, G.; Gómez Rosas, G.; Ocaña, J. L.; Flores, Jorge L.

    2016-09-01

    Strengthening techniques allows enhance metal physical properties. Laser shock peening (LSP) technique consist in a surface treatment which a high power laser pulse induces a compressive residual stress field through mechanical shock waves, increasing hardness, corrosion resistance, fatigue resistance. In comparison with the shot peening technique, LSP is a method that allows precision controlling the laser incidence on the surface under treatment increasing the surface quality in the surface under treatment. In this work, mechanical shock waves are induced in aluminum and measure using two different experimental approaches. First, using a PVDZ sensors and secondly, strain gauges are used. Experimental results are presented.

  4. Experimental measurement of the principal isentrope for aluminum 6061-T6 to 240 GPa.

    SciTech Connect

    Davis, Jean-Paul

    2005-02-01

    Using a magnetic pressure drive, an absolute measurement of stress and density along the principal compression isentrope is obtained for solid aluminum to 240 GPa. Reduction of the free-surface velocity data relies on a backward integration technique, with approximate accounting for unknown systematic errors in experimental timing. Maximum experimental uncertainties are {+-}4.7% in stress and {+-}1.4% in density, small enough to distinguish between different equation-of-state (EOS) models. The result agrees well with a tabular EOS that uses an empirical universal zero-temperature isotherm.

  5. Experimental measurement of the principal isentrope for aluminum 6061-T6 to 240 GPa.

    SciTech Connect

    Davis, Jean-Paul

    2006-02-01

    Using a magnetic pressure drive, an absolute measurement of stress and density along the principal compression isentrope is obtained for solid aluminum to 240 GPa. Reduction of the free-surface velocity data relies on a backward integration technique, with approximate accounting for unknown systematic errors in experimental timing. Maximum experimental uncertainties are +/-4.7% in stress and +/-1.4% in density, small enough to distinguish between different equation-of-state (EOS) models. The result agrees well with a tabular EOS that uses an empirical universal zero-temperature isotherm.

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

    NASA Technical Reports Server (NTRS)

    Hintze, Paul E.; Calle, Luz M.

    2005-01-01

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

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

    SciTech Connect

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

    2007-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    1983-01-01

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

  9. Examination of irradiated 304L stainless steel to 6061-T6 aluminum inertia welded transition joints after irradiation in a spallation neutron

    SciTech Connect

    Dunn, K.A.

    2000-04-28

    The Savannah River Technology Center (SRTC) designed and fabricated tritium target/blanket assemblies which were irradiated for six months at the Los Alamos Neutron Science Center (LANSCE). Cooling water was supplied to the assemblies through 1 inch diameter 304L Stainless Steel (SS) tubing. To attach the 304L SS tubing to the modules a 304L SS to 6061-T6 Aluminum (Al) inertia welded transition joint was used. These SS/Al inertia weld transition joints simulate expected transition joints in the Accelerator Production of Tritium (APT) Target/Blanket where as many as a thousand SS/Al weld transition joints will be used. Materials compatibility between the 304L SS and the 6061-T6 Al in the spallation neutron environment is a major concern as well as the corrosion associated with the cooling water flowing through the piping. The irradiated inertia weld examination will be discussed.

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

    SciTech Connect

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

    2007-01-01

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

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

    SciTech Connect

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

    2007-01-01

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

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

    SciTech Connect

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

    2009-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2014-05-01

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

  14. The effect of strain rate on the tensile properties of an Al[sub 2]O[sub 3p]/6061-T6 aluminum metal-matrix composite at low temperatures

    SciTech Connect

    Chia Chaw Perng; Jiun Ren Hwang; Ji Liang Doong )

    1993-08-01

    Alumina (Al[sub 2]O[sub 3]) particles reinforced aluminum matrix composites have recently become candidates for structural materials because of their good specific modulus and strength, and are considered to be valuable materials for aerospace and automobile industry applications. In view of such application, they might be processed or applied in high strain rate loading conditions, such as explosive forming, blast loading and metalworking, etc. Knowledge of the mechanical behavior of the metal matrix composites under high strain rate loading is a prerequisite. However, not much work related to this topic has been done. The objective of this study was to investigate the effect of the strain rate on the tensile properties of the Al[sub 2]O[sub 3p]/6061-T6 composite at low temperatures.

  15. Electron beam welding of 6061-T6 covers to A356-T6 machined cast housings: Final report

    SciTech Connect

    Miller, G.P.

    1988-03-01

    An electron beam welding process was developed to replace the manual gas tungsten arc welding process for welding 6061-T6 aluminum covers to the A356-T6 cast aluminum machined housing for a Filter Pack Assembly. Design change recommendations must be incorporated prior to implementation of the electron beam welding process. 3 refs., 9 figs., 5 tabs.

  16. 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%.

  17. Microstructure Characterization of Magnetic-Pulse-Welded AA 6061-T6 by Electron Backscattered Diffraction

    SciTech Connect

    Zhang, Yuan; Babu, Suresh; Zhang, P; Kenik, Edward A; Daehn, Glenn

    2008-01-01

    The grain boundary crystallographic misorientations of magnetic-pulse-welded (MPW) aluminum alloy (AA) 6061-T6 in linear and tubular configurations were examined using the electron backscattered diffraction (EBSD) technique. A refined structure of heavily deformed grains with higher grain boundary angles was observed in linear welds. Significant spalling was observed away from the joints, in the interior of tubular welds. The results show the complex interaction of shock waves with the materials during this impact welding process.

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

    SciTech Connect

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

    2008-01-01

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

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

    SciTech Connect

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

    2007-01-01

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

  20. Experimental Investigation of Turning Parameters on AA 6061-T6 Material

    NASA Astrophysics Data System (ADS)

    Parthiban, A.; Pugazhenthi, R.; Ravikumar, R.; Vivek, P.

    2017-03-01

    Turning is a broadly used material removal process to manufacture cylindrical products. The effects of various process parameters on turning like spindle speed, feed rate and depth of cut have been investigated to Impact on Material Removal Rate (MRR) and surface roughness (Ra) by using Response Surface Methodology. Experimental plan is performed by a Box-behenken design. The main purpose of this work is to study the effect of process parameters on Aluminium alloy AA6061-T6 surface, and to develop the mathematical model for Material removal rate and surface roughness on milling process. The quadratic model is best agreement with experimental data; finally the numerical optimization technique has been used to find out best optimum milling parameters. The optimal set of process parameters has also been predicted to maximize the MRR and minimize the surface roughness.

  1. Corrosion behaviors of Al-Si-Cu-based filler metals and 6061-T6 brazements

    NASA Astrophysics Data System (ADS)

    Su, T. L.; Wang, S. S.; Tsao, L. C.; Chang, S. Y.; Chuang, T. H.; Yeh, M. S.

    2002-04-01

    The corrosion behaviors of a series of Al-Si-Cu-based filler metals and the 6061-T6 butt joints brazed with these filler metals are evaluated by polarization tests and immersion tests in a 3.5% NaCl aqueous solution. For comparison, a traditional Al-12Si filler metal is also employed. The results indicate that the Al-Si-Cu-based filler metals before brazing possess much higher corrosion current densities and pitting tendencies than the Al-12Si filler metal. However, brazing of the 6061-T6 alloy with an Al-12Si filler metal produces a wider butt joint, which, in this case, creates a more extensive corrosion region. Severe galvanic corrosion occurs at the 6061-T6 joints when brazed with Al-Si-Cu-based filler metals. However, in the case of the 6061-T6/Al-12Si brazements, selective corrosion of the Al-12Si eutectic phase can be observed. The bonding strengths of the 6061-T6 butt joints brazed with various filler metals are also measured before and after the immersion tests.

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

    NASA Technical Reports Server (NTRS)

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

    1983-01-01

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

  3. The mechanical response of a 6061-T6 Al/Al{sub 2}O{sub 3} metal matrix composite at high rates of deformation

    SciTech Connect

    Yadav, S.; Chichili, D.R.; Ramesh, K.T.

    1995-12-01

    The mechanical properties of a 6061-T6 aluminum alloy reinforced with a 20 vol% fraction of alumina particles and of an unreinforced 6061-T6 alloy are studied over a range of strain rates (10{sup {minus}4} to 6 {times} 10{sup 5} s{sup {minus}1}) using quasistatic compression, compression and torsion Kolsky Bars, and high strain rate pressure-shear plate impact. At a given strain rate the composite displays increased strength but essentially the same strain hardening as the matrix. However, the composite displays a stronger rate-sensitivity than does the unreinforced alloy at high rates of deformation (> 10{sup 3} s{sup {minus}1}). The rate-sensitivity of the unreinforced alloy is shown to be largely the result of the imposed strain rate rather than of the rate history. For quasistatic deformations, a model proposed by Bao et al. (1991) describes the behavior of the composite fairly accurately given the behavior of the unreinforced alloy. This paper presents an extension of the model that is able to predict the dynamic behavior of the composite given the dynamic response of the monolithic alloy.

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

    NASA Astrophysics Data System (ADS)

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

    2016-02-01

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

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

    SciTech Connect

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

    2010-11-19

    In this work we analyze the plasticity, damage, and fracture characteristics of three different processed aluminum alloys (rolled 5083-H13, cast A356-T6, and extruded 6061-T6) under varying stress states (tension, compression, and torsion) and strain rates (0.001/, 1/s., and 1000/s). The stress state difference had more of a flow stress effect than the applied strain rates for those given in this study (0.001/sec up to 1000/sec). The stress state and strain rate also had a profound effect on the damage evolution of each aluminum alloy. Tension and torsional straining gave much greater damage nucleation rates than compression. Although the damage of all three alloys was found to be void nucleation dominated, the A356-T6 and 5083-H131 aluminum alloys incurred void damage via micron scale particles where the 6061-T6 aluminum alloy incurred void damage from two scales, micron-scale particles and nanoscale precipitates. Having two length scales of particles that participated in the damage evolution made the 6061-T6 incur a strain rate sensitive damage rate that was different than the other two aluminum alloys. Under tension, as the strain rate increased, the 6061-T6 aluminum alloy's void nucleation rate decreased, but the A356-T6 and 5083-H131 aluminum alloys void nucleation rate increased.

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

    NASA Astrophysics Data System (ADS)

    Soukieh, M.

    2004-02-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2013-03-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2014-08-01

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

  9. Corrosion characterization of aluminum alloys treated with a new sealing process -- Part 2

    SciTech Connect

    Banerjee, G.; Miller, A.E.; Vasanth, K.L.

    1999-07-01

    Continuing an earlier investigation a new sealing solution that contains catalytic amount of chromium (1--10{micro}g) was developed. Aluminum alloys 2024-T6 and 6061-T6 coupons were anodized and sealed with the new sealing formulation. Passivation characteristics of these samples were evaluated using potentiodynamic anodic polarization tests. Al 6061-T6 coupons were further subjected to prohesion tests. In this paper, the results obtained from these tests are compared to those obtained by aluminum alloy treated with standard chromate conversion coating.

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

    PubMed

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

    2013-08-01

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

  11. The Young's Modulus of 1018 Steel and 6061-T6 Aluminium Measured from Quasi-Static to Elastic Precursor Strain-Rates

    NASA Astrophysics Data System (ADS)

    Rae, Philip J.; Trujillo, Carl P.; Lovato, Manuel L.

    2009-12-01

    The assumption that Young's modulus is strain-rate invariant is tested for 6061-T6 aluminium alloy and 1018 steel over 10 decades of strain-rate. For the same billets of material, 3 quasi-static strain-rates are investigated with foil strain gauges at room temperature. The ultrasonic sound speeds are measured and used to calculate the moduli at approximately 104 s-1. Finally, 1D plate impact is used to generate an elastic pre-cursor in the alloys at a strain-rate of approximately 106 s1 from which the longitudinal sound speed may be obtained. It is found that indeed the Young's modulus is strain-rate independent within the experimental accuracy.

  12. Ultrasonic measurement of anisotropy and temperature dependence of elastic parameters by a dry coupling method applied to a 6061-T6 alloy.

    PubMed

    Augereau, F; Laux, D; Allais, L; Mottot, M; Caes, C

    2007-03-01

    A pulse-echo ultrasonic method is presented to measure elastic parameter variations during thermal loading with high accuracy. Using a dry coupling configuration dedicated to high temperature investigation, this technique has been applied on 6061-T6 aluminium samples up to 220 degrees C. Experimental settings are described to assess the measurement reproducibility estimated at a value of 0.2%. Consequently, the anisotropy of this aluminium between the rolling direction and two orthogonal axes has been clearly detected and also measured versus temperature. As regards the temperature dependence of these elastic parameters, these results are compared with the estimations of the Young's modulus obtained during mechanical tests in conditions of low cycle fatigue (LCF). The same linear variation versus temperature is found but with a shift of 7GPa. This difference has been classically attributed to systematic experimental error sources and to the distinction existing between dynamic and static elastic modulus.

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

    SciTech Connect

    Gates, W.G.; Jimenez, E.

    1981-04-01

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

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

    NASA Astrophysics Data System (ADS)

    Nounezi, Thomas

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

  15. Chromate-free corrosion resistant conversion coatings for aluminum

    SciTech Connect

    Buchheit, R.G. ); Stoner, G.E. . Dept. of Materials Science and Engineering)

    1993-01-01

    We have developed a method for generating chromate-free corrosion resistant coatings on aluminum alloys using a process procedurally similar to standard chromate conversion. These coatings provide good corrosion resistance on 6061-T6 and 1100 A1 under salt spray testing conditions. The resistance of the new coating is comparable to that of chromate conversion coatings in four point probe tests, but higher when a mercury probe technique is used. Initial tests of paint adhesion, and under paint corrosion resistance are promising. Primary advantage of this new process is that no hazardous chemicals are used or produced during the coating operation.

  16. Chromate-free corrosion resistant conversion coatings for aluminum

    SciTech Connect

    Buchheit, R.G.; Stoner, G.E.

    1993-03-01

    We have developed a method for generating chromate-free corrosion resistant coatings on aluminum alloys using a process procedurally similar to standard chromate conversion. These coatings provide good corrosion resistance on 6061-T6 and 1100 A1 under salt spray testing conditions. The resistance of the new coating is comparable to that of chromate conversion coatings in four point probe tests, but higher when a mercury probe technique is used. Initial tests of paint adhesion, and under paint corrosion resistance are promising. Primary advantage of this new process is that no hazardous chemicals are used or produced during the coating operation.

  17. Aluminum powder metallurgy processing

    SciTech Connect

    Flumerfelt, J.F.

    1999-02-12

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

  18. Alkaline oxide conversion coatings for aluminum alloys

    SciTech Connect

    Buchheit, R.G.

    1996-02-01

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

  19. The Aluminum Smelting Process

    PubMed Central

    2014-01-01

    This introduction to the industrial primary aluminum production process presents a short description of the electrolytic reduction technology, the history of aluminum, and the importance of this metal and its production process to modern society. Aluminum's special qualities have enabled advances in technologies coupled with energy and cost savings. Aircraft capabilities have been greatly enhanced, and increases in size and capacity are made possible by advances in aluminum technology. The metal's flexibility for shaping and extruding has led to architectural advances in energy-saving building construction. The high strength-to-weight ratio has meant a substantial reduction in energy consumption for trucks and other vehicles. The aluminum industry is therefore a pivotal one for ecological sustainability and strategic for technological development. PMID:24806722

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

    NASA Astrophysics Data System (ADS)

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

    2015-05-01

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

  1. Tests Of Polyurethane And Dichromate Coats On Aluminum

    NASA Technical Reports Server (NTRS)

    Danford, M. D.

    1992-01-01

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

  2. Numerical Simulation of Ballistic Impact of Layered Aluminum Nitride Ceramic

    DTIC Science & Technology

    2015-09-01

    tile(s) Aluminum nitride (AlN) 163 a Polymer layers Polyurethane foam 18 b Backing metal Aluminum 6061-T6 (Al) 23 c Projectile Tungsten heavy alloy ... alloys . Composites B: Engineering. 2009;40:443–450. 9. Clayton JD. Two-scale modeling of effects of microstructure and thermomechanical properties on...the dynamic performance of an aluminum alloy . International Journal of Materials and Structural Integrity. 2010;4:116– 140. 10. Clayton JD. A

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

    NASA Technical Reports Server (NTRS)

    Danford, M. D.

    1994-01-01

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

  4. 49 CFR 178.46 - Specification 3AL seamless aluminum cylinders.

    Code of Federal Regulations, 2010 CFR

    2010-10-01

    ... change in cylinder wall thickness, service pressure, or diameter; a 30 percent or greater change in water...) Size and service pressure. A DOT 3AL cylinder is a seamless aluminum cylinder with a maximum water... specimen 6061-T6 38,000 35,000 214 1 “D” represents specimen diameters. When the cylinder wall is...

  5. PROCESS FOR REMOVING ALUMINUM COATINGS

    DOEpatents

    Flox, J.

    1959-07-01

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

  6. Fabrication Process for Machined and Shrink-Fitted Impactor-Type Liners for the LOS Alamos Hedp Program

    NASA Astrophysics Data System (ADS)

    Randolph, B.

    2004-11-01

    Composite liners have been fabricated for the Los Alamos liner-driven High Energy Density Physics (HEDP) experiments using impactors formed by physical vapor deposition, and by machining and shrink fitting. Chemical vapor deposition has been proposed for some ATLAS liner applications. This paper describes the processes used to fabricate machined and shrink-fitted impactors; these processes have been used for copper impactors in 1100 aluminum liners and for 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-fitting and light press fitting. The processes used to date will be described along with some considerations for future composite liners for the HEDP Program.

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

    NASA Astrophysics Data System (ADS)

    Hilfi, H.; Brar, N. S.

    1996-05-01

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

  8. Mechanical properties of laser welded aluminum alloys

    SciTech Connect

    Douglass, D.M.; Mazumder, J.

    1996-12-31

    The demand for lighter weight vehicles has prompted accelerated development in processing aluminum alloys for automobile structural applications. One of the current research initiatives centers on laser beam welding of aluminum alloys. Autogenous butt welds have been performed on Al 3003, 5754, 6111, and 6061-T6 plates with a 6 kW CO2 laser. For 6061, tensile data indicate about 60% of the base metal strength was attained in the as-welded condition, with a brittle fracture occurring through the weld. A post-weld heat treatment to the T6 condition resulted in a recovery of original ultimate tensile strengths, although these also failed in the weld. Hardness measurements of the post-weld T6 reveal a uniform hardness across the HAZ and fusion zone that is comparable to the original hardness. All 3003 welds fractured in the parent material in a ductile fashion. A high quality bead was consistently achieved with the 3003 alloy, whereas the other alloys demonstrated bead irregularities. SEM photographs reveal large, spherical pores, suggesting that they were formed by gas entrapment rather than by shrinkage.

  9. Process for anodizing aluminum foil

    SciTech Connect

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

    1984-11-06

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

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

    SciTech Connect

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

    1991-02-01

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

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

    SciTech Connect

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

    2004-06-02

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

  12. Characterization of an effective cleaning procedure for aluminum alloys: surface enhanced Raman spectroscopy and zeta potential analysis.

    PubMed

    Cherepy, Nerine J; Shen, Tien H; Esposito, Anthony P; Tillotson, Thomas M

    2005-02-01

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

  13. PROCESS OF ELECTROPLATING METALS WITH ALUMINUM

    DOEpatents

    Schickner, W.C.

    1960-04-26

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

  14. Micro-finish hard anodized coatings on aluminum

    SciTech Connect

    Steffani, C.

    1992-03-01

    The production of thin hard anodized coatings on Single Point Diamond Turned (SPDT) 6061-T6 aluminum has been studied. The investigation centered on producing a surface finish of less than 10 microinch after anodizing. By starting with a 2 microinch (AA) surface finish and controlling time, temperature, current density and solution chemistry, coatings with surface finishes of 8 microinch and a thickness of .0003 inch, are obtained. Surface roughness from several anodizing solutions is compared. The operational life of a PTFE sliding seal against a coated cylinder bore is used as verification of finish quality.

  15. In situ surface studies of conversion coatings for steel and aluminum. Final report, 15 April 1989-14 September 1992

    SciTech Connect

    White, H.W.; Mansfeld, F.; Bryant, P.

    1992-11-10

    The primary goals of the work were to develop mechanisms of corrosion protection for cerium based surface layers on aluminum alloys and on polyacrylic acid (PAA) complexed zinc phosphate conversion coatings on steel. Atomic force microscopy (AFM) using tunnel current control was developed and applied to several problems. The cerium based coatings on AI 6061-T6 are shown to consist of two principle components--a poorly ordered monohydrated aluminum oxide, and an insoluble cerium oxide which forms at areas concentrated with impurities and alloying elements. Electrochemical action during the surface modification process fosters the precipitation of cerium compounds which inhibit further attack. The addition of high molecular weight PAA to the phosphating bath can significantly improve both resistance to corrosion and top-coat adherence of zinc phosphate conversion coatings on steel. Raman spectra showed the compositions of both unmodified and PAA modified films to be zinc phosphate dihydrate. Single crystallite surfaces were imaged using AFM. The morphologies of the unmodified and modified films were in general quite similar, but subtle differences were apparent. Several other projects involving surface layers and adsorbates were carried out and are described.

  16. Microstructural Characterization of 6061 Aluminum to 304L Stainless Steel Inertia Welds

    SciTech Connect

    Dunn, K.A.

    1999-09-29

    'Microstructural characterization of 6061-T6 aluminum-to-Type 304L stainless steel inertia welds provided a technical basis to conclude that transition joints fabricated from such welds should satisfactorily contain helium/hydrogen gas mixtures. This conclusion is based on the lack of semi-continuous alignments of particles and/or inclusions at, or near, the aluminum-to-stainless steel interface. These dissimilar metal transition joints play a key role in the operation of an accelerator driven, spallation neutron source designed for the production of tritium. The Accelerator Production of Tritium system will produce tritium through neutron interactions with 3He gas contained in water-cooled, 6061-T6 aluminum pressure tubes. Current design concepts include thousands of thin-walled pressure tubes distributed throughout a number of aluminum-clad, lead-filled, blanket modules. The aluminum pressure tubes are connected to a tritium extraction and purification system through a stainless steel manifold. The transition from aluminum to stainless steel is made via transition joints machined from the aluminum-to-stainless steel inertia welds. The paper describes the baseline microstructural characterization of the welds, including optical, scanning and transmission electron microscopy and uses that characterization to evaluate potential gas leakage across the weld.'

  17. Numerical modelling of thermal phenomenon in friction stir welding of aluminum plates

    NASA Astrophysics Data System (ADS)

    Vaira Vignesh, R.; Padmanaban, R.; Arivarasu, M.; Thirumalini, S.; Gokulachandran, J.; Sai Ram, Mutyala Sesha Satya

    2016-09-01

    Friction stir welding (FSW) is a solid state welding process with potential to join materials that are non weldable by conventional fusion welding techniques. The study of heat transfer in FSW aids in the identification of defects like flash, inadequate heat input, poor material flow and mixing etc. In this paper, transient temperature distribution during FSW of aluminum alloy AA6061-T6 was simulated using finite element modelling. The model was used to predict the peak temperature and analyse the thermal history during FSW. The effect of process parameters namely tool rotation speed, tool traverse speed (welding speed), shoulder diameter and pin diameter of tool on the temperature distribution was investigated using two level factorial design. The model results were validated using the experimental results from the published literature. It was found that peak temperature was directly proportional to tool rotation speed and shoulder diameter and inversely proportional to tool traverse speed. The effect of pin diameter on peak temperature was found to be trivial.

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

    NASA Astrophysics Data System (ADS)

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

    2015-10-01

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

  19. Process simulation of aluminum reduction cells

    SciTech Connect

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

    1996-10-01

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

  20. Anodization process produces opaque, reflective coatings on aluminum

    NASA Technical Reports Server (NTRS)

    1965-01-01

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

  1. Internal Heterogeneous Processes in Aluminum Combustion

    NASA Technical Reports Server (NTRS)

    Dreizin, E. L.

    1999-01-01

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

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

    SciTech Connect

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

    2009-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

  4. Decarbonization process for carbothermically produced aluminum

    DOEpatents

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

    2015-06-30

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

  5. Superplasticity in Thermomechanically Processed High Magnesium Aluminum-Magnesium Alloys.

    DTIC Science & Technology

    1984-03-01

    California DTIC EECTE JL I 1984 THESIS SUPERPLASTICITY IN THERMOMECHANICALLY PROCESSED HIGH MAGNESIUM ALUMINUM-MAGNESIUM ALLOYS C:L by CD) John J. Becker...High Magnesium Aluminum- March 1984 Magnesium Alloys S. PERFORMING ORG. REPORT NUMBER 7. AUTHOR(@) S. CONTRACT OR GRANT NUMBER(&) John J. Becker 9...magnesium, aluminum-magnesium alloys were investigated. The thermomechanical processing itself included warm rolling at 300°C to 94% reduction

  6. Numerical simulation of aluminum extrusion processes

    NASA Astrophysics Data System (ADS)

    Hughes, T. J.; Muller, A.

    1995-04-01

    This presentation describes a research program directed towards the development of automated design procedures for aluminum extrusion technology. The objective is to eliminate costly trial and error by being able to simultaneously design the product, die, billet, and process (e.g.. extrusion temperatures and speeds, uniformizing metal flow, etc.), within constraints of feasibility, and satisfying objectives including, but not limited to, optimizing shape, surface finish, and properties of the product, processing costs, time to market, and full utilization of capabilities. The approach is based on the development of efficient and effective analysis of the whole processing system employing newly developed finite element solution technologies for complex, multi region, multiphysical behavior. Generalizations of these methodologies to include Arbitrary Lagrangian-Eulerian (ALE) mesh descriptions for nonlinear, elastic viscoplastic mechanical constitution equations will allow the faithful modeling of the metal flow within the die system and the accurate attainment of final shape upon exit. Automatic meshing and adaptive remeshing will insure efficient and accurate simulation of the entire forming process. New element technologies facilitating the use of general meshing procedures for difficult metal-forming processes involving a variety of kinematical constraints, such as incompressibility, contact, etc., are utilized. Feature based design methodologies, parametric modeling, and knowledge-based engineering techniques will constitute the fundamental methodologies for representing designs, managing the hierarchy of analysis models, performing model reduction and feature removal, and effectively utilizing design knowledge.

  7. Corrosive wear of SiC whisker- and particulate-reinforced 6061 aluminum alloy composites

    SciTech Connect

    Yu, S.Y.; Ishii, H.; Chuang, T.H.

    1996-09-01

    Wear tests on SiC whisker- and SiC particulate-reinforced 6061-T6 aluminum matrix composites (SiCw/Al and SiCp/Al), fabricated using a high pressure infiltration method, were performed in laboratory air, ion-exchanged water and a 3 pct NaCl aqueous solution using a block-on-ring type apparatus. The effects of environment, applied load, and rotational (sliding) speed on the wear properties against a sintered alumina block were evaluated. Electrochemical measurements in ion-exchanged water and a 3 pct NaCl aqueous solution were also made under the same conditions as the wear tests. A comparison was made with the properties of the matrix aluminum alloy 6061-T6. The SiC-reinforced composites exhibited better wear resistance compared with the monolithic 6061 Al alloy even in a 3 pct NaCl aqueous solution. Increase in the wear resistance depended on the shape, size, and volume fraction of the SiC reinforcement. Good correlation was obtained between corrosion resistance and corrosion wear. The ratios of wear volume due to the corrosive effect to noncorrosive wear were 23 to 83 pct, depending on the wear conditions.

  8. Solution processed aluminum paper for flexible electronics.

    PubMed

    Lee, Hye Moon; Lee, Ha Beom; Jung, Dae Soo; Yun, Jung-Yeul; Ko, Seung Hwan; Park, Seung Bin

    2012-09-11

    As an alternative to vacuum deposition, preparation of highly conductive papers with aluminum (Al) features is successfully achieved by the solution process consisting of Al precursor ink (AlH(3){O(C(4)H(9))(2)}) and low temperature stamping process performed at 110 °C without any serious hydroxylation and oxidation problems. Al features formed on several kinds of paper substrates (calendar, magazine, and inkjet printing paper substrates) are less than ~60 nm thick, and their electrical conductivities were found to be as good as thermally evaporated Al film or even better (≤2 Ω/□). Strong adhesion of Al features to paper substrates and their excellent flexibility are also experimentally confirmed by TEM observation and mechanical tests, such as tape and bending tests. The solution processed Al features on paper substrates show different electrical and mechanical performance depending on the paper type, and inkjet printing paper is found to be the best substrate with high and stable electrical and mechanical properties. The Al conductive papers produced by the solution process may be applicable in disposal paper electronics.

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

    SciTech Connect

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

    2006-08-01

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

  10. Processing and characterization of aluminum oxynitride ceramics

    NASA Astrophysics Data System (ADS)

    Patel, Parimal Jagdish

    2000-10-01

    Aluminum oxynitride (AlON) ceramics are polycrystalline materials which have a cubic spinel structure. They have excellent mechanical and chemical properties and are transparent in the visible, mm, and IR frequency ranges. The combination of these properties qualifies AlON ceramics as primary candidate materials for electromagnetic windows, radomes, sensor protection and transparent armor applications. The major obstacle to its use is the lack of a low cost manufacturing method for obtaining a reproducible transparent material. The focus of this thesis is on defining processing parameters for producing AlON ceramics and characterization of their properties. After a careful review of the available literature, it was decided that transient liquid phase reactive sintering and hot pressed/reactive sintering techniques offered the potential for producing transparent AlON ceramics. Using these techniques, samples were prepared and thermally treated to different firing schedules, varying the temperatures and dwell times. The final samples all exhibited an unexpected high level of porosity. The origin of the porosity in the samples was shown to be due to the formation of a vapor phase present at the very high processing temperatures required. A strong nitrogen pressure dependence on composition was shown to occur at temperatures above 1900°C and a model was proposed to describe the mechanisms. As nitrogen pressure was reduced, an oxygen rich vapor phase forms resulting in unexpected increase in porosity. The phase relations of the system were investigated for temperatures above 1900°C to further understand this phenomena. Lattice parameter measurements were utilized for the first time to describe the reactions occurring at these temperatures and to determine the final composition of the AlON produced. It is anticipated that future investigations will rely on x-ray lattice parameter measurements to develop AlON ceramics with the required optical transparence.

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

    SciTech Connect

    Dr. Joseph A. Megy

    2000-09-22

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

  12. Process for strengthening aluminum based ceramics and material

    DOEpatents

    Moorhead, Arthur J.; Kim, Hyoun-Ee

    2000-01-01

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

  13. Processing of 2090 Aluminum Alloy for Superplasticity

    DTIC Science & Technology

    1988-06-01

    behavior has now been extensively documented in Al-Mg alloys, with elongations in excess of 1,000 percent obtained in many cases in these alloys. The...crucial. Characteristics of superplastic behavior include a fine grain size (two to five microns), a strain rate sensitivity coefficient m > 0.3, 1 I| and...seven to eight percent less and demonstrates ten percent higher stiffness than 7075 aluminum, an alloy it was designed to replace. This is due to the

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

    NASA Technical Reports Server (NTRS)

    Malina, R. F.; Cash, W.

    1978-01-01

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

  15. Coaxial Control of Aluminum and Steel Laser Brazing Processes

    NASA Astrophysics Data System (ADS)

    Frank, Sascha; Ungers, Michael; Rolser, Raphael

    Laser brazing has become firmly established as a joining process in the automotive industry. While this process offers many advantages, brazed seams also have to meet particularly high quality requirements. The challenge of creating a suitable online quality control system is magnified by the increasing use of aluminum in automotive engineering. This paper introduces recent works on the development of a system for controlling both aluminum and steel brazing processes. It also discusses some of the challenges connected to this task and discloses some of the results derived from the corresponding process analysis.

  16. A rotary arc furnace for aluminum dross processing

    SciTech Connect

    Drouet, M.G.; Meunier, J.; Laflamme, C.B.; Handfield, M.D.; Biscaro, A.; Lemire, C.

    1995-12-31

    Dross, a major by-product of all processes involving molten aluminum, forms at the surface of the molten metal as the latter reacts with the furnace atmosphere. It generally represents 1 to 5 wt% of the melt, depending on the process, and contains on average about 50% free aluminum dispersed in an oxide layer. Since aluminum production is highly energy-intensive, dross recycling is very attractive from both the energy and the economic standpoints. The conventional recycling process using salt rotary furnaces is thermally inefficient and environmentally non-acceptable because of the production of salt slags. Hydro-Quebec has developed and patented a new salt-free technology using a rotary furnace heated by an electric arc between two graphite electrodes, called DROSCAR{reg_sign}. A 600-kW pilot plant in operation at LTEE is in use to demonstrate the process. This process provides aluminum recovery rates over 90%, using a highly energy efficient, environmentally sound production method. In 1994, 400 tonnes of aluminum dross were treated in this facility and several tests on various types of dross have also been conducted in early 1995. A report on the results will be presented.

  17. A Preliminary Report on the Strength and Metallography of a Bimetallic Friction Stir Weld Joint Between AA6061 and MIL-DTL-46100E High Hardness Steel Armor

    DTIC Science & Technology

    2012-11-26

    plates of 6061-T6 aluminum alloy and High Hardness steel armor (MIL-STD-46100) were successfully joined by the friction stir welding ( FSW ) process using a...b 124 c FSW 194 d High Hardness Steel (HHS) base material 1034 e GMAW f tbd g AA6061/HHS FSW joint 176 8 a Kaiser Aluminum Certified Test...bimetallic friction stir weld joint between AA6061 and MIL-DTL-46100E High Hardness steel armor. ABSTRACT One half inch thick plates of 6061-T6 aluminum

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

    NASA Technical Reports Server (NTRS)

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

    1999-01-01

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

  19. The Aluminum Smelting Process and Innovative Alternative Technologies

    PubMed Central

    Drabløs, Per Arne

    2014-01-01

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

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

    ERIC Educational Resources Information Center

    Haupin, W. E.

    1983-01-01

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

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

    EPA Science Inventory

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

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

    DOEpatents

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

    1983-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    1983-01-01

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

  4. Pulsed ion beam surface treatment for preparing rapidly solidified corrosion resistant steel and aluminum surfaces

    SciTech Connect

    Buchheit, R.G.; Maestas, L.M.; McIntyre, D.C.; Stinnett, R.W.; Greenly, J.B.

    1995-03-01

    Intense, pulsed ion beams were used to melt and rapidly resolidify Types 316F, 316L and sensitized 304 stainless steel surfaces to eliminate the negative effects of microstructural heterogeneity on localized corrosion resistance. Anodic polarization curves determined for 316F and 316L showed that passive current densities were reduced and pitting potentials were increased due to ion beam treatment. Type 304 samples sensitized at 600 C for 100 h showed no evidence of grain boundary attack when surfaces were ion beam treated. Equivalent ion beam treatments were conducted with a 6061-T6 aluminum alloy. Electrochemical impedance experiments conducted with this alloy exposed to an aerated chloride solution showed that the onset of pitting was delayed compared to untreated control samples.

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

    DOEpatents

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

    1989-01-01

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

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

    DOEpatents

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

    1989-10-31

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

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

    NASA Technical Reports Server (NTRS)

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

    1978-01-01

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

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

    NASA Astrophysics Data System (ADS)

    Charit, Indrajit

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

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

    SciTech Connect

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

    2008-01-01

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

  10. Non-chromate talc conversion coatings for aluminum

    SciTech Connect

    Buchheit, R.G.; Drewien, C.A.; Finch, J.L.; Stoner, G.E.

    1994-01-01

    A method was developed for applying an inorganic conversion coating on that is procedurally similar to chromate conversion coating methods; this method, however does not use or involve hazardous/toxic chemicals. The coating forms by precipitation involving Al{sup 3+} Li{sup +}, OH{sup {minus}}, CO{sub 3}{sup 2}{minus}, and possibly other anions. This polycrystalline coating is continuous, conformal and persistent in aggressive environments. Coating thicknesses range from several tenths to ten micrometers. Although the outer portions of the coating are porous, the pores do not penetrate to the substrate interface. These coatings do not match the levels of performance offered by commercially available chromate conversion coatings, but are capable of meeting many of the corrosion resistance, electrical resistivity, and paint adhesion requirements established in MIL-C-5541E ``Chemical Conversion Coatings on Aluminum and Aluminum Alloys.`` In this paper, methods for producing the talc coating on aluminum alloys 1100 and 6061-T6 are described and compared to traditional chromate conversion coating methods. Resulting coating structure and composition are described. Performance data for the talc coatings in MIL-C-5541E required tests are presented along with data commercial chromate-based coatings.

  11. Aluminum base alloy powder metallurgy process and product

    NASA Technical Reports Server (NTRS)

    Paris, Henry G. (Inventor)

    1986-01-01

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

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

    SciTech Connect

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

    2007-04-23

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

  13. 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.

  14. Process of electrolysis and fractional crystallization for aluminum purification

    DOEpatents

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

    1983-10-25

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

  15. Process of electrolysis and fractional crystallization for aluminum purification

    DOEpatents

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

    1983-10-25

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

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

    DOEpatents

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

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

  17. Brazing process using'al-Si filler alloy reliably bonds aluminum parts

    NASA Technical Reports Server (NTRS)

    Beuyukian, C. S.; Johnson, W. R.

    1966-01-01

    Brazing process employs an aluminum-silicon filler alloy for diffusion bonding of aluminum parts in a vacuum or inert gas atmosphere. This process is carried out at temperatures substantially below those required in conventional process and produces bonds of greater strength and reliability.

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

    SciTech Connect

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

    1988-03-01

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

  19. Microstructural Effects of Multiple Passes during Friction Stir Processing of Nickel Aluminum Bronze

    DTIC Science & Technology

    2009-12-01

    various tool steel compositions for use with aluminum , and materials such as Densimet®, a tungsten-iron composite. Additionally, various other...TMAZ. 5 II. BACKGROUND INFORMATION A. FRICTION STIR PROCESSING To this date, FSP and FSW have been used most extensively on aluminum -based...EFFECTS OF MULTIPLE PASSES DURING FRICTION STIR PROCESSING OF NICKEL ALUMINUM BRONZE by Elizabeth A. Nelson December 2009 Thesis Advisor

  20. Interface Effects of the Properties and Processing of Graded Composite Aluminum Alloys

    DTIC Science & Technology

    2015-08-31

    Final Report: Interface effects of the properties and processing of graded composite aluminum alloys Report Title The objective of this STIR program...architecturally graded aluminum composite with a diffuse interface between alloys 5456 and 7055. The program supported the education and training of one graduate...2015 Approved for Public Release; Distribution Unlimited Final Report: Interface effects of the properties and processing of graded composite aluminum

  1. Processing and Characterization of Polycrystalline Yag (Yttrium Aluminum Garnet) Core-Clad Fibers - Postprint

    DTIC Science & Technology

    2015-01-01

    AFRL-RY-WP-TP-2014-0296 PROCESSING AND CHARACTERIZATION OF POLYCRYSTALLINE YAG ( YTTRIUM ALUMINUM GARNET) CORE-CLAD FIBERS -POSTPRINT...April 2013 – 1 April 2014 4. TITLE AND SUBTITLE PROCESSING AND CHARACTERIZATION OF POLYCRYSTALLINE YAG ( YTTRIUM ALUMINUM GARNET) CORE-CLAD FIBERS...of polycrystalline YAG ( Yttrium Aluminum Garnet) core-clad fibers Hyun Jun Kima,b, Geoff E. Faira*, Santeri A

  2. Effects of aluminum and zirconia contents on the reaction bonded aluminum oxide process

    NASA Astrophysics Data System (ADS)

    Sheedy, Paul Martin

    The effects of aluminum and ZrO2 contents on the reaction and sintering of reaction bonded aluminum oxide (RBAO) were investigated. It was apparent that ZrO2-containing RBAO powders with higher initial aluminum contents (>45 vol%) were increasingly more difficult to react and sinter. During oxidation in air, samples often underwent a self-propagating high-temperature synthesis (SHS) reaction which led to catastrophic failure. This reaction and cracking behavior was more pronounced with increasing aluminum and ZrO2 contents of the powders. Subsequently, it was shown that the SHS reaction was actually two combustion phenomena: a thermal explosion reaction on the surface of the sample between aluminum and oxygen, which (in ZrO2-containing samples) triggered a self propagating aluminothermic reduction of ZrO2, forming Al2O3 and Al 3Zr. Therefore, methods for controlling the rate of the initial oxidation reaction were effective since both SHS reactions were prevented. Despite the use of controlled firing, initial samples with increasing aluminum contents proved difficult to densify. It was found that in all RBAO samples (regardless of ZrO2 content), the reactively formed Al 2O3 underwent the gamma to alpha-Al2O 3 transformation, which resulted in the development of a vermicular microstructure. In ZrO2-containing RBAO samples, this transformation was inhibited and occurred concurrently with the start of densification. In addition, the start of bulk shrinkage in these samples was delayed and the densification rates were decreased in comparison to samples without ZrO 2. This ultimately resulted in a decrease in the limiting density to which ZrO2-containing RBAO samples could be sintered. Surprisingly, in samples without ZrO2, increasing the aluminum content did not appear to have any effects upon the densification behavior of RBAO. In examining RBAO samples with similar aluminum contents but increasing ZrO2 contents, it became apparent that the grain growth inhibiting

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

    SciTech Connect

    Kostrivas, A.; Lippold, J.C.

    2000-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    2005-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    2002-01-01

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

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

    NASA Technical Reports Server (NTRS)

    Okelly, K. P.

    1973-01-01

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

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

    SciTech Connect

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

    2015-02-20

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

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

    NASA Astrophysics Data System (ADS)

    Perez Regalado, Waldo Josue

    The real-time ultrasonic spot weld monitoring system, introduced by our research group, has been designed for the unsupervised quality characterization of the spot welding process. It comprises the ultrasonic transducer (probe) built into one of the welding electrodes and an electronics hardware unit which gathers information from the transducer, performs real-time weld quality characterization and communicates with the robot programmable logic controller (PLC). The system has been fully developed for the inspection of spot welds manufactured in steel alloys, and has been mainly applied in the automotive industry. In recent years, a variety of materials have been introduced to the automotive industry. These include high strength steels, magnesium alloys, and aluminum alloys. Aluminum alloys have been of particular interest due to their high strength-to-weight ratio. Resistance spot welding requirements for aluminum vary greatly from those of steel. Additionally, the oxide film formed on the aluminum surface increases the heat generation between the copper electrodes and the aluminum plates leading to accelerated electrode deterioration. Preliminary studies showed that the real-time quality inspection system was not able to monitor spot welds manufactured with aluminum. The extensive experimental research, finite element modelling of the aluminum welding process and finite difference modeling of the acoustic wave propagation through the aluminum spot welds presented in this dissertation, revealed that the thermodynamics and hence the acoustic wave propagation through an aluminum and a steel spot weld differ significantly. For this reason, the hardware requirements and the algorithms developed to determine the welds quality from the ultrasonic data used on steel, no longer apply on aluminum spot welds. After updating the system and designing the required algorithms, parameters such as liquid nugget penetration and nugget diameter were available in the ultrasonic data

  9. Severe plastic deformation processing and high strain rate superplasticity in an aluminum matrix composite

    SciTech Connect

    Mishra, R.S.; McFadden, S.X.; Mukherjee, A.K.; Valiev, R.Z.; Islamgaliev, R.K.

    1999-04-23

    Metal matrix composites possess an attractive set of properties for structural applications. For example, reinforcement of conventional aluminum alloys with second phase ceramic particulates increases the stiffness, high temperature strength, etc. A drawback of ceramic phase reinforcement is that it makes machining of components difficult. Superplastic forming is quite attractive for hard-to-machine materials like composites. A number of aluminum matrix composites exhibit superplasticity. The most attractive feature of superplasticity in aluminum matrix composite is the high strain rate (10{sup {minus}2}--10{sup 1} s{sup {minus}1}) for optimum ductility. This is significantly higher than the optimum superplastic strain rates of 10{sup {minus}4}--10{sup {minus}3} s{sup {minus}1} in conventional fine grained alloys. The optimum superplasticity in aluminum matrix composites is influenced by the thermo-mechanical processing. In the last five years or so, a number of aluminum alloys have been processes by severe plastic deformation (SePD). Severe plastic deformation processing leads to ultrafine grained aluminum alloys with attractive superplastic properties. In this short paper the authors report on successful processing of an ultrafine grained aluminum matrix composite by severe plastic deformation technique. The SePD processes 2009 Al-SiC{sub 2} composite exhibits high strain rate superplasticity.

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

    SciTech Connect

    Pinkerton, G.W.

    1993-12-31

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

  11. 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.

  12. Processing, microstructure evolution and properties of nanoscale aluminum alloys

    NASA Astrophysics Data System (ADS)

    Han, Jixiong

    In this project, phase transformations and precipitation behavior in age-hardenable nanoscale materials systems, using Al-Cu alloys as model materials, were first studied. The Al-Cu nanoparticles were synthesized by a Plasma Ablation process and found to contain a 2˜5 nm thick adherent aluminum oxide scale, which prevented further oxidation. On aging of the particles, a precipitation sequence consisting of, nearly pure Cu precipitates to the metastable theta' to equilibrium theta was observed, with all three forming along the oxide-particle interface. The structure of theta' and its interface with the Al matrix has been characterized in detail. Ultrafine Al-Cu nanoparticles (5˜25 nm) were also synthesized by inert gas condensation (IGC) and their aging behavior was studied. These particles were found to be quite stable against precipitation. Secondly, pure Al nanoparticles were prepared by the Exploding Wire process and their sintering and consolidation behavior were studied. It was found that nanopowders of Al could be processed to bulk structures with high hardness and density. Sintering temperature was found to have a dominant effect on density, hardness and microstructure. Sintering at temperatures >600°C led to breakup of the oxide scale, leading to an interesting nanocomposite composed of 100˜200 nm Al oxide dispersed in a bimodal nanometer-micrometer size Al matrix grains. Although there was some grain growth, the randomly dispersed oxide fragments were quite effective in pinning the Al grain boundaries, preventing excessive grain growth and retaining high hardness. Cold rolling and hot rolling were effective methods for attaining full densification and high hardness. Thirdly, the microstructure evolution and mechanical behavior of Al-Al 2O3 nanocomposites were studied. The composites can retain high strength at elevated temperature and thermal soaking has practically no detrimental effect on strength. Although the ductility of the composite remains

  13. The corrosion protection of aluminum by various anodizing treatments

    NASA Technical Reports Server (NTRS)

    Danford, Merlin D.

    1989-01-01

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

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

    DOEpatents

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

    1998-12-15

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

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

    NASA Astrophysics Data System (ADS)

    Tashiro, Shinichi; Tanaka, Manabu

    2014-08-01

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

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

    NASA Technical Reports Server (NTRS)

    Farley, G. L.

    1985-01-01

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

  17. Continuous Severe Plastic Deformation Processing of Aluminum Alloys

    SciTech Connect

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

    2006-06-30

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-08-01

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

  19. Manufacturing Methods for Process Effects on Aluminum Casting Allowables

    DTIC Science & Technology

    1985-03-01

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

  20. ALUREC -- A new salt-free process for recovery of aluminum from dross and aluminum containing materials

    SciTech Connect

    Gripenberg, H.; Graeb, H.; Flesch, G.; Muellerthann, M.

    1995-12-31

    To solve the environmental and financial problems of the traditional Rotary Salt Furnace process, a new salt-free method for aluminum dross and scrap melting, ALUREC, has been developed by AGA and its partners, Hoogovens Aluminium and MAN GHH. AGA and Hoogovens Aluminium developed the main process concept and jointly carried out trials on pilot plant scale. Owing to excellent results, the partners decided to jointly erect a commercial scale test plant. The order for the design and erection of the furnace went to MAN GHH. The three companies designed the test plant and began operation in the spring of 1994. The results have been excellent and the process is expected to be a technical and commercial success.

  1. The effects of aluminum alloy compositions in DIMOX process

    SciTech Connect

    Kim, Chang Wook; Kim, Cheol Soo

    1996-12-31

    Al{sub 2}O{sub 3}-Al composites have been produced by the directed oxidation of binary and ternary aluminum alloys. The Mg, Si, Zn, Sn, Cu, Ni, Ca and Ce have been investigated as alloying elements. The oxidation amount of Al-1wt%Mg alloy was more than that of Al-3wt%Mg alloy. The ternary systems such as Al-Mg-(Si, Sn) alloys were fabricated in the form of porous composites with large amount of oxidation. The amount of oxidation in Al-Mg-(Cu, Ni) was relatively less than that in Al-Mg-(Si, Sn) with some micro pores. Al{sub 2}O{sub 3}-Al composite is always locally growing in Al-xMg-xZn alloys at 1200{degrees}C.

  2. Redistribution Mechanisms and Quantification of Homogeneity in Friction Stir Welding and Processing of an Aluminum Silicon Alloy

    DTIC Science & Technology

    2012-09-01

    wide range of particle-containing materials. Materials such as Nickel Aluminum Bronze (NAB), high yield (HY) Steels , and AA5083 are common in many...REDISTRIBUTION MECHANISMS AND QUANTIFICATION OF HOMOGENEITY IN FRICTION STIR WELDING AND PROCESSING OF AN ALUMINUM SILICON ALLOY by Jeffrey C. Woertz...Homogeneity in Friction Stir Welding and Processing of an Aluminum Silicon Alloy 5. FUNDING NUMBERS 6. AUTHOR(S) Jeffrey C. Woertz 7

  3. Processing Studies of Aluminum-Magnesium and Aluminum-Copper-Lithium Alloys

    DTIC Science & Technology

    1990-03-01

    mechanisim of microstructural refinement during processing. Most recently, Gorsuch has investigated the effects of varying the annealing time between...obtained during testing at 300°C [Ref 3]. A portion of this research will follow that of Gorsuch by extending the annealing interval to 60 minutes in...on an Al.10Mg.0.lZr(wt.pct) alloy wherein Gorsuch varied the annealing times between rolling passes. As the annealing times are increased from 5

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

    NASA Astrophysics Data System (ADS)

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

    2013-09-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-11-01

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

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

    SciTech Connect

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

    2005-08-24

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

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

    NASA Astrophysics Data System (ADS)

    Kurk, Justin Irvin

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

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

    SciTech Connect

    Bibber, J.W.

    1999-07-01

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

  9. Hybrid manufacturing processes for fusion welding and friction stir welding of aerospace grade aluminum alloys

    NASA Astrophysics Data System (ADS)

    Gegesky, Megan Alexandra

    Friction stir welding and processing can provide for joints in aerospace grade aluminum alloys that have preferable material properties as compared to fusion welding techniques. Aerospace grade aluminum alloys such as AA2024-T3 and AA7075-T6 are considered non-weldable by traditional fusion welding techniques. Improved mechanical properties over previously used techniques are usually preferable for aerospace applications. Therefore, by combining traditional fusion welding and friction stir processing techniques, it could be plausible to create more difficult geometries in manufactured parts instead of using traditional techniques. While this combination of fusion welding and friction stir processing is not a new technology, its introduction to aerospace grade aluminum alloys as well as non-weldable alloys, is new. This is brought about by a lowered required clamping force required by adding a fusion weld before a friction stir processing technique. The changes in properties associated with joining techniques include: microstructural changes, changes in hardness, tensile strength, and corrosion resistance. This thesis illustrates these changes for the non-weldable AA2024-T351 and AA7075-T651 as well as the weldable alloy AA5052-H32. The microhardness, tensile strength and corrosion resistance of the four processing states: base material, fusion welded material, friction stir welded material, and friction stir processed fusion welded material is studied. The plausibility of this hybrid process for the three different materials is characterized, as well as plausible applications for this joining technique.

  10. Tensile strength on friction stir processed AMg5 (5083) aluminum alloy

    NASA Astrophysics Data System (ADS)

    Chumaevsky, A. V.; Eliseev, A. A.; Filippov, A. V.; Rubtsov, V. E.; Tarasov, S. Yu.

    2016-11-01

    The results of the tensile tests carried out both on AMg5 (5083) aluminum alloy samples base and those obtained using friction stir processing technique are reported. The tensile test samples have been prepared from the friction stir processed plates so that their tensile axis was parallel to the processing direction. The maximum tensile strength of the processed samples was 9% higher than of the base metal. The fractographic examination shows the presence of flat areas inherent of the brittle fracture in all three friction processed samples. The load-extension curves show that friction stir processing may suppress the serrated yielding.

  11. Development and Processing Improvement of Aerospace Aluminum Alloys

    NASA Technical Reports Server (NTRS)

    Lisagor, W. Barry; Bales, Thomas T.

    2007-01-01

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

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

    SciTech Connect

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

    1996-06-01

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

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

    NASA Technical Reports Server (NTRS)

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

    1980-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    2007-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    1995-01-01

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

  16. Processing and properties of low-aluminum alloy FAPY

    SciTech Connect

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

    1996-07-01

    This paper deals with the melting, processing, properties, and microstructure of three commercially melted heats of Fe-16 at. % Al alloy FAPY. All of the heats were air-induction melted (AIM), two at Hoskins Manufacturing Company (Hamburg, Michigan) and one at United Defense (Anniston, Alabama). One ingot from each of the heats was used for testing at the Oak Ridge National Laboratory. A 127-mm.-long section from each ingot was used for determining properties and microstructure in the as-cast, cast and hot-processed, and cold-rolled conditions. The fine-grained sheet showed 20% elongation at room temperature.

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

    NASA Astrophysics Data System (ADS)

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

    2016-08-01

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

  18. Fusion boundary microstructure evolution in aluminum alloys

    NASA Astrophysics Data System (ADS)

    Kostrivas, Anastasios Dimitrios

    2000-10-01

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

  19. Metallurgical Evaluations of Depainting Processes on Aluminum Substrate

    NASA Technical Reports Server (NTRS)

    McGill, Preston

    1999-01-01

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

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

    SciTech Connect

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

    1999-01-06

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

  1. The Effect of Alloy Additions on Superplasticity in Thermomechanically Processed High Magnesium Aluminum-Magnesium Alloys.

    DTIC Science & Technology

    1984-12-01

    AD-Ri55 142 THE EFFECT OF ALLOY ADDITIONS ON SUPERPLASTICITY IN I/2 THERMOMECHANICALLY PR-.(U) NAVAL POSTGRADUATE SCHOOL UNCLSSIIED MONTEREY CA R J...Ln Monterey, California DTr J U N 1985 * THESIS THE EFFECT OF ALLOY ADDITIONS ON SUPERPLASTICITY IN THERMOMECHANICALLY PROCESSED HIGH MAGNESIUM *0...ALUMINUM-MAGNESIUM ALLOYS >by 0 (Richard J. Self December 1984 C-31 Thesis Advisor: Terry McNelley Approved for public release; distribution is unlimited

  2. Influence of surface micro grooving pretreatment on MAO process of aluminum alloy

    NASA Astrophysics Data System (ADS)

    Huang, Hongjian; Wei, Xiaowei; Yang, Junxia; Wang, Jian

    2016-12-01

    A pretreatment of micro grooving was applied before the MAO process on the surface of aluminum. The influence of micro grooves on oxide ceramic coating was characterized by XRD, SEM, EDS and micro-hardness tester. The experiment shows that the micro groove could significantly increase the partial growth rate (from 0.66 to 1.0 μm min-1) and hardness of oxide ceramic coating; the parameter of current and process time have a big influence on coating thickness and smoothness; the micro groove can be completely filled with the products of ejection under the appropriate process parameter and continuous smooth with the coating out of the grooves.

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

    NASA Astrophysics Data System (ADS)

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

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

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

    SciTech Connect

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

    2009-01-14

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

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

    SciTech Connect

    Collins, Jack Lee; Pye, S. L.

    2009-02-01

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

  6. Process for recycling waste aluminum with generation of high-pressure hydrogen.

    PubMed

    Hiraki, Takehito; Yamauchi, Satoru; Iida, Masayasu; Uesugi, Hiroshi; Akiyama, Tomohiro

    2007-06-15

    An innovative environmently friendly hydrolysis process for recycling waste aluminum with the generation of high-pressure hydrogen has been proposed and experimentally validated. The effect of the concentration of sodium hydroxide solution on hydrogen generation rate was the main focus of the study. In the experiments, distilled water and aluminum powder were placed in the pressure-resistance reactor made of Hastelloy, and was compressed to a desired constant water pressure using a liquid pump. The sodium hydroxide solution was supplied by liquid pump with different concentrations (from 1.0 to 5.0 mol/dm3) at a constant flow rate into the reactor by replacing the distilled water, and the rate of hydrogen generated was measured simultaneously. The liquid temperature in the reactor increased due to the exothermic reaction given by Al + OH(-) + 3H2O = 1.5H2 + Al(OH)4(-) + 415.6 kJ. Therefore, a high-pressure hydrogen was generated at room temperature by mixing waste aluminum and sodium hydroxide solution. As the hydrogen compressor used in this process consumes less energy than the conventional one, the generation of hydrogen having a pressure of almost 30 MPa was experimentally validated together with Al(OH)3, a useful byproduct.

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

    PubMed Central

    Eslami, P.; Taheri, A. Karimi

    2011-01-01

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

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

    SciTech Connect

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

    2002-12-24

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

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

    DOEpatents

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

    2002-12-24

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

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

    NASA Technical Reports Server (NTRS)

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

    1973-01-01

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

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

    SciTech Connect

    Vigil, M.G.

    1997-05-01

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

  12. Extraction and characterization of alumina nanopowders from aluminum dross by acid dissolution process

    NASA Astrophysics Data System (ADS)

    Sarker, Md. Saifur Rahman; Alam, Md. Zahangir; Qadir, Md. Rakibul; Gafur, M. A.; Moniruzzaman, Mohammad

    2015-04-01

    A significant amount of aluminum dross is available as a waste in foundry industries in Bangladesh. In this study, alumina was extracted from aluminum dross collected from two foundry industries situated in Dhamrai and Manikgang, near the capital city, Dhaka. Aluminum dross samples were found to approximately contain 75wt% Al2O3 and 12wt% SiO2. An acid dissolution process was used to recover the alumina value from the dross. The effects of various parameters, e.g., temperature, acid concentration, and leaching time, on the extraction of alumina were studied to optimize the dissolution process. First, Al(OH)3 was produced in the form of a gel. Calcination of the Al(OH)3 gel at 1000°C, 1200°C, and 1400°C for 2 h produced γ-Al2O3, (α+γ)-Al2O3, and α-alumina powder, respectively. Thermal characterization of the Al(OH)3 gel was performed by thermogravimetric/differential thermal analysis (TG/DTA) and differential scanning calorimetry (DSC). The phases and crystallite size of the alumina were determined by X-ray diffraction analysis. The dimensions of the alumina were found to be on the nano level. The chemical compositions of the aluminum dross and alumina were determined by X-ray fluorescence (XRF) spectroscopy. The microstructure and morphology of the alumina were studied with scanning electron microscopy. The purity of the alumina extracted in this study was found to be 99.0%. Thus, it is expected that the obtained alumina powders can be potentially utilized as biomaterials.

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

    SciTech Connect

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

    2009-01-01

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

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

    NASA Technical Reports Server (NTRS)

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

    2014-01-01

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

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

    SciTech Connect

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

    2001-06-12

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

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

    SciTech Connect

    Babaei, A. Mashhadi, M.M.

    2014-09-15

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

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

    NASA Astrophysics Data System (ADS)

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

    2010-06-01

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

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

    SciTech Connect

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

    2010-06-15

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

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

    DOEpatents

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

    1998-01-01

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

  20. Response Surface Method for the Rapid Design of Process Parameters in Tube Hydroforming

    SciTech Connect

    Chebbah, M. S.; Hecini, M.; Naceur, H.; Belouettar, S.

    2007-05-17

    This paper deals with the optimization of tube hydroforming parameters in order reduce defects which may occur at the end of forming process such as necking and wrinkling. We propose a specific methodology based on the coupling between an inverse method for the rapid simulation of tube hydroforming process, and a Response Surface Method based on diffuse approximation. The response surfaces are built using Moving Least Squares approximations and constructed within a moving region of interest which moves across a predefined discrete grid of authorized experimental designs. An application of hydroforming of a bulge from aluminium alloy 6061-T6 tubing has been utilized to validate our methodology. The final design is validated with ABAQUS Explicit Dynamic commercial code.

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

    NASA Technical Reports Server (NTRS)

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

    1983-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

  3. Process for the recovery of aluminum from dross without use of salt flux

    SciTech Connect

    Geus, E.H.; Lussi, V.; Spoel, H.

    1995-12-31

    A process has been developed to recover aluminum from dross which does not require the use of salt flux as commonly employed. This results in a salt-free residue which has potential industrial uses or alternatively can be safely land-filled. The dross is first heated by an air-fuel or oxy-fuel burner in a sealable rotary furnace. At a suitable temperature the burner is turned off and the temperature of the dross thereafter controlled by means of an atmosphere of oxidative and inert gases. When the free metal has agglomerated it is first discharged from the furnace, followed by the residues.

  4. A Novel Processing Approach for Additive Manufacturing of Commercial Aluminum Alloys

    NASA Astrophysics Data System (ADS)

    Roberts, Christopher E.; Bourell, David; Watt, Trevor; Cohen, Julien

    Aluminum 6061 is of great commercial interest due to its ubiquitous use in manufacturing, advantageous mechanical properties, and its successful certification in aerospace applications. However, as an off-eutectic with accompanying large freezing range, attempts to process the material by additive manufacturing have resulted in part cracking and diminished mechanical properties. A unique approach using mixed powders is presented to process this historically difficult-to-process material. Expansion of this combined-powder approach to other materials systems not typically compatible with additive manufacturing is possible. Dense parts without solidification cracking have been produced by the SLM process, as verified using SEM and EDS. An overview of this approach is presented along with test results using an Al-Si mixture.

  5. Influence of Process Parameters on Laser Weld Characteristics in Aluminum Alloys

    DTIC Science & Technology

    1988-08-01

    1 1󈧚 , 4 4 2.1.2 Alloying Element Vaporization Alloying elements added to aluminum for improving the mechanical properties and corrosion...effects the properties of the base metal surrounding the weld zone called the heat affected zone (HAZ). In the non-heat treatable aluminum alloys in the...Hydrogen in Aluminum . Magnesium, Copper, and Their Alloys . Int. Metall. Reviews, Review 201, 20:166-184. 31. Hatch, J.E. 1984. Aluminum , Properties and

  6. Design and Processing of Bimetallic Aluminum Alloys by Sequential Casting Technique

    NASA Astrophysics Data System (ADS)

    Karun, Akhil S.; Hari, S.; Ebhota, Williams S.; Rajan, T. P. D.; Pillai, U. T. S.; Pai, B. C.

    2017-01-01

    Sequential casting is a facile and fairly new technique to produce functionally graded materials (FGMs) and components by controlled mold filling process. In the present investigation, functionally graded bimetallic aluminum alloys are produced by sequential gravity casting using A390-A319 and A390-A6061 alloy combinations. The control in pouring time between two melts has shown a significant effect on the quality and nature of interface bonding. The microstructure reveals good interface miscibility achieved through diffusion bonding between the alloys. A higher hardness of 160 BHN in the A390 region is obtained in both sequential cast systems, and a minimum value of 105 and 91 BHN is observed in the A319 and A6061 regions, respectively. The tensile and compression strength for A390-A319 are 337 and 490 MPa, whereas for A390-A6061, they are 364 and 401 MPa, respectively, which are significantly higher compared with the standard values of the base alloys, which confirms strong interface bonding. The A390 region shows higher wear resistance compared with other regions of the sequential cast system. The process described in this study is a potential and efficient approach to create good bonding between two different aluminum alloys to develop advanced functional and structural materials.

  7. Numerical Simulation of the Roll Forming Process of Aluminum Folded Micro-channel Tube

    NASA Astrophysics Data System (ADS)

    Zou, Tianxia; Zhou, Ning; Peng, Yinghong; Tang, Ding; Li, Dayong

    2016-08-01

    Micro-channel tube is the most important component of flat tube heat exchangers. The folded microchannel tube is made of clad aluminum sheet through roll forming process, and has great advantage in the aspect of corrosion resistance over extruded tube. The folded tube's sub-millimeter channel size as well as tight dimensional precision requirement brings great challenge to roll forming process design. In this paper, the finite element model of the whole roll forming process of a ten-channel tube is established by using ABAQUS/Explicit. The deformation at different forming stands are investigated and compared with experiment. The hydraulic pressure test is carried out on the developed tube and its pressure bearing capacity is evaluated.

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

    SciTech Connect

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

    2005-05-01

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

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

    SciTech Connect

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

    2009-01-01

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

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

    NASA Astrophysics Data System (ADS)

    Chiu, Po-Hsun

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

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

    NASA Astrophysics Data System (ADS)

    Keist, Jay

    2005-04-01

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

  12. Study of polycrystalline silicon obtained by aluminum-induced crystallization depending on process conditions

    NASA Astrophysics Data System (ADS)

    Pereyaslavtsev, Alexander; Sokolov, Igor; Sinev, Leonid

    2016-11-01

    In this paper, we have decided to consider an alternative method of producing polycrystalline silicon and study change of its electrophysical characteristics depending on process parameters. As an alternative low-pressure chemical vapor deposition method appears aluminum-induced crystallization (AIC), which allows to obtain a polycrystalline silicon film is significantly larger grain size, thereby reducing contribution of grain boundaries. A comprehensive study of polycrystalline silicon was carried out using a variety of microscopic (OM, SEM) and spectroscopic (RAMAN, XPS) and diffraction (EBSD, XRD) analytic methods. We also considered possibility of self-doping in AIC, result of which was obtained polycrystalline silicon with different resistance. Additionally considered changes in temperature coefficient of resistance depending on technological parameters of AIC process.

  13. Effect of magnesium and silicon on the DIMOX processing of aluminum alloys

    SciTech Connect

    Yang, L.; Zhu, D.; Zhang, J.; Xu, C.Q.; Zhang, J.

    1995-08-01

    This paper deals with the reaction mechanisms of the DIMOX processing of aluminum alloys. Emphasis is placed on the distribution of Mg and Si in the products so that the behaviors of these two crucial elements for the oxidation aluminum could be revealed. Alterative methods, including optical and SEM microscopy, electron-probing and wave spectrum analysis were applied to specify the microstructure characters of the products and locate the position of both Mg and Si in the reaction products. It is shown that the products can be divided into four regions from where directly connected to the residual bulky metals to the surface area distinguished by microstructure. Both Mg and Si are rather concentrated in specific regions than homogeneously distributed in the whole products. The contents of Mg and Si in the surface region are not as high as expected with most of the Mg being concentrated in the region directly neighboring to the bulky metals and most of the Si in the residual bulky metals, although the contents of these two elements in the surface region are a little higher than the regions next to the surface. These characters, combined with other investigations, lead to the suggestion that circulated reactions could be a possible mechanism to explain the decisive role of the slight amount of Mg and Si in the nucleation and growth of Al{sub 2}O{sub 3}.

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

    PubMed Central

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

    2008-01-01

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

  15. Aluminum-Cycle Ion Exchange Process for Hardness Removal: A New Approach for Sustainable Softening.

    PubMed

    Li, Jinze; Koner, Suman; German, Michael; SenGupta, Arup K

    2016-11-01

    From a sustainability viewpoint, sodium exchange softening, although used widely, is under scrutiny due to its production of excess Na-laden spent regenerant and subsequent discharge to the environment. Many arid regions are introducing regulations disallowing dumping of concentrated sodium salts, the residuals from popular Na-exchange softening. The sodium content of the softened water is, also, always higher than in the feed, which poses a dietary health concern when used for drinking or cooking. An efficient, easy-to-operate hardness removal process with reduced sodium in both the treated water and in the spent regenerant is an unmet global need. Use of a cation exchange resin in Al(3+)-form for hardness removal, that is, exchange of divalent Ca(2+) or Mg(2+) with trivalent Al(3+), is counterintuitive, and this is particularly so, because the aluminum ion to be exchanged has higher affinity than calcium. Nevertheless, ion exchange accompanied by precipitation of aluminum hydroxide allows progress of the cation exchange reaction leading to hardness removal. Experimental results demonstrated that calcium can be consistently removed for multiple cycles using a stoichiometric amount of AlCl3 as the regenerant. The process essentially operates at the maximum possible thermodynamic efficiency: removal of one equivalent of Ca(2+) corresponds to use of one equivalent of Al(3+) as a regenerant. During the Al-cycle process there is no increase in Na(+) concentration and partial reduction in the total dissolved solids (TDS) of the treated water. It is noteworthy that the ion-exchange resin used, components of the fixed-bed column and operational protocol are nearly the same as traditional softening processes on Na-cycle. Thus, existing Na-cycle systems can be retrofitted into Al-cycle operation without major difficulty.

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

    SciTech Connect

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

    2015-01-22

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

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

    NASA Technical Reports Server (NTRS)

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

    2014-01-01

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

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

    SciTech Connect

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

    2005-02-01

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

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

    SciTech Connect

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

    2013-08-15

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

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

    NASA Technical Reports Server (NTRS)

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

    1983-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-10-01

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

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

    SciTech Connect

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

    1994-12-31

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

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

    PubMed

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

    2015-12-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2011-08-01

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

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

    SciTech Connect

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

    2011-01-15

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

  6. Carbothermic Aluminum Production Using Scrap Aluminum As A Coolant

    DOEpatents

    LaCamera, Alfred F.

    2002-11-05

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

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

    NASA Astrophysics Data System (ADS)

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

    2015-08-01

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

  8. 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

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

    NASA Technical Reports Server (NTRS)

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

    2003-01-01

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

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

    SciTech Connect

    Thomas D. Briselden

    2007-10-31

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

  11. Mechanical and Microstructural Effects of Cold Spray Aluminum on Al 7075 Using Kinetic Metallization and Cold Spray Processes (Preprint)

    DTIC Science & Technology

    2007-01-01

    Prior to spraying the coatings, the Al7075 sheets substrates were grit blasted (TRINCO Dry Blast) using 16 to 20 grit aluminum oxide powder (TRINCO...the as-processed state. The effect of this age treatment alters the temper of the 5 Al7075 substrate from T6 to an overage T76 condition. Select

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

    NASA Astrophysics Data System (ADS)

    Li, Mingxin; Jin, Guangyong; Guo, Ming; Wang, Di; Gu, Xiuying

    2014-12-01

    In this paper, we establish a physical model to simulate the melt ejection induced by millisecond pulsed laser on aluminum alloy and use the finite element method to simulate the melting and vaporization process of aluminum alloy. Compared with the conventional model, this model explicitly adds the source terms of gas dynamics in the thermal-hydrodynamic equations, completes the trace of the gas-liquid interface and improves the traditional level-set method. All possible effects which can impact the dynamic behavior of the keyhole are taken into account in this two-dimensional model, containing gravity, recoil pressure of the metallic vapor, surface tension and Marangoni effect. This simulation is based on the same experiment condition where single pulsed laser with 3ms pulse width, 57J energy and 1mm spot radius is used. By comparing the theoretical simulation data and the actual test data, we discover that: the relative error between the theoretical values and the actual values is about 9.8%, the melt ejection model is well consistent with the actual experiment; from the theoretical model we can see the surrounding air of the aluminum alloy surface exist the metallic vapor; an increment of the interaction time between millisecond pulsed laser and aluminum alloy material, the temperature at the center of aluminum alloy surface increases and evaporation happens after the surface temperature reaches boiling point and later the aluminum alloy material sustains in the status of equilibrium vaporization; the keyhole depth is linearly increased with the increase of laser energy, respectively; the growth of the keyhole radius is in the trend to be gentle. This research may provide the theoretical references to the understanding of the interaction between millisecond pulsed laser and many kinds of materials, as well as be beneficial to the application of the laser materials processing and military field.

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

    NASA Astrophysics Data System (ADS)

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

    2016-09-01

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

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

    NASA Astrophysics Data System (ADS)

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

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

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

    NASA Astrophysics Data System (ADS)

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

    1998-02-01

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

  16. Aluminum phosphide

    Integrated Risk Information System (IRIS)

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

  17. Processing, structure, property and performance relationships for the thermal spray of the internal surface of aluminum cylinders

    NASA Astrophysics Data System (ADS)

    Cook, David James

    The increased need for automotive weight reduction has necessitated the use of aluminum for engine blocks. Conventional aluminum alloys cannot survive the constant wear from a piston ring reciprocating on the surface. However, a wear resistant thermal spray coating can be applied on the internal surface of the cylinder bore, which has significant advantages over other available options. Thermal spray is a well-established process for depositing molten, semi-molten, or solid particles onto a substrate to form a protective coating. For this application, the two main challenges were obtaining good wear resistance, and achieving good adhesion. To design a system capable of producing a well-adhered, wear resistant coating for this high volume application it is necessary to identify the overall processing, structure, properties, and performance relationships. The results will demonstrate that very important relationships exist among particle characteristics, substrate conditions, and the properties of the final coating. However, it is the scientific studies to understand some of the process physics in these relationships that allow recognition of the critical processing conditions that need to be controlled to ensure a consistent, reliable thermal spray coating. In this investigation, it will be shown that the critical microstructural aspect of the coating that produced the required tribological properties was the presence of wuestite (FeO). It was found that by using a low carbon steel material with compressed air atomizing gas, it was possible to create an Fe/FeO structure that exhibited excellent tribological properties. This study will also show that traditional thermal spray surface preparation techniques were not ideal for this application, therefore a novel alternative approach was developed. The application of a flux to the aluminum surface prior to thermal spray promotes excellent bond strengths to non-roughened aluminum. Analysis will show that this flux strips

  18. Chloride removal from recycled cooling water using ultra-high lime with aluminum process.

    PubMed

    Abdel-Wahab, Ahmed; Batchelor, Bill

    2002-01-01

    Chloride is a deleterious ionic species in cooling water systems because it promotes corrosion, and most of the scale and corrosion inhibitors are sensitive to chloride concentration in the water. Chloride can be removed from cooling water by precipitation as calcium chloroaluminate [Ca4Al2Cl2(OH)12]. A set of equilibrium experiments and one kinetic experiment were conducted to evaluate chloride removal using the ultra-high lime with aluminum (UHLA) process and to characterize the equilibrium conditions of calcium chloroaluminate precipitation. A total of 48 batch-equilibrium experiments were conducted on a 30 mM NaCl solution over a range of values for lime dose (0 to 200 mM) and sodium aluminate dose (0 to 100 mM). Experimental results showed that the UHLA process can remove chloride and that the formation of a calcium chloroaluminate solid phase is a reasonable mechanism that is able to adequately describe experimental results. An average value of the ion activity product of 10(-94.75) was obtained and can be used as an estimate of the solubility product for Ca4Al2Cl2(OH)12.

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

    NASA Astrophysics Data System (ADS)

    Balle, Frank; Magin, Jens

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

  20. Solid waste from aluminum recycling process: characterization and reuse of its economically valuable constituents.

    PubMed

    Shinzato, M C; Hypolito, R

    2005-01-01

    Due to economic advantages, many companies in Brazil recover Al from the process of crushing and water-leaching of secondary aluminum dross. Wastes from this process (non-metallic products and salts) are usually landfilled or disposed without treatment, causing many environmental damages. The purpose of this work is to investigate, in a recycling company sited in Sao Paulo metropolitan area (Brazil), the potential use of the non-metallic product (NMP) in the production of concrete blocks and to evaluate the presence of important chemical compounds that may be useful for other applications. Chemical and mineralogical analyses revealed that NMP is composed of refractory and abrasive oxides (alpha-Al2O3, MgAl2O4, SiO2) and an important source of transition alumina: alpha-Al(OH)3. Concrete blocks were made by adding two parts of NMP to one part of cement and four parts of sand. The blocks were tested according to the Brazilian standard (NBR7173/1982) and they passed dimension, humidity and absorption tests but not compressive strength tests. However, particular NMP constituents have accelerated the strength rate development of the blocks, thus decreasing working time. The commercial use of NMP can reduce the amount of discarded wastes contributing to environmental preservation.

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

    NASA Technical Reports Server (NTRS)

    Ring, L. R.

    1990-01-01

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

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

    SciTech Connect

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

    1981-03-03

    A method for recovering aluminum values from fly ash comprises sintering the fly ash with a mixture of NaCl and Na2CO3 to a temperature in the range 700*-900* C for a period of time sufficient to convert greater than 90% of the aluminum content of the fly ash into an acid-soluble fraction and then contacting the thus-treated fraction with an aqueous solution of nitric or sulfuric acid to effect dissolution of aluminum and other metal values in said solution.

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

    DOEpatents

    McDowell, William J.; Seeley, Forest G.

    1981-01-01

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

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

    DOEpatents

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

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

  5. Effect of Particles Content on Microstructure, Mechanical Properties, and Electrochemical Behavior of Aluminum-Based Hybrid Composite Processed by Accumulative Roll Bonding Process

    NASA Astrophysics Data System (ADS)

    Fattah-Alhosseini, Arash; Naseri, Majid; Alemi, Mohamad Hesam

    2017-03-01

    Effect of B4C/SiC particles content on the microstructure, deformation, and electrochemical behavior of aluminum-based hybrid composite processed by accumulative roll bonding (ARB) was investigated. The ARB process was used to fabricate hybrid composites which consist of 1 and 2.5 wt pct of B4C/SiC mixed particles as reinforcement. The microstructure of the fabricated hybrid composites after the ninth cycle of the ARB process exhibited an excellent distribution of B4C/SiC particles in the aluminum matrix where no porosity was observed. In addition, with increasing the particle content in the aluminum matrix, the hybrid composites demonstrated higher tensile strength and lower elongation. The ARB-processed hybrid composites exhibited 3.12 and 3.37 times higher hardness for samples having 1 and 2.5 wt pct B4C/SiC, respectively, than that of the annealed aluminum. Electrochemical impedance spectroscopy and potentiodynamic polarization curves revealed that the corrosion resistance dropped drastically by increasing the number of ARB cycles from 3 to 5. However, by further ARB processing, the corrosion resistance gradually increased, and finally, after 9 cycles reached to the values higher than those of 3-cycle ARB-processed samples.

  6. Effect of Particles Content on Microstructure, Mechanical Properties, and Electrochemical Behavior of Aluminum-Based Hybrid Composite Processed by Accumulative Roll Bonding Process

    NASA Astrophysics Data System (ADS)

    Fattah-Alhosseini, Arash; Naseri, Majid; Alemi, Mohamad Hesam

    2017-01-01

    Effect of B4C/SiC particles content on the microstructure, deformation, and electrochemical behavior of aluminum-based hybrid composite processed by accumulative roll bonding (ARB) was investigated. The ARB process was used to fabricate hybrid composites which consist of 1 and 2.5 wt pct of B4C/SiC mixed particles as reinforcement. The microstructure of the fabricated hybrid composites after the ninth cycle of the ARB process exhibited an excellent distribution of B4C/SiC particles in the aluminum matrix where no porosity was observed. In addition, with increasing the particle content in the aluminum matrix, the hybrid composites demonstrated higher tensile strength and lower elongation. The ARB-processed hybrid composites exhibited 3.12 and 3.37 times higher hardness for samples having 1 and 2.5 wt pct B4C/SiC, respectively, than that of the annealed aluminum. Electrochemical impedance spectroscopy and potentiodynamic polarization curves revealed that the corrosion resistance dropped drastically by increasing the number of ARB cycles from 3 to 5. However, by further ARB processing, the corrosion resistance gradually increased, and finally, after 9 cycles reached to the values higher than those of 3-cycle ARB-processed samples.

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

    NASA Astrophysics Data System (ADS)

    Alleyne, Fatima Sierre

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

  8. Purifying Aluminum by Vacuum Distillation

    NASA Technical Reports Server (NTRS)

    Du Fresne, E. R.

    1985-01-01

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

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

    SciTech Connect

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

    2007-05-17

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

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

    NASA Astrophysics Data System (ADS)

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

    2007-05-01

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

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

    NASA Technical Reports Server (NTRS)

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

    2008-01-01

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

  12. Stability of Indium Gallium Zinc Aluminum Oxide Thin-Film Transistors with Treatment Processes

    NASA Astrophysics Data System (ADS)

    Lin, Yung-Hao; Lee, Ching-Ting

    2017-02-01

    The indium-gallium-zinc-aluminum-oxide (IGZAO) channel layer of the bottom-gate-type thin-film transistors (TFTs) was deposited on indium tin oxide-coated glass substrates using a magnetron radio frequency co-sputtering system with dual targets of indium gallium zinc oxide and Al. The 3 s orbital of Al cations provided an extra transport pathway and widened the bottom of the conduction band, thus increasing the electron mobility in the IGZAO films. The Al-O bonds could sustain the stability of oxygen of the IGZAO films. The IGZAO TFTs were processed by O2 plasma and post-annealing treatments. Hysteresis analysis was carried out in order to study the stability of the resulting IGZAO TFTs, the positive bias temperature stress (PBTS) performance, and the hot carrier effect were also measured. For the IGZAO TFTs, the threshold voltage shift of the PBTS performance and the hot carrier effect were 0.1 V and 0.06 V, respectively. Overall, the IGZAO TFTs exhibited good stability in this study.

  13. Control of the anodic aluminum oxide barrier layer opening process by wet chemical etching.

    PubMed

    Han, Catherine Y; Willing, Gerold A; Xiao, Zhili; Wang, H Hau

    2007-01-30

    In this work, it has been shown that, through a highly controlled process, the chemical etching of the anodic aluminum oxide membrane barrier layer can be performed in such a way as to achieve nanometer-scale control of the pore opening. As the barrier layer is etched away, subtle differences revealed through AFM phase imaging in the alumina composition in the barrier layer give rise to a unique pattern of hexagonal walls surrounding each of the barrier layer domes. These nanostructures observed in both topography and phase images can be understood as differences in the oxalate anion contaminated alumina versus pure alumina. This information bears significant implication for catalysis, template synthesis, and chemical sensing applications. From the pore opening etching studies, the etching rate of the barrier layer (1.3 nm/min) is higher than that of the inner cell wall (0.93 nm/min), both of which are higher than the etching rate of pure alumina layer (0.5-0.17 nm/min). The established etching rates together with the etching temperature allow one to control the pore diameter systematically from 10 to 95 nm.

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

    NASA Astrophysics Data System (ADS)

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

    2016-06-01

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

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

    SciTech Connect

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

    2014-12-01

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

  16. Aluminum reference electrode

    DOEpatents

    Sadoway, D.R.

    1988-08-16

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

  17. Aluminum reference electrode

    DOEpatents

    Sadoway, Donald R.

    1988-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-03-01

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

  19. Recovery of aluminum oxide by the Ames lime-soda sinter process: scale-up using a rotary kiln

    SciTech Connect

    Murtha, M.J.; Burnet, G.; Harnby, N.

    1985-01-01

    The Ames Lime-Soda Sinter Process provides a means for recovering aluminum oxide from power plant fly ash while producing a residue that can be used in the manufacture of sulfate resistant (Type V) portland cement. The process has been fully researched and its feasibility is now being demonstrated through pilot plant scale investigation. This paper reports results of the pelletized feed preparation by agglomeration in a rotary pan granulator, continuous feed sintering in an electrically heated rotary kiln, and product recovery from the clinker by aqueous extraction, desilication of the filtrate, and precipitation of a hydrated aluminum oxide. Results from earlier bench-scale research have been found to apply consistently to the pilot plant scale work.

  20. Corrosion of aluminum and aluminum alloys

    SciTech Connect

    Davis, J.R.

    1999-01-01

    This new handbook presents comprehensive coverage of the corrosion behavior of aluminum and aluminum alloys, with emphasis on practical information about how to select and process these materials in order to prevent corrosion attack. Described are the characteristics of these materials and the influences of composition, mechanical working, heat treatment, joining methods, microstructure, and environmental variables on their corrosion.

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

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

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

    SciTech Connect

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

    1998-01-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-10-01

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

  4. Structural Evaluation and Mechanical Properties of Aluminum/Tungsten Carbide Composites Fabricated by Continual Annealing and Press Bonding (CAPB) Process

    NASA Astrophysics Data System (ADS)

    Amirkhanlou, Sajjad; Ketabchi, Mostafa; Parvin, Nader; Drummen, G. P. C.

    2014-12-01

    In the present work, a novel technique is introduced called continual annealing and press bonding (CAPB) for the manufacturing of a bulk aluminum matrix composite dispersed with 10 vol pct tungsten carbide particles (Al/WCp composite). The microstructural evolution and mechanical properties of the Al/WCp composite during various CAPB cycles were examined by scanning electron microscopy (SEM), wavelength dispersive X-ray spectroscopy (WDX), and tensile testing. The microstructure of the fabricated composite after fourteen cycles of CAPB showed homogenous distribution of the WC particles in the aluminum matrix and strong bonding between the various layers. According to WDX analysis, the manufactured Al/WCp composite did not evidence the presence of additional elements. The results indicated that the tensile strength of the composites increased with the number of CAPB cycles, and reached a maximum value of 140 MPa at the end of the fourteenth cycle, which was 1.6 times higher than the obtained value for annealed aluminum (raw material, 88 MPa). Even though the elongation of the Al/WCp composite was reduced during the initial cycles of CAPB process, it increased significantly during the final cycles. SEM observation of fracture surfaces showed that the rupture mode in the CAPB-processed Al/WCp composite was of the shear ductile rupture type.

  5. 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.

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

    PubMed

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

    2015-01-01

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

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

    NASA Astrophysics Data System (ADS)

    Harach, David John

    2000-10-01

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

  8. Mixed Mode Stable Tearing of Thin Sheet Al 6061-T6 Specimens: Experimental Measurements and Finite Element Simulations using a Modified Mohr-Coulomb Fracture Criterion

    DTIC Science & Technology

    2010-11-01

    grounding. Oliver (1996a,b), Teng (2008) andXue (2007a) reported on successful application of contin- uum damage mechanics in simulating initiation and...the accumulated damage should reach the critical value and the load carrying capacity must vanish in the post-initiate range. It should be noted that...specimen using fracture coupled with damage plastic- ity approach. Different from Mode I, little thickness reduction is observed for Mode III loading, as

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

    NASA Astrophysics Data System (ADS)

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

    1992-07-01

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

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

    SciTech Connect

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

    1996-06-01

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

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

    SciTech Connect

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

    1996-12-31

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

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

    SciTech Connect

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

    1995-11-01

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

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

    SciTech Connect

    Donna Post Guillen; Brian G. Williams

    2005-05-01

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

  14. BONDING ALUMINUM METALS

    DOEpatents

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

    1961-06-13

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

  15. On the role of magnesium and silicon in the formation of alumina from aluminum alloys by means of DIMOX processing

    NASA Astrophysics Data System (ADS)

    Yang, Liu; Zhu, Degui; Xu, Changqing; Zhang, Jun; Zhang, Jian

    1996-08-01

    This article deals with the reaction mechanisms of the DIMOX (Directed Melt Oxided) processing of aluminum alloys. An orthogonalized experimental procedure was introduced to stipulate the effects of the reaction temperature, reaction time, and additional metallic elements, magnesium and silicon, on the oxidation process of aluminum alloys. Emphasis is placed on the distribution of magnesium and silicon in the products so that the behaviors of these two crucial elements for the formation of alumina from directed oxidation of aluminum alloys could be revealed. Alterative methods, including optical and scanning electron microscopy (SEM), electron probing, and wave spectrum analysis were applied to specify the microstructure characters of the products and locate the position of both magnesium and silicon in the reaction products. Judged by the weight gain after reaction, the results indicated that the temperature is the most influential factor in controlling the oxidation kinetics. Silicon is more effective than magnesium in accelerating the process, although magnesium is indispensable for the process to take place. While judged by the morphology of the reaction products, an excessive amount of silicon is harmful to the DIMOX process in that the final products consist of a large amount of porosity. Both magnesium and silicon are rather concentrated in specific regions than homogeneously distributed in the whole products. The contents of magnesium and silicon in the surface region are not as high as expected, with most of the magnesium being concentrated in the region directly neighboring the bulky metals and most of the Si in the residual bulky metals, although the contents of these two elements in the surface region are a little higher than the regions next to the surface. These characteristics, combined with other investigations, suggest that the decisive role of the slight amount of magnesium and silicon in the nucleation and growth of Al2O3 could be explained by

  16. Aluminum: Recycling of Aluminum Dross/Saltcake

    SciTech Connect

    Blazek, S.

    1999-01-29

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

  17. Electrically conductive anodized aluminum coatings

    NASA Technical Reports Server (NTRS)

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

    2001-01-01

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

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

    NASA Technical Reports Server (NTRS)

    Justi, S.

    1985-01-01

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

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

    SciTech Connect

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

    1999-11-20

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

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

    SciTech Connect

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

    1999-06-23

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

  1. Synthesis, analysis and processing of novel materials in the yttrium oxide-aluminum oxide system

    NASA Astrophysics Data System (ADS)

    Marchal, Julien Claudius

    In the current work, liquid feed flame spray pyrolysis (LF-FSP) was used to create three novel nanopowders in the Y2O3-Al 2O3 system: alpha-Al2O3, YAG (garnet Y3Al5O12) and hexagonal Y3Al 5O12. For example, LF-FSP combustion of metalloorganic yttrium and aluminum precursors in a 3/5 ratio forms hexagonal Y3Al5O 12, a newly discovered crystalline phase detailed in this work. The resulting 15-35 nm average particle size, single crystal nanopowders were characterized by TGA-DTA, XRD, HR-TEM, electron diffraction and FTIR. The data was used to establish a model for the crystal structure of this new phase (hexagonal, with crystal parameter of a = 0.736 nm, c = 1.052) consisting of a superlattice of substituted hexagonal YAlO3. YAG has been extensively investigated for its applications as scintillators, phosphors and as a laser host. Fully dispersible, unaggregated single crystal YAG nanopowders with average particle sizes of 35-50 nm were obtained from hexagonal Y3Al5O12 after annealing at 850°C-1200°C (for 2h-8d). The resulting YAG nanopowder was processed into green bodies using cold isostatic pressing after adding binders. 99%+ dense monoliths were obtained after sintering at 1400°C in vacuum (6-8 h), while maintaining grain sizes < 500 nm. The ability to sinter while keeping sub-micron grains differs from present techniques (where translucency is obtained through exaggerated grain growth to 5-10 microns) reported in the literature for sintering polycrystalline YAG, and is the first step for improving polycrystalline YAG laser host optical properties. LF-FSP processing of transition Al2O3 nanopowders converts them to single crystal alpha-Al2O3 nanopowders, previously thought impossible to obtain. The alpha-Al2O 3 nanopowders thus obtained, consist of unaggregated 30-40 nm single particles. These nanopowders were characterized by XRD, HR-TEM, SEM, DLS, FTIR. Green bodies of alpha-Al2O3 nanopowders were sintered to 99% density without sintering aids at 1400°C (6

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

    SciTech Connect

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

    1991-11-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2013-12-01

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

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

    SciTech Connect

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

    2012-01-01

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

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

    SciTech Connect

    Guan, Xiaofei; Zink, Peter; Pal, Uday

    2012-03-11

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

  6. On the role of magnesium and silicon in the formation of alumina from aluminum alloys by means of DIMOX processing

    SciTech Connect

    Yang, L.; Zhu, D.; Xu, C.; Zhang, J.; Zhang, J.

    1996-08-01

    This article deals with the reaction mechanisms of the DIMOX (Directed Melt Oxided) processing of aluminum alloys. An orthogonalized experimental procedure was introduced to stipulate the effects of the reaction temperature, reaction time, and additional metallic elements, magnesium and silicon, on the oxidation process of aluminum alloys. Emphasis is placed on the distribution of magnesium and silicon in the products so that the behaviors of these two crucial elements for the formation of alumina from directed oxidation of aluminum alloys could be revealed. Alterative methods, including optical and scanning electron microscopy (SEM), electron probing, and wave spectrum analysis were applied to specify the microstructure characters of the products and locate the position of both magnesium and silicon in the reaction products. Judged by the weight gain after reaction, the results indicated that the temperature is the most influential factor in controlling the oxidation kinetics. Both magnesium and silicon are rather concentrated in specific regions than homogeneously distributed in the whole products. The contents of magnesium and silicon in the surface region are not as high as expected, and most of the magnesium being concentrated in the region directly neighboring the bulky metals and most of the Si in the residual bulky metals, although the contents of these two elements in the surface region are a little higher than the regions next to the surface. These characteristics, combined with other investigations, suggest that the decisive role of the slight amount of magnesium and silicon in the nucleation and growth of Al{sub 2}O{sub 3} could be explained by the proposed circulated reaction.

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

    NASA Astrophysics Data System (ADS)

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

    2016-03-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2014-09-01

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

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

    NASA Astrophysics Data System (ADS)

    Kusada, Kentaro

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

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

    DOEpatents

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

    1995-01-01

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

  11. New Low Temperature Processing for Boron Carbide/Aluminum Based Composite Armor

    DTIC Science & Technology

    1990-06-01

    powders has shown the surface to be domi- nated by the acidic properties of a boric acid overlayer.11.12 Inspection of Table 1 * Micron Separations, Inc...stainless steel pressure filter (see Appendix A). After ROC, about half of the gradient parts had laminar cracks between the 70/30 and 60/40 B4 C/Al...Metal MaIx Baked out greeliware were enclosed in fitted cans of low carbon steel or 1100 aluminum; internal spaces between the can and the parts were

  12. Study of Processing and Microstructure of a Superplastic 5083 Aluminum Alloy

    DTIC Science & Technology

    2002-09-01

    AA5083 aluminum alloys designated lot numbers 978083 and 978901 were conducted at the Naval Postgraduate School in conjunction with mechanical testing...the ARCO materials and corresponding AA5083 materials, designated lot numbers 978083(A25) and 978901(A20), that were deformed under tensile...the OIM system were the AA5083 alloys deformed at 500ºC and 3x10-4s-1 and designated lot numbers 978083(A24) or 978901(A17). The procedure used to

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

    PubMed

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

    2013-12-01

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

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

    NASA Astrophysics Data System (ADS)

    Wei, Zhang; Jin, Guangyong; Wang, Yibin

    2016-01-01

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

  15. An Aluminum Microfluidic Chip Fabrication Using a Convenient Micromilling Process for Fluorescent Poly(dl-lactide-co-glycolide) Microparticle Generation

    PubMed Central

    Lin, Yung-Sheng; Yang, Chih-Hui; Wang, Chih-Yu; Chang, Fang-Rong; Huang, Keng-Shiang; Hsieh, Wan-Chen

    2012-01-01

    This study presents the development of a robust aluminum-based microfluidic chip fabricated by conventional mechanical micromachining (computer numerical control-based micro-milling process). It applied the aluminum-based microfluidic chip to form poly(lactic-co-glycolic acid) (PLGA) microparticles encapsulating CdSe/ZnS quantum dots (QDs). A cross-flow design and flow-focusing system were employed to control the oil-in-water (o/w) emulsification to ensure the generation of uniformly-sized droplets. The size of the droplets could be tuned by adjusting the flow rates of the water and oil phases. The proposed microfluidic platform is easy to fabricate, set up, organize as well as program, and is valuable for further applications under harsh reaction conditions (high temperature and/or strong organic solvent systems). The proposed method has the advantages of actively controlling the droplet diameter, with a narrow size distribution, good sphericity, as well as being a simple process with a high throughput. In addition to the fluorescent PLGA microparticles in this study, this approach can also be applied to many applications in the pharmaceutical and biomedical area. PMID:22438719

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

    NASA Astrophysics Data System (ADS)

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

    2015-06-01

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

  17. Aluminum Hydroxide

    MedlinePlus

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

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

    PubMed

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

    2015-04-01

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

  19. [Process and mechanism of plants in overcoming acid soil aluminum stress].

    PubMed

    Zhao, Tian-Long; Xie, Guang-Ning; Zhang, Xiao-Xia; Qiu, Lin-Quan; Wang, Na; Zhang, Su-Zhi

    2013-10-01

    Aluminum (Al) stress is one of the most important factors affecting the plant growth on acid soil. Currently, global soil acidification further intensifies the Al stress. Plants can detoxify Al via the chelation of ionic Al and organic acids to store the ionic Al in vacuoles and extrude it from roots. The Al extrusion is mainly performed by the membrane-localized anion channel proteins Al(3+)-activated malate transporter (ALMT) and multi-drug and toxin extrusion (MATE). The genes encoding ABC transporter and zinc-finger protein conferred plant Al tolerance have also been found. The identification of these Al-resistant genes makes it possible to increase the Al resistance of crop plants and enhance their production by the biological methods such as gene transformation and mark-associated breeding. The key problems needed to be solved and the possible directions in the researches of plant Al stress resistance were proposed.

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

    DOEpatents

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

    1995-07-04

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-04-01

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

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

    PubMed

    Qian, Linbo; Chen, Baoliang

    2014-01-15

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

  3. Microstructural evolution of a recycled aluminum alloy deformed by equal channel angular pressing process

    NASA Astrophysics Data System (ADS)

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

    2012-11-01

    The microstructural evolution of a recycled aluminum alloy after equal channel angular pressing (ECAP) up to four passes was investigated using X-ray diffraction (XRD) analysis and transmission electron microscopy (TEM). Microhardness tests were performed to determine the associated changes in mechanical properties. An ultrafine-grained material has been obtained with a microstructure showing a mixture of highly strained crystallites. A high density of dislocations was achieved as a result of severe plastic deformation (SPD) through the die. Changes in mechanical behavior are also revealed after ECAP due to strain hardening. Thermal analysis and TEM micrographs obtained after annealing indicate the succession of the recovery, recrystallization, and grain growth phenomena. Moreover, the energy stored during ECAP may be related to the dislocation density introduced by SPD. We finally emphasize the role played by the precipitates in this alloy.

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

    PubMed

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

    2015-10-01

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

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

    NASA Astrophysics Data System (ADS)

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

    2016-07-01

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

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

    SciTech Connect

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

    2012-01-15

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

  7. 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)

  8. 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

    2016-12-01

    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.

  9. 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.

  10. Infrared sensor by inkjet printing cytochrome c on suspending aluminum electrodes of post CMOS process

    NASA Astrophysics Data System (ADS)

    Liang, Shuo-Feng; Yen, Po-Hsien; Su, Guo-Dung John

    2016-09-01

    Cytochrome c protein thin film possesses a high temperature coefficient of resistance. In this paper, we systematically investigated the characteristics of cytochrome c, whose absorption coefficient is 65% at wavelengths of 8 12 μm. We found that the changes in resistance resulted from surface roughness. We also discovered that, while cytochrome c improves the temperature coefficient of resistance, a pure protein solution does not conduct well. It needs a buffer solution, acting as an electrolyte, to increase electrical conductance. However, the buffer solution decreases the temperature coefficient. Therefore, optimization of the ratio of cytochrome c protein to buffer solution is required. We determined the best mixing ratio of the protein solution for a sensing material. We then designed a chip for an infrared microbolometer with a MEMS structure of suspended aluminum electrodes. The protein solution was deposited on the sensing pixel using an inkjet printer. The temperature coefficient of resistance, thermal conductance, time constant and responsivity were 25.98%/K, 7.96 × 10-5 W/K, 1.094 ms and 2.57 × 105 V/W at 2 μA bias current, respectively. We experimentally demonstrated integrating cytochrome c protein with a CMOS circuit as a sensing pixel for a longwavelength infrared microbolometer. Based on our experimental results, such a microbolometer array holds promise for the future.

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

    NASA Astrophysics Data System (ADS)

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

    2016-08-01

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

  12. Numerical Modeling of Flow Dynamics in The Aluminum Smelting Process: Comparison Between Air-Water and CO2-Cryolite Systems

    NASA Astrophysics Data System (ADS)

    Zhao, Zhibin; Feng, Yuqing; Schwarz, M. Philip; Witt, Peter J.; Wang, Zhaowen; Cooksey, Mark

    2016-12-01

    Air-water models have been widely applied as substitutes for CO2-cryolite systems in the study of the complex bubble dynamics and bubble-driven flow that occurs in the molten electrolyte phase in the aluminum electrolytic process, but the detailed difference between the two systems has not been studied. This paper makes a numerical comparison between the bubble dynamics for the two systems. Simulations of both single bubble and continuous bubbling were conducted using a three-dimensional computational fluid dynamics (3D CFD) modeling approach with a volume of fluid (VOF) method to capture the phase interfaces. In the single bubble simulations, it was found that bubbles sliding under an anode in a CO2-cryolite system have a smaller bubble thickness and a higher sliding velocity than those in the air-water system for bubbles of the same volume. Dimensionless analysis and numerical simulation show that contact angle is the dominant factor producing these differences; the effects of kinematic viscosity, surface tension, and density are very small. In the continuous bubbling simulations, the continuous stream of air bubbles detaches from the anode sidewall after a period of climbing, just as it does in the single bubble simulation, but bubbles have less tendency to migrate away from the wall. Quasi-stable state flow characteristics, i.e., time-averaged bath flow pattern, turbulence kinetic energy, turbulence dissipation rate, and gas volume fraction, show a remarkable agreement between the two systems in terms of distribution and magnitude. From the current numerical comparisons, it is believed that the air-water model is a close substitutive model for studying bubble-driven bath flow in aluminum smelting processes. However, because of the difference in bubble morphologies between the two systems, and also the reactive generation and growth of bubbles in the real system, there will likely be some differences in bubble coverage of the anode in the anode-cathode gap.

  13. Numerical Modeling of Flow Dynamics in The Aluminum Smelting Process: Comparison Between Air-Water and CO2-Cryolite Systems

    NASA Astrophysics Data System (ADS)

    Zhao, Zhibin; Feng, Yuqing; Schwarz, M. Philip; Witt, Peter J.; Wang, Zhaowen; Cooksey, Mark

    2017-04-01

    Air-water models have been widely applied as substitutes for CO2-cryolite systems in the study of the complex bubble dynamics and bubble-driven flow that occurs in the molten electrolyte phase in the aluminum electrolytic process, but the detailed difference between the two systems has not been studied. This paper makes a numerical comparison between the bubble dynamics for the two systems. Simulations of both single bubble and continuous bubbling were conducted using a three-dimensional computational fluid dynamics (3D CFD) modeling approach with a volume of fluid (VOF) method to capture the phase interfaces. In the single bubble simulations, it was found that bubbles sliding under an anode in a CO2-cryolite system have a smaller bubble thickness and a higher sliding velocity than those in the air-water system for bubbles of the same volume. Dimensionless analysis and numerical simulation show that contact angle is the dominant factor producing these differences; the effects of kinematic viscosity, surface tension, and density are very small. In the continuous bubbling simulations, the continuous stream of air bubbles detaches from the anode sidewall after a period of climbing, just as it does in the single bubble simulation, but bubbles have less tendency to migrate away from the wall. Quasi-stable state flow characteristics, i.e., time-averaged bath flow pattern, turbulence kinetic energy, turbulence dissipation rate, and gas volume fraction, show a remarkable agreement between the two systems in terms of distribution and magnitude. From the current numerical comparisons, it is believed that the air-water model is a close substitutive model for studying bubble-driven bath flow in aluminum smelting processes. However, because of the difference in bubble morphologies between the two systems, and also the reactive generation and growth of bubbles in the real system, there will likely be some differences in bubble coverage of the anode in the anode-cathode gap.

  14. Microstructure, Hardness and Impact Toughness of Heat-Treated Nanodispersed Surface and Friction Stir-Processed Aluminum Alloy AA7075

    NASA Astrophysics Data System (ADS)

    Refat, M.; Elashery, A.; Toschi, S.; Ahmed, M. M. Z.; Morri, A.; El-Mahallawi, I.; Ceschini, L.

    2016-11-01

    Friction stir processing (FSP) is a recent surface engineering processing technique that is gaining wide recognition for manufacturing nanodispersed surface composites, which are of high specific strength, hardness and resistance to wear and corrosion. Herein, four-pass FSP was applied on aluminum alloy 7075 (AA7075-O) with and without the addition of alumina nanoparticles (Al2O3) of average size 40 nm. All FSP parameters were constant at 40 mm/min transverse speed, 500 rpm and tilt angle of 3°. FSP rotation direction was reversed every other pass. The friction stir-processed materials were sectioned and solution treated at 515 °C for 1.5 h, followed by age hardening at 120 °C for 12, 24, 36, 48 and 60 h. The effect of heat treatment regimes on microstructure, hardness and toughness was examined, as well as the fracture mode. The new friction stir-processed surfaces without and with nanodispersion showed enhancement in the hardness of the surface of the AA7075-O material (65 HV) to almost a double (100 and 140 HV) after four-pass FSP (before heat treatment) without and with incorporating nanoalumina particles, respectively. After 48-h aging at 120 °C, a significant enhancement in impact toughness was achieved for both the friction stir-processed without and with nanodispersion (181 and 134 J, respectively), compared to the reference material AA7075 in T6 condition (104 J).

  15. Laser welding of aluminum alloys

    SciTech Connect

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

    1997-03-01

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

  16. The effect of processing on the mechanical and fatigue properties of semi-solid formed A357 aluminum

    NASA Astrophysics Data System (ADS)

    Basner, Timothy Glen

    2001-11-01

    The fundamental relationship between semi-solid processing and microstructure and their effect on the flow characteristics of semisolid metals have been studied for several years. However, how the process related microstructure influences mechanical and fatigue properties has not been given the same attention. This study examines the influence of process-related microstructures on the mechanical and fatigue properties of semi-solid formed A357 alloys. Low solid fraction (<40% solid) and high solid fraction (>50% solid) semi-solid A357 aluminum were formed by two different processes, rheocasting and thixocasting. Solid fraction, globule size, globule shape factor, globule density, and the eutectic particle size and aspect ratio after T6 heat treatment were evaluated to determine their effect on the as-cast, T5, and T6 properties. The mechanical properties of low solid fraction (LSF) and high solid fraction (HSF) semi-solid formed A357 vary considerably with solid fraction, microstructure, chemistry, and heat treatment. In spite of these differences, common traits were identified that influence the mechanical properties, regardless of the process or the heat treatment condition. Increasing globule size, porosity, and iron content have a detrimental effect on strength and ductility in the as-cast, T5, and T6 conditions. Low solid fraction semi-solid formed A357 alloys apparently have lower strength in the as-cast and T5 conditions than high solid fraction semi-solid formed A357 alloys. This is attributed to the higher processing temperature and its adverse affect on the solid solubility of magnesium in the primary alpha-aluminum globules. Fatigue life was found to be a function of material strength, increasing with increasing ultimate tensile strength. Extrinsic fatigue initiation features, such as pores, were found to reduce the axial fatigue life by 25% or more, as compared to fatigue initiation features associated with the microstructure. Linear elastic fracture

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

    NASA Technical Reports Server (NTRS)

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

    2006-01-01

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

  18. Microstructure and Mechanical Properties of Cryorolled Aluminum Alloy AA2219 in Different Thermomechanical Processing Conditions

    NASA Astrophysics Data System (ADS)

    Sarkar, Aditya; Saravanan, K.; Nayan, Niraj; Murty, S. V. S. Narayana; Narayanan, P. Ramesh; Venkitakrishnan, P. V.; Mukhopadhyay, J.

    2017-01-01

    In the present study, aluminum alloy AA2219-T87 bars were cryorolled to various amounts of deformation in two pre-deformation conditions: (1) without solution treatment i.e., as-received T87 (WST-CR) and (2) with solution treatment (ST + CR). The solution treated and cryorolled bars were further annealed leading to a third condition: (3) solution treated, cryorolled, and annealed (CR + Annealed). Room-temperature mechanical properties have been evaluated for all three cryorolled conditions. Significant improvement in the 0.2 pct YS and UTS values was obtained for bars cryorolled to cross-sectional area reduction of more than 50 pct in the solution-treated condition (ST + CR), whereas for bars cryorolled in the without solution-treated condition (WST-CR), only an improvement in the 0.2 pct YS was observed. Cryorolling did not enhance the precipitation kinetics nor did it increase the response of the alloy to aging. The mechanical properties were correlated to the microstructures obtained by optical and transmission electron microscopy. Microstructural evolution in the ST + CR condition indicated gradual progression of the principal restoration mechanism from dynamic recovery (DRV) to dynamic recrystallization with an increasing amount of plastic deformation. Transmission electron microscopy of WST-CR and ST + CR specimens showed an increase in dislocation density as a function of the amount of deformation indicating suppression of DRV at cryogenic temperatures. Cryorolling in the solution-treated condition to cross-sectional area reduction of more than 50 pct (ST + 70 pct CR) was found to impart an optimum combination of strength and percent elongation in the present study.

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

    NASA Astrophysics Data System (ADS)

    Zhu, Jun

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

  20. Comparison of three thermographic post processing methods for the assessment of a repaired aluminum plate with composite patch

    NASA Astrophysics Data System (ADS)

    Daryabor, P.; Safizadeh, M. S.

    2016-11-01

    Composite patches are widely used to repair damaged metal structures, especially in aerospace industry. Perfect patch and bonding are necessary to achieve an effective repair. Various thermographic methods such as step heating thermography are commonly applied to inspect repaired structures. Since accurate determination of defect features are admirable, some techniques are used to process the thermal films. In this study, three common post processing techniques of thermography (namely, principle component analysis (PCA), pulse phase thermography (PPT) and thermal signal reconstruction (TSR)) have been utilized to inspect an aluminum plate repaired with carbon/epoxy patches. Several delaminations with various sizes and locations along with some disbond defects were artificially embedded in five samples of composite patches to experimentally investigate the performance of the three techniques for post-processing of the step heating thermography data. Furthermore, the outputs of the mentioned processing techniques were quantitatively compared to find the most effective one. Based on the comparison results, it was demonstrated that, TSR outputs leads to the more accurate defect sizing.

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

    NASA Technical Reports Server (NTRS)

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

    2002-01-01

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

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

    SciTech Connect

    Not Available

    2008-07-01

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

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

    SciTech Connect

    Robert De Saro

    2004-08-24

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

  4. Shock consolidation of nanocrystalline aluminum for bulk component formation

    SciTech Connect

    Fredenburg, D. A.; Vogler, T. J.; Saldana, C. J.; Thadhani, N. N.

    2007-12-12

    Al 6061-T6 powder particles with a partially nanocrystalline graded microstructure in three distinct morphologies are compacted at an impact velocity of 650 m/s. Recovered samples are characterized to determine degree of compaction, deformation characteristics, and mechanical properties. Compacts range from 96-98% of theoretical density, exhibiting relatively low elastic moduli. Nano-indentation yields relatively consistent hardness values of {approx}1.4 GPa, indicating hardness of starting powders is preserved after compaction. Micro-indentation indicates varying degrees of compaction through specimen cross-section, which is supported by EBSD and optical microscopy.

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

    PubMed

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

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

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

    PubMed

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

    2005-01-01

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

  7. Dust Explosion Characteristics of Aluminum, Titanium, Zinc, and Iron-Based Alloy Powders Used in Cold Spray Processing

    NASA Astrophysics Data System (ADS)

    Sakata, K.; Tagomori, K.; Sugiyama, N.; Sasaki, S.; Shinya, Y.; Nanbu, T.; Kawashita, Y.; Narita, I.; Kuwatori, K.; Ikeda, T.; Hara, R.; Miyahara, H.

    2014-01-01

    Compared to conventional thermal spray coating, cold spray processing typically employs finer, smaller-diameter metal powders. Furthermore, cold-sprayed particles exhibit fewer surface oxides than thermally sprayed particles due to the absence of particle melting during spraying. For these reasons, it is important to consider the potential for dust explosions or fires during cold spray processing, for both industrial and R&D applications. This work examined the dust explosion characteristics of metal powders typically used in cold spray coating, for the purpose of preventing dust explosions and fires and thus protecting the health and safety of workers and guarding against property damage. In order to safely make use of the new cold spray technology in industrial settings, it is necessary to manage the risks based on an appropriate assessment of the hazards. However, there have been few research reports focused on such risk management. Therefore, in this study, the dust explosion characteristics of aluminum, titanium, zinc, carbonyl iron, and eutectoid steel containing chromium at 4 wt.% (4 wt.% Cr-eutectoid steel) powders were evaluated according to the standard protocols JIS Z 8818, IEC61241-2-3(1994-09) section 3, and JIS Z 8817. This paper reports our results concerning the dust explosion properties of the above-mentioned metal powders.

  8. The effect of friction stir processing on the microstructure, mechanical properties and fracture behavior of investment cast titanium aluminum vanadium

    NASA Astrophysics Data System (ADS)

    Pilchak, Adam L.

    The use of investment cast titanium components is becoming increasingly common in the aerospace industry due to the ability to produce large, one-piece components with complex geometries that were previously fabricated by mechanically fastening or welding multiple smaller parts together. However, the coarse, fully lamellar microstructure typical of investment cast alpha + beta titanium alloys results in relatively poor fatigue strength compared to forged titanium products. As a result, investment castings are not considered for use in fatigue limited structures. In recent years, friction stir processing has emerged as a solid state metalworking technique capable of substantial microstructure refinement in aluminum and nickel-aluminum-bronze alloys. The purpose of the present study is to determine the feasibility of friction stir processing and assess its effect on the microstructure and mechanical properties of the most widely used alpha + beta titanium alloy, Ti-6Al-4V. Depending on processing parameters, including tool travel speed, rotation rate and geometry, the peak temperature in the stir zone was either above or below the beta transus. The resulting microstructures consisted of either ˜1 mum equiaxed a grains, ˜25 mum prior beta grains containing a colony alpha + beta microstructure or a combination of 1 mum equiaxed alpha and fine, acicular alpha + beta. The changes in microstructure were characterized with scanning and transmission electron microscopy and electron backscatter diffraction. The texture in the stir zone was nearly random for all processing conditions, however, several components of ideal simple shear textures were observed in both the hexagonal close packed alpha and the body centered cubic beta phases which provided insight into the operative grain refinement mechanisms. Due to the relatively small volume of material affected by friction stir processing, conventionally sized test specimens were unable to be machined from the stir zone

  9. Lost-Soap Aluminum Casting.

    ERIC Educational Resources Information Center

    Mihalow, Paula

    1980-01-01

    Lost-wax casting in sterling silver is a costly experience for the average high school student. However, this jewelry process can be learned at no cost if scrap aluminum is used instead of silver, and soap bars are used instead of wax. This lost-soap aluminum casting process is described. (Author/KC)

  10. 76 FR 30650 - Aluminum Extrusions from the People's Republic of China: Antidumping Duty Order

    Federal Register 2010, 2011, 2012, 2013, 2014

    2011-05-26

    ... forms, produced by an extrusion process, made from aluminum alloys having metallic elements corresponding to the alloy series designations published by The Aluminum Association commencing with the numbers... subject merchandise made from aluminum alloy with an Aluminum Association series designation...

  11. Explosively Joining Dissimilar Metal Tubes.

    DTIC Science & Technology

    1979-11-01

    both steel, photograph (7), and the Ni-Cu specimen, photograph (8) , showed considerable pitting corrosion in the aluminum . 4. The paint was then...for 6061 -T6 aluminum and are: collision angle 5 - 200, collision velocity 270 - 350 m/sec, with an impact pressure of at least 27 Kbar (391 Kpsi...Welded Aluminum Alloy 1 .. 5 rn-i (P0 -I Op. 2si 11 6W TABLE I Explosive2 Cladder Metal Base Metal Explosive Loading (gins/in2 6061 -T6 Al 304 SS TSE- 1004

  12. Extraction processes for the production of aluminum, titanium, iron, magnesium, and oxygen and nonterrestrial sources

    NASA Technical Reports Server (NTRS)

    Rao, D. B.; Choudary, U. V.; Erstfeld, T. E.; Williams, R. J.; Chang, Y. A.

    1979-01-01

    The suitability of existing terrestrial extractive metallurgical processes for the production of Al, Ti, Fe, Mg, and O2 from nonterrestrial resources is examined from both thermodynamic and kinetic points of view. Carbochlorination of lunar anorthite concentrate in conjunction with Alcoa electrolysis process for Al; carbochlorination of lunar ilmenite concentrate followed by Ca reduction of TiO2; and subsequent reduction of Fe2O3 by H2 for Ti and Fe, respectively, are suggested. Silicothermic reduction of olivine concentrate was found to be attractive for the extraction of Mg becaue of the technological knowhow of the process. Aluminothermic reduction of olivine is the other possible alternative for the production of magnesium. The large quantities of carbon monoxide generated in the metal extraction processes can be used to recover carbon and oxygen by a combination of the following methods: (1) simple disproportionation of CO,(2) methanation of CO and electrolysis of H2O, and (3) solid-state electrolysis of gas mixtures containing CO, CO2, and H2O. The research needed for the adoption of earth-based extraction processes for lunar and asteroidal minerals is outlined.

  13. Oxide film microstructure: the link between surface preparation processes and strength/durability of adhesively bonded aluminum. Final report

    SciTech Connect

    Hsia, K. Jimmy; Pearlstein, Arne J.; Scheeline, Alexander; Shang, Jian Ku

    2000-11-30

    Strength and durability of adhesive bonding of aluminum alloys structures are intrinsically determined by the surface microstructures and interfacial failure micromechanisms. The current project presents a multidisciplinary approach to addressing critical issues controlling the strength and durability of adhesive bonds of aluminum alloys. Three main thrust areas have been pursued: surface treatment technology development to achieve desirable surface microstructures; relationship between surface structure and properties of adhesive bonds; and failure mechanisms of adhesively bonded components.

  14. Kinetics of transformation in an in-situ aluminum-strontium deformation processed metal-metal composite

    NASA Astrophysics Data System (ADS)

    Frerichs, Andrew Elliott

    2011-12-01

    Efficient electricity transmission is a key component in all plans to increase the amount of renewable power used in the decades ahead. Prime solar and wind generation sites are usually distant from major population centers, resulting in the need for improved conductor wires that are stronger, lighter, and have better conductivity than conventional conductors. Deformation processed metal-metal composites (DMMCs) have a desirable combination of high strength and good conductivity. One such DMMC, aluminum-strontium, was investigated in this study. The composite wire was created by extrusion, swaging, and wire drawing of bundled Al and Sr wires. Intermetallic compound formation between Al and Sr is of particular interest to produce a strong, conductive wire with good high-temperature strength. Samples of swaged and drawn Al-Sr composite wire were heat treated at 483K, 513K, 543K and 573K to produce samples at varying stages of intermetallic compound formation. Resistivity measurements were taken from samples over a range of heat treatment times and temperatures to calculate the activation energy for Al-Sr intermetallic compound formation. Scanning electron microscopy, differential scanning calorimetry, and x-ray diffraction were used to investigate the changes in the microstructure occurring in the samples as a function of heat treatment. In addition, mechanical properties data were generated for pure Sr metal.

  15. Carbon nanofiber reinforced aluminum matrix composite fabricated by combined process of spark plasma sintering and hot extrusion.

    PubMed

    Kwon, Hansang; Kurita, Hiroki; Leparoux, Marc; Kawasaki, Akira

    2011-05-01

    Spark plasma sintering and hot extrusion processes have been employed for fabricating carbon nanofiber (CNF)-aluminum (Al) matrix bulk materials. The Al powder and the CNFs were mixed in a mixing medium of natural rubber. The CNFs were well dispersed onto the Al particles. After removal of the natural rubber, the Al-CNF mixture powders were highly densified. From the microstructural viewpoint, the composite materials were observed by optical, field-emission scanning electron, and high-resolution transmission electron microscopies. The CNFs were found to be located on every grain boundary and aligned with the extrusion direction of the Al-CNF bulk materials. Some Al carbides (Al4C3) were also observed at the surface of the CNFs. This carbide was created by a reaction between the Al and the disordered CNF. The CNFs and the formation of Al4C3 play an important role in the enhancement of the mechanical properties of the Al-CNF bulk material. The CNFs can also be used for engineering reinforcement of other matrix materials such as ceramics, polymers and more complex matrices.

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

    SciTech Connect

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

    2015-05-13

    In this article, the effect of pin features and orientation/placement of the materials on advancing side were investigated for friction stir welding (FSW) of dissimilar aluminum alloys AA2050 and AA6061. Pins for FSW were produced with a 2.12 mm pitch thread having three flats/flutes. Three sets of rotational speed/welding speed were used to perform a series of welds in a butt joint arrangement. The results show that, joint quality, process response variables and welding temperature are highly affected by pin features and material orientation in FSW. Defect free joints with effective material transportation in the weld nugget zone were obtained when welding was performed with AA2050 on the advancing side. The tool also encounters less in-plane reaction force for welding with 2050 on the advancing side. Pin with thread+3 flats produces quality welds at low rotational and travel speed regardless of the location of alloys on advancing or retreating side.

  17. 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

  18. 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.

  19. Plasma enhanced atomic layer batch processing of aluminum doped titanium dioxide

    SciTech Connect

    Lehnert, Wolfgang; Ruhl, Guenther; Gschwandtner, Alexander

    2012-01-15

    Among many promising high-k dielectrics, TiO{sub 2} is an interesting candidate because of its relatively high k value of over 40 and its easy integration into existing semiconductor manufacturing schemes. The most critical issues of TiO{sub 2} are its low electrical stability and its high leakage current density. However, doping TiO{sub 2} with Al has shown to yield significant improvement of layer quality on Ru electrodes [S. K. Kim et al., Adv. Mater. 20, 1429 (2008)]. In this work we investigated if atomic layer deposition (ALD) of Al doped TiO{sub 2} is feasible in a batch system. Electrical characterizations were done using common electrode materials like TiN, TaN, or W. Additionally, the effect of plasma enhanced processing in this reactor was studied. For this investigation a production batch ALD furnace has been retrofitted with a plasma source which can be used for post deposition anneals with oxygen radicals as well as for directly plasma enhanced ALD. After evaluation of several Ti precursors a deposition process for AlTiO{sub x} with excellent film thickness and composition uniformity was developed. The effects of post deposition anneals, Al{sub 2}O{sub 3} interlayers between electrode and TiO{sub 2}, Al doping concentration, plasma enhanced deposition and electrode material type on leakage current density are shown. An optimized AlTiO{sub x} deposition process on TaN electrodes yields to leakage current density of 5 x 10{sup -7} A/cm{sup 2} at 2 V and k values of about 35. Thus, it could be demonstrated that a plasma enhanced batch ALD process for Al doped TiO{sub 2} is feasible with acceptable leakage current density on a standard electrode material.

  20. Advanced neutron source materials surveillance program

    SciTech Connect

    Heavilin, S.M.

    1995-01-01

    The Advanced Neutron Source (ANS) will be composed of several different materials, one of which is 6061-T6 aluminum. Among other components, the reflector vessel and the core pressure boundary tube (CPBT), are to be made of 6061-T6 aluminum. These components will be subjected to high thermal neutron fluences and will require a surveillance program to monitor the strength and fracture toughness of the 6061-T6 aluminum over their lifetimes. The purpose of this paper is to explain the steps that were taken in the summer of 1994 toward developing the surveillance program. The first goal was to decide upon standard specimens to use in the fracture toughness and tensile testing. Second, facilities had to be chosen for specimens representing the CPBT and the reflector vessel base, weld, and heat-affected-zone (HAZ) metals. Third, a timetable had to be defined to determine when to remove the specimens for testing.

  1. Aluminum Analysis.

    ERIC Educational Resources Information Center

    Sumrall, William J.

    1998-01-01

    Presents three problems based on the price of aluminum designed to encourage students to be cooperative and to use an investigative approach to learning. Students collect and synthesize information, analyze results, and draw conclusions. (AIM)

  2. Microstructure and strength of a deformation processed aluminum-20%tin metal-metal composite

    NASA Astrophysics Data System (ADS)

    Xu, Kai

    An Al-20vol.% Sn metal-metal composite was deformation processed by extrusion, swaging, and wire drawing to a total true strain of 7.4, resulting in a microstructure with Sn filaments in an Al matrix. Both the size and spacing of the Sn filaments decreased as deformation processing progressed. Immediately after deformation, the Sn second phase showed a convoluted, ribbon-shaped filamentary morphology, but the Sn filaments spheroidized during prolonged storage at room temperature. The driving force for spheroidization is chemical potential gradient due to curvature difference along Sn filaments. A critical wavelength of lambda crit = 2piR can be used to determine the spheroidization tendency of Sn cylinder. When lambda > 2piR, spheroidization is predicted to occur. The strength of these composites increased exponentially with the reduction in spacing of the Sn filaments. The relationship between UTS and deformation true strain is UTS = 72.6 exp(0.20eta). A Hall-Petch relationship between strength and filament spacing has been observed. Strengthening results from the filaments acting as barriers for dislocation motion. The primary shape instability modes are cylinderization of ribbons, boundary splitting, spheroidization of cylinders, and edge spheroidization of ribbons. The determining factors dictating which mechanism is active are grain boundary energy, interfacial energy, and ribbon cross section aspect ratio. The fiber texture was determined by orientation imaging microscopy to be <100> for Al and <001> for Sn. The 290 MPa ultimate tensile strength of the composite was greater than the rule-of-mixtures prediction. Comparisons are made with Al-Nb, Al-Ti and Al-Mg deformation processed metal metal composites and to various strengthening models for metal-metal composites.

  3. Directionally Solidified Aluminum - 7 wt% Silicon Alloys: Comparison of Earth and International Space Station Processed Samples

    NASA Technical Reports Server (NTRS)

    Grugel, Richard N,; Tewari, Surendra; Rajamure, R. S.; Erdman, Robert; Poirier, David

    2012-01-01

    Primary dendrite arm spacings of Al-7 wt% Si alloy directionally solidified in low gravity environment of space (MICAST-6 and MICAST-7: Thermal gradient approx. 19 to 26 K/cm, Growth speeds varying from 5 to 50 microns/s show good agreement with the Hunt-Lu model. Primary dendrite trunk diameters of the ISS processed samples show a good fit with a simple analytical model based on Kirkwood s approach, proposed here. Natural convection, a) decreases primary dendrite arm spacing. b) appears to increase primary dendrite trunk diameter.

  4. On the processing, structure and properties of aluminum oxide-magnesium aluminate nanocomposites

    NASA Astrophysics Data System (ADS)

    McEnerney, Bryan William

    Improvement in the mechanical properties of ceramic materials is required to better integrate them into new technological applications, such as ballistic armor. While considerable attention has been given to advanced power preparation and powder processing techniques, there has been comparatively little investigation of the nanostructure of the materials. No systematic study has been performed to correlate very fine grain sizes with dynamic mechanical properties of ceramic materials. The purpose of this study is to investigate the high-strain-rate behavior of nanocomposite ceramic materials fabricated by a cost-effective, scalable processing. The starting powders chosen were Baikowski RC-SPT DBM Al 2O3 and Malakoff S30CR MgAl2O4, both being high-purity sub-1 mum powders. The test compositions studied were Al2O3---20 vol. % MgAl2O4, Al2O3---40 vol. % MgAl2O4, and Al2O3---60 vol. % MgAl2O4. The powders were consolidated by spray drying and then melting in a direct current (DC) arc plasma and, subsequently, quenched in water. The metastable powders were comminuted, cold pressed, and densified using hot isostatic pressing. The Vickers hardness of the materials was measured as a function of indentation load, and the strength was measured using a Split-Hopkinson Pressure Bar. The hardness of all three compositions was found to be unexpectedly high. This high hardness was attributed to the unique nanostructure of the materials. This nanostructure developed during decomposition of the metastable, plasma melted powder to the thermodynamically stable phases by solid state diffusion during hot isostatic pressing. With decreasing processing temperatures, the hardness of the samples improved significantly for the Al2O 3---40 vol. % MgAl2O4 and Al2O 3---60 vol. % MgAl2O4 compositions. It was further found that, within the standard deviation, there was minimal deviation between the hardness behaviors of these compositions, which was contrary to the behavior of the control samples

  5. Processing, phase equilibria and environmental degradation of molybdenum (silicom,aluminum)(2) intermetallic compound

    NASA Astrophysics Data System (ADS)

    Eason, Paul Duane

    The Mo(Si,Al)2 C40 compound was chosen for investigation as a possible high temperature structural material. To produce the C40 phase, several processing routes were explored with emphasis on obtaining microstructure/property relationships (i.e. control of grain size and minimization of secondary phases). To facilitate processing of single phase material, the phase equilibria of the Mo-Si-Al ternary system were reevaluated with respect to the phases adjacent to the C40 compound. An anomalous environmental degradation appeared to be the primary obstacle to further study of the compound and was investigated accordingly. Several processing routes were assessed for the production of dense, nearly single-phase Mo(Si,Al)2. Hot powder compaction was chosen as the method of sample production as is the case with many refractory silicide based materials. Therefore, variations in the processing techniques came from the choice of precursor materials and methods of powder production. Mechanical alloying, arc-melting and comminution, and blending of both elemental and compound powders were all employed to produce charges for hot uniaxial pressing. The final compacts were compared on the basis of density, grain size and presence of secondary phases. Establishment of a Mo-Si-Al ternary isothermal phase diagram at 1400°C was performed. Multiphase alloy compositions were selected to identify the phase boundaries of the C40, C54, T1 and Mo3Al8 phase fields, as well as to verify the existence of the C54 phase at 1400°C. The alloys were equilibrated by heat treatment and analyzed for phase identification and quantitative compositional information. The environmental degradation phenomenon was approached as a classical "pest" with an emphasis of study on grain boundary chemistry and atmospheric dependence of attack. Both Auger spectroscopy and electron microscopy revealed carbon-impurity-induced grain boundary segregation responsible for the embrittlement and material loss. Means of

  6. An evaluation of direct pressure sensors for monitoring the aluminum die casting process

    SciTech Connect

    Zhang, X.

    1997-12-31

    This study was conducted as part of the US Department of Energy (DOE) sponsored project Die Cavity Instrumentation. One objective of that project was to evaluate thermal, pressure, and gas flow process monitoring sensors in or near the die cavity as a means of securing improved process monitoring and control and better resultant part quality. The objectives of this thesis are to (1) evaluate a direct cavity pressure sensor in a controlled production campaign at the GM Casting Advanced Development Center (CADC) at Bedford, Indiana; and (2) develop correlations between sensor responses and product quality in terms of the casting weight, volume, and density. A direct quartz-based pressure sensor developed and marked by Kistler Instrument Corp. was acquired for evaluating as an in-cavity liquid metal pressure sensor. This pressure sensor is designed for use up to 700 C and 2,000 bars (29,000 psi). It has a pressure overload capacity up to 2,500 bars (36,250 psi).

  7. Facile and environmentally friendly solution-processed aluminum oxide dielectric for low-temperature, high-performance oxide thin-film transistors.

    PubMed

    Xu, Wangying; Wang, Han; Xie, Fangyan; Chen, Jian; Cao, Hongtao; Xu, Jian-Bin

    2015-03-18

    We developed a facile and environmentally friendly solution-processed method for aluminum oxide (AlOx) dielectrics. The formation and properties of AlOx thin films under various annealing temperatures were intensively investigated by thermogravimetric analysis-differential scanning calorimetry (TGA-DSC), X-ray diffraction (XRD), spectroscopic ellipsometry, atomic force microscopy (AFM), attenuated total reflectance-Fourier transform infrared spectroscopy (ATR-FTIR), X-ray photoelectron spectroscopy (XPS), impedance spectroscopy, and leakage current measurements. The sol-gel-derived AlOx thin film undergoes the decomposition of organic residuals and nitrate groups, as well as conversion of aluminum hydroxides to form aluminum oxide, as the annealing temperature increases. Finally, the AlOx film is used as gate dielectric for a variety of low-temperature solution-processed oxide TFTs. Above all, the In2O3 and InZnO TFTs exhibited high average mobilities of 57.2 cm(2) V(-1) s(-1) and 10.1 cm(2) V(-1) s(-1), as well as an on/off current ratio of ∼10(5) and low operating voltages of 4 V at a maximum processing temperature of 300 °C. Therefore, the solution-processable AlOx could be a promising candidate dielectric for low-cost, low-temperature, and high-performance oxide electronics.

  8. Production of aluminum-silicon alloy and ferrosilicon and commercial-purity aluminum by the direct-reduction process. Third annual technical report, 1980 January 1-1980 December 31

    SciTech Connect

    Bruno, M.J.

    1981-01-01

    Progress on the program to demonstrate the technical feasibility of a pilot-sized Direct Reduction Process for producing aluminium and aluminium-silicon alloy is reported for Phase C. Progress is reported on reduction including the following tasks: supply burden material; burden beneficiation; effects of pilot operating parameters; pilot modifications; reactor scale-up design; calculating heat and mass balance; processing mathematical modeling; effects of process variables; information on supportive analytical, phase identification, and mechanical engineering data. Progress on alloy purification is reported in the following tasks: pilot unit installation; effects of pilot operating parameters; pilot unit modifications; and supportive mechanical engineering. Progress on purification to commercial grade aluminum is reported on: pilot unit installation; effects of pilot operating parameters; pilot unit modifications; support pilot operations; and supportive expended man-hours. Plans for Phase D are noted. (MCW)

  9. Studies and research on the microstructure of brazed aluminum alloys in the repair process

    NASA Astrophysics Data System (ADS)

    Dimitescu, A.; Amza, Gh; Niţoi, D. F.; Amza, C. Gh; Apostolescu, Z.

    2016-08-01

    In aeronautical industry, in recent years, brazing joints got a growing spread. Therefore, it is necessary a detailed study on the microstructure of the assembly base and filler material brazed in conditions of reconditioning operation [1]. The methods of destructive examination are not associated with any particular type of test piece but lay down the general principles of the types of testing described. It is emphasized that a satisfactory examination method can only be developed and used after taking into account all the relevant factors regarding the equipment to be used and the characteristics of the test pieces being examined. [1, 2]. Brazing joints are most often systematically designed to be resistant to shearing, and the size of the joint influences the shear strength more than the tensile strength. Studies and researches on the microstructure may be necessary to determine the effects of brazing process or of any subsequent heat treatment on the characteristics of the joint.

  10. Multiscale Modeling of Damage Processes in fcc Aluminum: From Atoms to Grains

    NASA Technical Reports Server (NTRS)

    Glaessgen, E. H.; Saether, E.; Yamakov, V.

    2008-01-01

    Molecular dynamics (MD) methods are opening new opportunities for simulating the fundamental processes of material behavior at the atomistic level. However, current analysis is limited to small domains and increasing the size of the MD domain quickly presents intractable computational demands. A preferred approach to surmount this computational limitation has been to combine continuum mechanics-based modeling procedures, such as the finite element method (FEM), with MD analyses thereby reducing the region of atomic scale refinement. Such multiscale modeling strategies can be divided into two broad classifications: concurrent multiscale methods that directly incorporate an atomistic domain within a continuum domain and sequential multiscale methods that extract an averaged response from the atomistic simulation for later use as a constitutive model in a continuum analysis.

  11. Numerical simulation of friction stir spot welding process for aluminum alloys

    NASA Astrophysics Data System (ADS)

    Kim, Dongun; Badarinarayan, Harsha; Ryu, Ill; Kim, Ji Hoon; Kim, Chongmin; Okamoto, Kazutaka; Wagoner, R. H.; Chung, Kwansoo

    2010-04-01

    Thermo-mechanical simulations of the Friction Stir Spot Welding (FSSW) processes were performed for AA5083-H18 and AA6022-T4, utilizing commercial Finite Element Method (FEM) and Finite Volume Method (FVM) codes, which are based on Lagrangian and Eulerian formulations, respectively. The Lagrangian explicit dynamic FEM code, PAM-CRASH, and the Eulerian Computational Fluid Dynamics (CFD) FVM code, STAR-CD, were utilized to understand the effect of pin geometry on weld strength and material flow under the unsteady state condition. Using FVM code, material flow patterns near the tool boundary were analyzed to explain weld strength difference between welds by a cylindrical pin and welds by a triangular pin, whereas the frictional energy concept using the FEM code had a limited capacity to explain the weld strength difference.

  12. Evaluation of Various Depainting Processes on Mechanical Properties of 2024-T3 Aluminum Substrate

    NASA Technical Reports Server (NTRS)

    McGill, P.

    2001-01-01

    Alternate alkaline and neutral chemical paint strippers have been identified that, with respect to corrosion requirements, perform as well as or better than a methylene chloride baseline. These chemicals also, in general, meet corrosion acceptance criteria as specified in SAE MA 4872. Alternate acid chemical paint strippers have been identified that, with respect to corrosion requirements, perform as well as or better than a methylene chloride baseline. However, these chemicals do not generally meet corrosion acceptance criteria as specified in SAE MA 4872, especially in the areas of non-clad material performance and hydrogen embrittlement. Media blast methods reviewed in the study do not, in general, adversely affect fatigue performance or crack detectability of 2024-T3 substrate. Sodium bicarbonate stripping exhibited a tendency towards inhibiting crack detectability. These generalizations are based on a limited sample size and additional testing should be performed to characterize the response of specific substrates to specific processes.

  13. Lift-Off Processing and Aluminum on Silicon Superconducting Circuit Coherence

    NASA Astrophysics Data System (ADS)

    Dunsworth, Andrew; Megrant, Anthony; Quintana, Chris; Chen, Zijun; Barends, Rami; Chen, Yu; Fowler, Austin; Jeffrey, Evan; Mutus, Josh; Roushan, Pedram; Sank, Daniel; Hoi, Iochun; Campbell, Brooks; Chiaro, Ben; Kelly, Julian; Neil, Charels; O'Malley, Peter; Vainsencher, Amit; Wenner, Jim; White, Ted; Cleland, Andrew; Martinis, John; Martinis Group Team

    2015-03-01

    Dielctric loss from two level states (TLS's) are a limiting decoherence method in planar superconducting qubits. Previously we have shown that liftoff deposited metal has more loss than etched devices. Current fabrication techniques of Xmon qubit devices limit this loss by using liftoff metal on only a small area of the transmon including the Josephson junctions. However this method leads to excess loss when used on a silicon substrate. I have used quality factor measurments of coplanar waveguide resonator circuits as a tool to measure isolated steps in the liftoff processes. I will report on the effects of these steps and their added loss. This research was funded by the Office of the Director of National Intelligence (ODNI), Intelligence Advanced Research Projects Activity (IARPA), through the Army Research Office Grant JMAR-05.

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

    NASA Astrophysics Data System (ADS)

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

    2016-08-01

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

  15. Production of aluminum metal by electrolysis of aluminum sulfide

    DOEpatents

    Minh, N.Q.; Loutfy, R.O.; Yao, N.P.

    1982-04-01

    Metallic aluminum may be produced by the electrolysis of Al/sub 2/S/sub 3/ at 700 to 800/sup 0/C in a chloride melt composed of one or more alkali metal chlorides, and one or more alkaline earth metal chlorides and/or aluminum chloride to provide improved operating characteristics of the process.

  16. Production of aluminum metal by electrolysis of aluminum sulfide

    DOEpatents

    Minh, Nguyen Q.; Loutfy, Raouf O.; Yao, Neng-Ping

    1984-01-01

    Production of metallic aluminum by the electrolysis of Al.sub.2 S.sub.3 at 700.degree.-800.degree. C. in a chloride melt composed of one or more alkali metal chlorides, and one or more alkaline earth metal chlorides and/or aluminum chloride to provide improved operating characteristics of the process.

  17. Weld Repair of Thin Aluminum Sheet

    NASA Technical Reports Server (NTRS)

    Beuyukian, C. S.; Mitchell, M. J.

    1986-01-01

    Weld repairing of thin aluminum sheets now possible, using niobium shield and copper heat sinks. Refractory niobium shield protects aluminum adjacent to hole, while copper heat sinks help conduct heat away from repair site. Technique limits tungsten/inert-gas (TIG) welding bombardment zone to melt area, leaving surrounding areas around weld unaffected. Used successfully to repair aluminum cold plates on Space Shuttle, Commercial applications, especially in sealing fractures, dents, and holes in thin aluminum face sheets or clad brazing sheet in cold plates, heat exchangers, coolers, and Solar panels. While particularly suited to thin aluminum sheet, this process also used in thicker aluminum material to prevent surface damage near weld area.

  18. The use of primary dross from the aluminum industry for manufacturing aluminum sulfate

    SciTech Connect

    Osborne, B.W.

    1995-12-31

    The use of primary dross as a source for aluminum ion in the manufacture of aluminum sulfate offers opportunities for an inexpensive raw material. The aluminum sulfate industry in the US is a mature market with numerous small plants operating close to major users. The majority of manufacturers use either bauxite or aluminum oxide trihydrate as a source for the aluminum ion. However, using process technology developed and patented by IWC, the oxides are removed from primary dross for use in manufacturing aluminum sulfate prior to metal recovery. This process offers the benefit of reducing costs for metal recovery. This paper discusses some of the methodology used in this process.

  19. Microstructure-strength relationship of a deformation processed aluminum-titanium composite

    SciTech Connect

    Lund, T.

    1998-02-23

    The mechanical properties, electrical properties and microstructures have been evaluated for an Al-20 wt % Ti deformation processed metal metal matrix composite (DMMC). The strength of the swaged, extruded and wire drawn composite increases several-fold with increasing deformation up to a true strain of 12.1, the maximum investigated. At this point the Ti was elongated and SEM and TEM analysis of the transverse direction of the wire showed the ribbon-like filaments that are common for this type of material. Texture development was also characterized to explain the deformation characteristics of the composite materials. The Ti filaments acquired a <10{bar 1}0> fiber texture during deformation, and the Al filaments acquired a dual texture of (111) and (100). Resistivity measurements of the composite showed that for the highest deformed sample ({eta} = 12.1), the resistivity increased linearly with temperature up to the temperature where Al{sub 3}Ti formed. At this point the slope increased. Beyond this point, the resistivity of the sample never returned to its original value. The temperature where Al{sub 3}Ti forms was investigated using DTA and XRD analysis. The reaction temperature decreases with increasing deformation true strain ({eta}) and filament spacing.

  20. Temperature distribution study during the friction stir welding process of Al2024-T3 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Yau, Y. H.; Hussain, A.; Lalwani, R. K.; Chan, H. K.; Hakimi, N.

    2013-08-01

    Heat flux characteristics are critical to good quality welding obtained in the important engineering alloy Al2024-T3 by the friction stir welding (FSW) process. In the present study, thermocouples in three different configurations were affixed on the welding samples to measure the temperatures: in the first configuration, four thermocouples were placed at equivalent positions along one side of the welding direction; the second configuration involved two equivalent thermocouple locations on either side of the welding path; while the third configuration had all the thermocouples on one side of the layout but with unequal gaps from the welding line. A three-dimensional, non-linear ANSYS computational model, based on an approach applied to Al2024-T3 for the first time, was used to simulate the welding temperature profiles obtained experimentally. The experimental thermal profiles on the whole were found to be in agreement with those calculated by the ANSYS model. The broad agreement between the two kinds of profiles validates the basis for derivation of the simulation model and provides an approach for the FSW simulation in Al2024-T3 and is potentially more useful than models derived previously.

  1. Controlled Directional Solidification of Aluminum - 7 wt Percent Silicon Alloys: Comparison Between Samples Processed on Earth and in the Microgravity Environment Aboard the International Space Station

    NASA Technical Reports Server (NTRS)

    Grugel, Richard N.; Tewari, Surendra N.; Erdman, Robert G.; Poirier, David R.

    2012-01-01

    An overview of the international "MIcrostructure Formation in CASTing of Technical Alloys" (MICAST) program is given. Directional solidification processing of metals and alloys is described, and why experiments conducted in the microgravity environment aboard the International Space Station (ISS) are expected to promote our understanding of this commercially relevant practice. Microstructural differences observed when comparing the aluminum - 7 wt% silicon alloys directionally solidified on Earth to those aboard the ISS are presented and discussed.

  2. Experimental and analytical investigation of the seizure process in aluminum-silicon alloy/steel tribocontacts

    NASA Astrophysics Data System (ADS)

    He, Xiaozhou

    1998-12-01

    This research is an experimental and analytical investigation of the scuffing/seizure mechanism in Al-Si alloy/steel tribocontacts. An analytical model is developed based on analyses and experiments to predict scuffing/seizure failure in Al-Si alloy/steel tribocontacts, which can be applied to tribo-components in engines, refrigerators and air conditioners. The wear and scuffing/seizure experiments have been conducted through a block-on-ring tester for 339 and ESE-M2A137 Al-Si alloys under the dry and boundary lubrication conditions. The experimental research consists of: (a) wear debris generation and EDX analysis, (b) wear surface morphological analysis, (c) scuffing/seizure mechanism and process analysis, (d) scuffing/seizure PV curves under the dry contact and boundary lubrication, and (e) effects of several main factors on scuffing/seizure. The analytical research includes the following: (a) the investigation of the scuffing/seizure mechanisms in the Al-Si alloy/steel tribocontacts, (b) 3-D asperity contact pressures for longitudinal, transverse and isotropic surface roughness profiles, (c) 3-D surface asperity contact temperature rise due to the friction, (d) failure analyses of the various lubricating films, (e) analyses of the temperature dependence of surface tangential traction and shear strength in a surface layer of Al-Si alloy, (f) the scuffing/seizure failure analytical model under dry contact and boundary lubrication. The analytical model is based on the new hypothesis of three defense lines against scuffing/seizure failure: the adsorbed oil film, oxide film and the ratio of surface tangential traction with the shear strength in a surface layer. These two films together with a surface layer itself form three defense lines against scuffing/seizure. The surface tangential traction exceeds the bulk shear strength in a surface layer of Al-Si alloy is the necessary and sufficient condition for the scuffing/seizure occurrence. The analytical model has a

  3. 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

  4. Nondestructive detection of an undesirable metallic phase, T.sub.1, during processing of aluminum-lithium alloys

    DOEpatents

    Buck, Otto; Bracci, David J.; Jiles, David C.; Brasche, Lisa J. H.; Shield, Jeffrey E.; Chumbley, Leonard S.

    1990-08-07

    A method is disclosed for detecting the T.sub.1 phase in aluminum-lithium alloys through simultaneous measurement of conductivity and hardness. In employing eddy current to measure conductivity, when the eddy current decreases with aging of the alloy, while the hardness of the material continues to increase, the presence of the T.sub.1 phase may be detected.

  5. Aluminum alloy

    NASA Technical Reports Server (NTRS)

    Blackburn, Linda B. (Inventor); Starke, Edgar A., Jr. (Inventor)

    1989-01-01

    This invention relates to aluminum alloys, particularly to aluminum-copper-lithium alloys containing at least about 0.1 percent by weight of indium as an essential component, which are suitable for applications in aircraft and aerospace vehicles. At least about 0.1 percent by weight of indium is added as an essential component to an alloy which precipitates a T1 phase (Al2CuLi). This addition enhances the nucleation of the precipitate T1 phase, producing a microstructure which provides excellent strength as indicated by Rockwell hardness values and confirmed by standard tensile tests.

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

    NASA Technical Reports Server (NTRS)

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

    1977-01-01

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

  7. AM2 Opposite Lay Evaluation

    DTIC Science & Technology

    2015-06-01

    fabricated from a single 6061-T6 aluminum alloy extrusion with end connectors welded to the 24-in. ends to form a complete panel. The core of the extruded...commercial products. All product names and trademarks cited are the property of their respective owners. The findings of this report are not to be...19 Figure 21. Insertion of aluminum locking bar between

  8. REMOVAL OF ALUMINUM COATINGS

    DOEpatents

    Peterson, J.H.

    1959-08-25

    A process is presented for dissolving aluminum jackets from uranium fuel elements without attack of the uranium in a boiling nitric acid-mercuric nitrate solution containing up to 50% by weight of nitrtc acid and mercuric nitrate in a concentration of between 0.05 and 1% by weight.

  9. Orbital fabrication of aluminum foam and apparatus therefore

    NASA Technical Reports Server (NTRS)

    Tucker, Dennis S. (Inventor)

    2010-01-01

    A process for producing foamed aluminum in space comprising the steps of: heating aluminum until it is molten; applying the force of gravity to the molten aluminum; injecting gas into the molten aluminum to produce molten foamed aluminum; and allowing the molten foamed aluminum to cool to below melting temperature. The apparatus for carrying out this invention comprises: a furnace which rotates to simulate the force of gravity and heats the aluminum until it is molten; a door on the furnace, which is opened for charging the aluminum into the furnace, closed for processing and opened again for removal of the foamed aluminum; a gas injection apparatus for injecting gas into the molten aluminum within the furnace; and an extraction apparatus adjacent the door for removing the foamed aluminum from the furnace.

  10. Detachment of Tertiary Dendrite Arms during Controlled Directional Solidification in Aluminum - 7 wt Percent Silicon Alloys: Observations from Ground-based and Microgravity Processed Samples

    NASA Technical Reports Server (NTRS)

    Grugel, Richard N.; Erdman, Robert; Van Hoose, James R.; Tewari, Surendra; Poirier, David

    2012-01-01

    Electron Back Scattered Diffraction results from cross-sections of directionally solidified aluminum 7wt% silicon alloys unexpectedly revealed tertiary dendrite arms that were detached and mis-oriented from their parent arm. More surprisingly, the same phenomenon was observed in a sample similarly processed in the quiescent microgravity environment aboard the International Space Station (ISS) in support of the joint US-European MICAST investigation. The work presented here includes a brief introduction to MICAST and the directional solidification facilities, and their capabilities, available aboard the ISS. Results from the ground-based and microgravity processed samples are compared and possible mechanisms for the observed tertiary arm detachment are suggested.

  11. Fabrication of Porous Aluminum Using Gases Intrinsically Contained in Aluminum Alloy Die Castings

    NASA Astrophysics Data System (ADS)

    Hangai, Yoshihiko; Utsunomiya, Takao

    2009-06-01

    Closed-cell porous aluminum was fabricated using gases intrinsically contained in aluminum alloy die castings without using a blowing agent. By incorporating the friction stir processing technique, porous aluminum with a porosity of more than 50 pct was successfully obtained at a holding temperature of 923 to 948 K and a holding time of 10 minutes. This proposed die-casting route has high potential for fabricating porous aluminum at a low cost by a higher productivity process.

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

    SciTech Connect

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

    2007-08-16

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

  13. Reactively Deposited Aluminum Oxide and Fluoropolymer Filled Aluminum Oxide Protective Coatings for Polymers

    NASA Technical Reports Server (NTRS)

    Rutledge, Sharon K.; Banks, Bruce A.; Hunt, Jason

    1995-01-01

    Reactive ion beam sputter deposition of aluminum simultaneous with low energy arrival of oxygen ions at the deposition surface enables the formation of highly transparent aluminum oxide films. Thick (12 200 A), adherent, low stress, reactively deposited aluminum oxide films were found to provide some abrasion resistance to polycarbonate substrates. The reactively deposited aluminum oxide films are also slightly more hydrophobic and more transmitting in the UV than aluminum oxide deposited from an aluminum oxide target. Simultaneous reactive sputter deposition of aluminum along with polytetrafluoroethylene (PTFE Teflon) produces fluoropolymer-filled aluminum oxide films which are lower in stress, about the same in transmittance, but more wetting than reactively deposited aluminum oxide films. Deposition properties, processes and potential applications for these coatings will be discussed.

  14. Aluminum Nanoholes for Optical Biosensing

    PubMed Central

    Barrios, Carlos Angulo; Canalejas-Tejero, Víctor; Herranz, Sonia; Urraca, Javier; Moreno-Bondi, María Cruz; Avella-Oliver, Miquel; Maquieira, Ángel; Puchades, Rosa

    2015-01-01

    Sub-wavelength diameter holes in thin metal layers can exhibit remarkable optical features that make them highly suitable for (bio)sensing applications. Either as efficient light scattering centers for surface plasmon excitation or metal-clad optical waveguides, they are able to form strongly localized optical fields that can effectively interact with biomolecules and/or nanoparticles on the nanoscale. As the metal of choice, aluminum exhibits good optical and electrical properties, is easy to manufacture and process and, unlike gold and silver, its low cost makes it very promising for commercial applications. However, aluminum has been scarcely used for biosensing purposes due to corrosion and pitting issues. In this short review, we show our recent achievements on aluminum nanohole platforms for (bio)sensing. These include a method to circumvent aluminum degradation—which has been successfully applied to the demonstration of aluminum nanohole array (NHA) immunosensors based on both, glass and polycarbonate compact discs supports—the use of aluminum nanoholes operating as optical waveguides for synthesizing submicron-sized molecularly imprinted polymers by local photopolymerization, and a technique for fabricating transferable aluminum NHAs onto flexible pressure-sensitive adhesive tapes, which could facilitate the development of a wearable technology based on aluminum NHAs. PMID:26184330

  15. Effect of aluminum speciation on fouling mechanisms by pre-coagulation/ultrafiltration process with different NOM fractions.

    PubMed

    Sun, Weiguang; Nan, Jun; Yao, Meng; Xing, Jia; Tian, Jiayu

    2016-09-01

    Ultrafiltration is an emerging technology for drinking water production, but the membrane fouling is still a challenge. This study was carried out to investigate the effect of aluminum speciation on UF membrane fouling behavior by different NOM fractions-humic substances and proteins, as represented by humic acid (HA) and bovine serum albumin (BSA), respectively. The interesting results showed that the total fouling resistance of the mixture of HA-BSA-kaolinite solution without coagulant demonstrated a slight decrease in comparison with those of the individually filtered substances, indicating a mitigatory fouling effect. The hydrolysis of aluminum products was various as pH and membrane fouling was related to aluminum speciation. The average size of flocs dramatically increased and fractal dimension of flocs decreased with the increasing of pH value independent on water quality, which indicated that aluminum speciation had a significant impact on floc properties. For the mixture of HA-BSA-kaolinte, the slightly larger of flocs average size in comparison with the individual organic fraction after coagulation was probably attributing that BSA was encapsulated by HA to enlarge the molecular length and floc size further increased. The membrane performance also showed that coagulation effluent of HA-BSA-kaolinite mitigated membrane fouling. The strong linear relationship was observed between flocs fractal dimension and final membrane flux in this research. From the results, the control of flocs fractal dimension should be considered as a new technique for traditional hybrid coagulation/ultrafiltration system, which resulted in minimized total and irreversible fouling and has a meaningful engineering application value.

  16. Aluminum reclamation from dross. (Latest citations from the Aluminum Industry Abstracts database). Published Search

    SciTech Connect

    1996-06-01

    The bibliography contains citations concerning aluminum reclamation from dross. Topics include dross treatment technology, the environmental benefits of aluminum recovery from dross, and the economics of aluminum reclamation in dross processing systems. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

  17. Production of anhydrous aluminum chloride composition

    DOEpatents

    Vandergrift, G.F. III; Krumpelt, M.; Horwitz, E.P.

    1981-10-08

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

  18. Process development for the direct solvent extraction of nickel and cobalt from nitrate solution: aluminum, cobalt, and nickel separation using Cyanex 272

    NASA Astrophysics Data System (ADS)

    Ichlas, Zela T.; Ibana, Don C.

    2017-01-01

    A direct solvent extraction (DSX) process for purifying nickel and cobalt from the nitric acid leach solution of nickel laterite ores was conceived and experimentally probed. The proposed process consists of two solvent extraction (SX) steps but with only one extractant — bis(2,4,4-trimethylpentyl)phosphinic acid (Cyanex® 272) — used in both steps. The first extraction step involved the removal of aluminum and zinc, whereas the second extraction step involved the separation of cobalt along with manganese from nickel. The experimental results showed essentially quantitative removal of aluminum (>97%) and zinc (>99%) in a single extraction stage using 20vol% Cyanex 272 at pH 2.1. Some cobalt (32%) and manganese (55%) were co-extracted but were easily scrubbed out completely from the loaded organic phase using dilute sulfuric acid at pH ≤ 1.38. Cobalt and manganese in the first extraction raffinate were extracted completely in four extraction stages at staggered pH values of 4.0, 4.4, 4.5, and 4.0 in the first, second, third, and fourth stages, respectively, using also 20vol% Cyanex 272. A small amount of nickel (up to 6.6%) was co-extracted but was easily scrubbed out completely with dilute sulfuric acid at pH 2.0. A flow diagram showing the input and output conditions and the metals separated under the deduced optimum conditions is presented.

  19. Aluminum: Industry of the future

    SciTech Connect

    1998-11-01

    For over a century, the US aluminum industry has led the global market with advances in technology, product development, and marketing. Industry leaders recognize both the opportunities and challenges they face as they head into the 21st century, and that cooperative R and D is key to their success. In a unique partnership, aluminum industry leaders have teamed with the US Department of Energy`s Office of Industrial Technologies (OIT) to focus on innovative technologies that will help to strengthen the competitive position of the US aluminum industry and, at the same time, further important national goals. This industry-led partnership, the Aluminum Industry of the Future, promotes technologies that optimize the use of energy and materials in operations and reduce wastes and energy-related emissions. Led by The Aluminum Association, industry leaders began by developing a unified vision of future market, business, energy, and environmental goals. Their vision document, Partnerships for the Future, articulates a compelling vision for the next 20 years: to maintain and grow the aluminum industry through the manufacture and sale of competitively priced, socially desirable, and ecologically sustainable products. Continued global leadership in materials markets will require the combined resources of industry, universities, and government laboratories. By developing a unified vision, the aluminum industry has provided a framework for the next step in the Industries of the Future process, the development of a technology roadmap designed to facilitate cooperative R and D.

  20. Transfer and transport of aluminum in filtration unit.

    PubMed

    Wen-dong, Wang; Hong-wei, Yang; Hua-zhang, Zhao; Zhan-peng, Jiang

    2007-01-01

    Aluminum salt coagulants were used prevalently in various water works. In this article, the effects of filtration on residual aluminum concentration and species distribution were researched by determining the concentration of different aluminum species before and after single layer filter, double layer filter, and membrane filtration units. In the research, size exclusion chromatography (SEC) was used to separate colloidal and soluble aluminum, ion exchange chromatography (IEC) was used to separate organic and inorganic aluminum, and inductivity coupled plasma-atomic emission spectrometry (ICP-AES) was used to determine the aluminum concentration. The results showed that the rapid filtration process had the ability of removing residual aluminum from coagulant effluent water, and that double layer filtration was more effective in residual aluminum removal than single layer filtration, while nano filtration was more effective than micro filtration. It was found that when the residual aluminum concentration was below 1 mg/L in sediment effluent, the residual aluminum concentration in treated water was above 0.2 mg/L. The direct rapid filtration process mainly removed the suspended aluminum. The removal of soluble and colloidal aluminum was always less than 10% and the natural small particles that adsorbed the amount of soluble or small particles aluminum on their surface were difficult to be removed in this process. Micro filtration and nano filtration were good technologies for removing aluminum; the residual aluminum concentration in the effluent was less than 0.05 mg/L.

  1. Effects of casting conditions and deformation processing on A356 aluminum and A356-20 vol. pct SiC composites

    NASA Technical Reports Server (NTRS)

    Rozak, G. A.; Lewandowski, J. J.; Wallace, J. F.; Altmisoglu, A.

    1992-01-01

    The effects of casting conditions and deformation processing on the mechanical properties of unreinforced A356 aluminum and A356-20 vol pct SiC composite were investigated by tensile properties in these compounds fabricated by either sand casting or squeeze casting techniques followed by hot working to 33, 50, 90, and 95 percent reductions. The evolution of the microstructure and values of tensile properties were evaluated for the cast materials in each of the hot worked conditions. It was found that, while the deformation processing of the sand-cast composite resulted in banding of the Al and SiC particles within the microstructure, such features were not observed in the squeeze-cast microstructure. The tensile strengths of the squeeze cast materials was found to be higher than those of the sand cast materials, for both the unreinforced and composite samples, while increased amounts of deformation were found to improve the ductility of the composite.

  2. Infrared and Raman spectroscopic studies of tris-[3-(trimethoxysilyl)propyl] isocyanurate, its sol-gel process, and coating on aluminum and copper.

    PubMed

    Li, Ying-Sing; Church, Jeffrey S; Woodhead, Andrea L; Vecchio, Nicolas E; Yang, Johnny

    2014-11-11

    Tris-[3-(trimethoxysilyl)propyl] isocyanurate (TTPI) has been used as a precursor to prepare a sol using ethanol as the solvent under acidic conditions. The sol-gel was applied for the surface treatment of aluminum and copper. Infrared and Raman spectra have been recorded for pure TTPI and the TTPI sol, xerogel and TTPI sol-gel coated metals. From the vibrational spectra, TTPI is likely to have the C1 point group. Vibrational assignments are suggested based on group frequencies, the expected reactions in the sol-gel process and the vibrational studies of some related molecules. From the experimental infrared spectra of xerogels annealed at different temperatures and from the thermal-gravimetric analysis, it is found that the TTPI xerogel decomposes at around 450°C with silica being the major decomposition product. A cyclic voltammetric study of the metal electrodes coated with different concentrations of TTPI ranging from 5% to 42% (v/v) has shown that the films with high concentrations of sol would provide better corrosion protection for aluminum and copper.

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

    NASA Astrophysics Data System (ADS)

    Pan, Yi; Lados, Diana A.

    2017-01-01

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

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

    NASA Astrophysics Data System (ADS)

    Pan, Yi; Lados, Diana A.

    2017-04-01

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

  5. Aluminum Carbothermic Technology

    SciTech Connect

    Bruno, Marshall J.

    2005-03-31

    This report documents the non-proprietary research and development conducted on the Aluminum Carbothermic Technology (ACT) project from contract inception on July 01, 2000 to termination on December 31, 2004. The objectives of the program were to demonstrate the technical and economic feasibility of a new carbothermic process for producing commercial grade aluminum, designated as the ''Advanced Reactor Process'' (ARP). The scope of the program ranged from fundamental research through small scale laboratory experiments (65 kW power input) to larger scale test modules at up to 1600 kW power input. The tasks included work on four components of the process, Stages 1 and 2 of the reactor, vapor recovery and metal alloy decarbonization; development of computer models; and economic analyses of capital and operating costs. Justification for developing a new, carbothermic route to aluminum production is defined by the potential benefits in reduced energy, lower costs and more favorable environmental characteristics than the conventional Hall-Heroult process presently used by the industry. The estimated metrics for these advantages include energy rates at approximately 10 kWh/kg Al (versus over 13 kWh/kg Al for Hall-Heroult), capital costs as low as $1250 per MTY (versus 4,000 per MTY for Hall-Heroult), operating cost reductions of over 10%, and up to 37% reduction in CO2 emissions for fossil-fuel power plants. Realization of these benefits would be critical to sustaining the US aluminum industries position as a global leader in primary aluminum production. One very attractive incentive for ARP is its perceived ability to cost effectively produce metal over a range of smelter sizes, not feasible for Hall-Heroult plants which must be large, 240,000 TPY or more, to be economical. Lower capacity stand alone carbothermic smelters could be utilized to supply molten metal at fabrication facilities similar to the mini-mill concept employed by the steel industry. Major

  6. Evaluating of NASA-Langley Research Center explosion seam welding

    NASA Technical Reports Server (NTRS)

    Otto, H. E.; Wittman, R.

    1977-01-01

    An explosion bonding technique to meet current fabrication requirements was demonstrated. A test program was conducted on explosion bonded joints, compared to fusion joints in 6061-T6 aluminum. The comparison was made in required fixtures, non-destructive testing, static strength and fatigue strength.

  7. Structural Damage Identification in Stiffened Plate Fatigue Specimens Using Piezoelectric Active Sensing

    DTIC Science & Technology

    2011-09-01

    welded. The base plate and bulkhead material consist of 3/8 and 1/4 inch thick 5083-H116 aluminum, while the stiffeners are made of extruded 6061 - T6...and weld repair on crack propagation behaviour in aluminium alloy 5083 plates,” Materials & Design, 23(2):201-208. 8. Raghavan, A. and C. E. S

  8. High Strain Rate Mechanical Properties of Epoxy and Epoxy-Based Particulate Composites (Preprint)

    DTIC Science & Technology

    2007-05-01

    stainless steel or 6061 -T6 aluminum. The striker is 305 mm long and made of the same material as the other bars. The samples, which were nominally 8 mm...Property Correlation in Discontinuously-Reinforced Aluminium Matrix Composites as a Function of Relative Particle Size Ratio. Mat. Sci. Eng., 2002. A337: p

  9. High Strain Rate Mechanical Properties of Epoxy and Epoxy-Based Particulate Composites

    DTIC Science & Technology

    2007-08-01

    steel or 6061 -T6 aluminum. The striker is 305 mm long and made of the same material as the other bars. The samples, which were nominally 8 mm...Correlation in Discontinuously-Reinforced Aluminium Matrix Composites as a Function of Relative Particle Size Ratio. Mat. Sci. Eng., 2002. A337: p

  10. Optimization of wet shaking table process using response surface methodology applied to the separation of copper and aluminum from the fine fraction of shredder ELVs.

    PubMed

    Jordão, Helga; Sousa, António Jorge; Carvalho, M Teresa

    2016-02-01

    With the purpose of reducing the waste generated by end-of-life vehicles (ELVs) by enhancing the recovery and recycling of nonferrous metals, an experimental study was conducted with the finest size fraction of nonferrous stream produced at an ELV shredder plant. The aim of this work was to characterize the nonferrous stream and to evaluate the efficiency of a gravity concentration process in separating light and heavy nonferrous metal particles that could be easily integrated in a ELV shredder plant (in this case study the separation explicitly addressed copper and aluminum separation). The characterization of a sample of the 0-10mm particle size fraction showed a mixture of nonferrous metals with a certain degree of impurity due to the present of contaminants such as plastics. The majority of the particles exhibited a wire shape, preventing an efficient separation of materials without prior fragmentation. The gravity concentration process selected for this study was the wet shaking table and three operating parameters of the equipment were manipulated. A full factorial design in combination with a central composite design was employed to model metals recovery. Two second order polynomial equations were successfully fitted to describe the process and predict the recovery of copper and aluminum in Cu concentrate under the conditions of the present study. The optimum conditions were determined to be 11.1° of inclination, 2.8L/min of feed water flow and 4.9L/min of wash water flow. All three final products of the wet shaking table had a content higher than 90% in relation to one of the metals, wherein a Cu concentrate product was obtained with a Cu content of 96%, and 78% of Cu recovery and 2% of Al recovery.

  11. 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)

  12. Design for aluminum recycling

    SciTech Connect

    Not Available

    1993-10-01

    This article describes the increasing use of aluminum in automobiles and the need to recycle to benefit further growth of aluminum applications by assuring an economical, high-quality source of metal. The article emphasizes that coordination of material specifications among designers can raise aluminum scrap value and facilitate recycling. Applications of aluminum in automobile construction are discussed.

  13. Automobile bodies: Can aluminum be an economical alternative to steel?

    NASA Astrophysics Data System (ADS)

    Roth, Richard; Clark, Joel; Kelkar, Ashish

    2001-08-01

    Although the use of aluminum in cars has been increasing for the past two decades, progress has been limited in developing aluminum auto bodies. In fact, most aluminum substitution has come in the form of castings and forgings in the transmission, wheels, etc. Car manufacturers have developed all-aluminum cars with two competing designs: conventional unibody and the spaceframe. However, aluminum is far from being a material of choice for auto bodies. The substitution of aluminum for steel is partly influenced by regulatory pressures to meet fuel efficiency standards by reducing vehicle weight, and to meet recycling standards. The key obstacles are the high cost of primary aluminum as compared to steel and added fabrication costs of aluminum panels. Both the aluminum and the automotive industries have attempted to make aluminum a cost-effective alternative to steel. This paper analyzes the cost of fabrication and assembly of four different aluminum car body designs, making comparisons with conventional steel designs at current aluminum prices and using current aluminum fabrication technology. It then attempts to determine if aluminum can be an alternative to steel at lower primary aluminum prices, and improved fabrication processes.

  14. Aluminum industry applications for OTEC

    SciTech Connect

    Jones, M.S.; Leshaw, D.; Sathyanarayana, K.; Sprouse, A.M.; Thiagarajan, V.

    1980-12-01

    The objective of the program is to study the integration issues which must be resolved to realize the market potential of ocean thermal energy conversion (OTEC) power for the aluminum industry. The study established, as a baseline, an OTEC plant with an electrical output of 100 MWe which would power an aluminum reduction plant. The reduction plant would have a nominal annual output of about 60,000 metric tons of aluminum metal. Three modes of operation were studied, viz: 1. A reduction plant on shore and a floating OTEC power plant moored offshore supplying energy by cable. 2. A reduction plant on shore and a floating OTEC power plant at sea supplying energy by means of an ''energy bridge.'' 3. A floating reduction plant on the same platform as the OTEC power plant. For the floating OTEC/aluminum plantship, three reduction processes were examined. 1. The conventional Hall process with prebaked anodes. 2. The drained cathode Hall cell process. 3. The aluminum chloride reduction process.

  15. Optomechanics of Single Aluminum Nanodisks.

    PubMed

    Su, Man-Nung; Dongare, Pratiksha D; Chakraborty, Debadi; Zhang, Yue; Yi, Chongyue; Wen, Fangfang; Chang, Wei-Shun; Nordlander, Peter; Sader, John E; Halas, Naomi J; Link, Stephan

    2017-04-12

    Aluminum nanostructures support tunable surface plasmon resonances and have become an alternative to gold nanoparticles. Whereas gold is the most-studied plasmonic material, aluminum has the advantage of high earth abundance and hence low cost. In addition to understanding the size and shape tunability of the plasmon resonance, the fundamental relaxation processes in aluminum nanostructures after photoexcitation must be understood to take full advantage of applications such as photocatalysis and photodetection. In this work, we investigate the relaxation following ultrafast pulsed excitation and the launching of acoustic vibrations in individual aluminum nanodisks, using single-particle transient extinction spectroscopy. We find that the transient extinction signal can be assigned to a thermal relaxation of the photoexcited electrons and phonons. The ultrafast heating-induced launching of in-plane acoustic vibrations reveals moderate binding to the glass substrate and is affected by the native aluminum oxide layer. Finally, we compare the behavior of aluminum nanodisks to that of similarly prepared and sized gold nanodisks.

  16. A Processing Map for Hot Deformation of an Ultrafine-Grained Aluminum-Magnesium-Silicon Alloy Prepared by Mechanical Milling and Hot Extrusion

    NASA Astrophysics Data System (ADS)

    Asgharzadeh, Hamed; Rahbar Niazi, Masoud; Simchi, Abdolreza

    2015-12-01

    Uniaxial compression test at different temperatures [573 K to 723 K (300 °C to 450 °C)] and strain rates (0.01 to 1 s-1) was employed to study the hot deformation behavior of an ultrafine-grained (UFG) Al6063 alloy prepared by the powder metallurgy route. The UFG alloy with an average grain size of ~0.3 µm was prepared by mechanical milling of a gas-atomized aluminum alloy powder for 20 hours followed by hot powder extrusion at 723 K (450 °C). To elaborate the effect of grain size, the aluminum alloy powder was extruded without mechanical milling to attain a coarse-grained (CG) structure with an average grain size of about 2.2 µm. By employing the dynamic materials model, processing maps for the hot deformation of the UFG and CG Al alloy were constructed. For investigation of microstructural evolutions and deformation instability occurring upon hot working, optical microscopy, scanning electron microscopy coupled with electron backscattered diffraction and transmission electron microscopy were utilized. It is shown that the grain refinement increases the deformation flow stress while reducing the strain hardening and power dissipation efficiency during the deformation process at the elevated temperatures. Restoration mechanisms, including dynamic recovery and recrystallization are demonstrated to control microstructural evolutions and thus the deformation behavior. Coarsening of the grain structure in the UFG alloy is illustrated, particularly when the deformation is performed at high temperatures and low strain rates. The manifestations of instability are observed in the form of cracking and void formation.

  17. Aluminum-stabilized NB3SN superconductor

    DOEpatents

    Scanlan, Ronald M.

    1988-01-01

    An aluminum-stabilized Nb.sub.3 Sn superconductor and process for producing same, utilizing ultrapure aluminum. Ductile components are co-drawn with aluminum to produce a conductor suitable for winding magnets. After winding, the conductor is heated to convert it to the brittle Nb.sub.3 Sn superconductor phase, using a temperature high enough to perform the transformation but still below the melting point of the aluminum. This results in reaction of substantially all of the niobium, while providing stabilization and react-in-place features which are beneficial in the fabrication of magnets utilizing superconducting materials.

  18. Low-aluminum content iron-aluminum alloys

    SciTech Connect

    Sikka, V.K.; Goodwin, G.M.; Alexander, D.J.

    1995-06-01

    The low-aluminum-content iron-aluminum program deals with the development of a Fe-Al alloy with aluminum content such as a produce the minimum environmental effect at room temperature. The FAPY is an Fe-16 at. % Al-based alloy developed at the Oak Ridge National Laboratory as the highest aluminum-containing alloy with essentially no environmental effect. The chemical composition for FAPY in weight percent is: aluminum = 8.46, chromium = 5.50, zirconium = 0.20, carbon = 0.03, molybdenum = 2.00, yttrium = 0.10 and iron = 83.71. The ignots of the alloy can be hot worked by extrusion, forging, and rolling processes. The hot-worked cast structure can be cold worked with intermediate anneals at 800{degrees}C. Typical room-temperature ductility of the fine-grained wrought structure is 20 to 25% for this alloy. In contrast to the wrought structure, the cast ductility at room temperature is approximately 1% with a transition temperature of approximately 100 to 150{degrees}C, above which ductility values exceed 20%. The alloy has been melted and processed into bar, sheet, and foil. The alloy has also been cast into slabs, step-blocks of varying thicknesses, and shapes. The purpose of this section is to describe the welding response of cast slabs of three different thicknesses of FAPY alloy. Tensile, creep, and Charpy-impact data of the welded plates are also presented.

  19. Nanostructure of aluminum oxide inclusion and formation of hydrogen bubbles in molten aluminum.

    PubMed

    Zeng, Jianmin; Li, Dezhi; Kang, Minglong; He, Huan; Hu, Zhiliu

    2013-10-01

    Hydrogen in molten aluminum is one of the major factors that lead to pore formation in the solidification process of aluminum castings. Previous research showed that aluminum oxide inclusion had a close correlation with the hydrogen content in molten aluminum. Though some researchers thought there must have been a relationship between surface morphology of the inclusion and hydrogen concentration in molten aluminum, very few documents have reported on the surface property of aluminum oxide inclusion. In the present work, AFM (Atomic Force Microscope) was first used to investigate surface morphology of aluminum oxide inclusion in molten aluminum. It was found that there were a large number of nanoscale micropores on the surface of aluminum oxide inclusion. The interior of the micropores was approximated as a tapered shape. These micropores were thought to be helpful to heterogeneous nucleation for hydrogen atoms aggregation because they provided necessary concentration fluctuation and energy undulation for the growth of hydrogen bubbles. Based on the nanostructure observed on the surface of aluminum oxide inclusion, a theoretical model was developed to describe the hydrogen pore formation in aluminum casting under the condition of heterogeneous nucleation.

  20. 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.

  1. Correlating shaped charge performance with processing conditions and microstructure of an aluminum alloy 1100 liner enabled by a new method to arrest nascent jet formation

    NASA Astrophysics Data System (ADS)

    Scheid, James Eric

    Aluminum-lined shaped charges are used in special applications where jet and / or slug residue in the target is undesired. The three different microstructures of the aluminum liners studied herein resulted from three different manufacturing interpretations of the same design. One interpretation was completely machining the liners from best available annealed round stock. The second was to cold-forge the liners from annealed round-stock in an open-die forge to near-final dimensions, and then machine the liners to the final dimensions. The third variant in this study was to use the above forged liner, but with annealing after the machining. These three manufacturing choices resulted in significant variations in shaped charge performance. The goal of this research was to clarify the relationships between the liner metal microstructure and properties, and the corresponding shaped charge dynamic flow behavior. What began as an investigation into user-reported performance problems associated inherently with liner manufacturing processes and resultant microstructure, resolved into new understandings of the relationships between aluminum liner microstructure and shaped charge collapse kinetics. This understanding was achieved through an extensive literature review and the comprehensive characterization of the material properties of three variants of an 1100 aluminum shaped charge liner with a focus on collapse and nascent jet formation. The machined liner had a microstructure with large millimeter-sized grains and fine particles aligned in bands parallel to the charge axis. The forged liner microstructure consisted of very small one micrometer-sized (1 mum) subgrains and fine particles aligned largely in bands elongated parallel to the liner contour. The annealed liner was characterized by ten micrometer (10 mum) sized equiaxed grains with residual fine particles in the forged alignment. This characterization was enabled by the development, execution and validation of a

  2. UPDATE ON FRICTION BONDING OF MONOLITHIC U-MO FUEL PLATES

    SciTech Connect

    D. E. Burkes; N. P. Hallinan; J. M. Wight; M. D. Chapple

    2007-09-01

    Friction Bonding (FB), formerly referred to as Friction Stir Welding, is an alternative plate fabrication technique to encapsulate monolithic U-Mo fuel foils inside 6061-T6 aluminum alloy cladding. Over the past year, significant progress has been made in the area of FB, including improvements in tool material, tool design, process parameters, cooling capability and capacity and modeling, all of which improve and enhance the quality of fabricated fuel plates, reproducibility of the fabrication process and bond quality of the fuel plates. Details of this progress and how it relates to the observed improvements and enhancements are discussed. In addition, details on how these improvements have been implemented into the last two RERTR mini-plate irradiation campaigns are also discussed.

  3. Update on friction bonding of monolithic U-Mo fuel plates

    SciTech Connect

    Burkes, D.E.; Hallinan, N.P.; Wight, J.M.; Chapple, M.D.

    2008-07-15

    Friction Bonding (FB), formerly referred to as Friction Stir Welding, is an alternative plate fabrication technique to encapsulate monolithic U-Mo fuel foils inside 6061-T6 aluminum alloy cladding. Over the past year, significant progress has been made in the area of FB, including improvements in tool material, tool design, process parameters, cooling capability and capacity and modeling, all of which improve and enhance the quality of fabricated fuel plates, reproducibility of the fabrication process and bond quality of the fuel plates. Details of this progress and how it relates to the observed improvements and enhancements are discussed. In addition, details on how these improvements have been implemented into the last two RERTR mini-plate irradiation campaigns are also discussed. (author)

  4. The chemistry of iron, aluminum, and dissolved organic material in three acidic, metal-enriched, mountain streams, as controlled by watershed and in-stream processes

    USGS Publications Warehouse

    McKnight, Diane M.; Bencala, Kenneth E.

    1990-01-01

    Several studies were conducted in three acidic, metal-enriched, mountain streams, and the results are discussed together in this paper to provide a synthesis of watershed and in-stream processes controlling Fe, Al, and DOC (dissolved organic carbon) concentrations. One of the streams, the Snake River, is naturally acidic; the other two, Peru Creek and St. Kevin Gulch, receive acid mine drainage. Analysis of stream water chemistry data for the acidic headwaters of the Snake River shows that some trace metal solutes (Al, Mn, Zn) are correlated with major ions, indicating that watershed processes control their concentrations. Once in the stream, biogeochemical processes can control transport if they occur over time scales comparable to those for hydrologic transport. Examples of the following in-stream reactions are presented: (1) photoreduction and dissolution of hydrous iron oxides in response to an experimental decrease in stream pH, (2) precipitation of Al at three stream confluences, and (3) sorption of dissolved organic material by hydrous iron and aluminum oxides in a stream confluence. The extent of these reactions is evaluated using conservative tracers and a transport model that includes storage in the substream zone.

  5. Effect of Temperature and Velocity of Pressing on Grain Refinement in AA5083 Aluminum Alloy During Repetitive Corrugation and Straightening Process

    NASA Astrophysics Data System (ADS)

    Thangapandian, N.; Balasivanandha Prabu, S.; Padmanabhan, K. A.

    2016-12-01

    Repetitive corrugation and straightening experiments were carried out on sheets of aluminum alloy, AA5083, at room temperature and 573 K (300 °C) and two pressing velocities (0.5 and 2 mm/s). In every case, the sheet was processed to the maximum possible number of passes. Electron backscattered diffraction analysis and transmission electron microscopy were used to characterize microstructure evolution. After room temperature processing with a pressing velocity of 0.5 mm/s, the average grain size had decreased to 11 microns from 45 microns, with 70 pct of the grain boundaries of the high-angle type. In contrast, sub-grain formation was present at a pressing velocity of 2 mm/s. Mechanical properties like tensile strength and hardness were correlated with microstructures. It is concluded that the velocity of pressing plays a crucial role in grain refinement and recovery and the resulting mechanical properties, as the time available for dislocation rearrangements during processing depends strongly on this variable. An increase in temperature of deformation leads to softening and a deterioration in the mechanical properties.

  6. Welding of Aluminum Alloys to Steels: An Overview

    DTIC Science & Technology

    2013-08-01

    95] K. Kimapong1, T. Watanabe, Effect of welding process parameters on mechanical property of FSW lap joint between aluminum alloy and steel ...UNCLASSIFIED: Distribution Statement A. Approved for public release. 1 UNCLASSIFIED Welding of aluminum alloys to steels : an overview M. Mazar...welding methods for joining aluminum alloys to steels . The microstructural development, mechanical properties and application of the joints are discussed

  7. LDEF (Postflight)

    NASA Technical Reports Server (NTRS)

    1990-01-01

    LDEF (Postflight) The viscous magnetic damper housing is shown after removal from the interior of the LDEF. The spherical dome is fabricated from 1/32 inch thick 6061-T6 aluminum alloy sheet and is attached to the cylindrical base with aluminum screws. The cylindrical portion of the housing is a fiberglass (181 cloth / epon 828 resin) structure is covered with an aluminum tape, both inside and outside, to meet thermal control requirements. The mounting plate material is 6061-T6 aluminum alloy, with the top and bottom surfaces covered with aluminum tape. A thermistor is mounted in the top center of the dome to provide house keeping data. The lead wire, covered with a strip of aluminum tape, can be seen along the housing periphery. The assembled damper housing, with the damper inside, is mounted to the space end frame with stainless steel fasteners.

  8. Specific features of aluminum nanoparticle water and wet air oxidation

    SciTech Connect

    Lozhkomoev, Aleksandr S. Glazkova, Elena A. Svarovskaya, Natalia V. Bakina, Olga V. Kazantsev, Sergey O. Lerner, Marat I.

    2015-10-27

    The oxidation processes of the electrically exploded aluminum nanopowders in water and in wet air are examined in the paper. The morphology of the intermediate reaction products of aluminum oxidation has been studied using the transmission electron microscopy. It was shown that the aluminum nanopowder water oxidation causes the formation of the hollow spheres with mesoporous boehmite nanosheets coating. The wedge-like bayerite particles are formed during aluminum nanopowder wet air oxidation.

  9. Crystal Plasticity Analysis of Texture Evolution of Pure Aluminum During Processing by a New Severe Plastic Deformation Technique

    NASA Astrophysics Data System (ADS)

    Khajezade, Ali; Parsa, Mohammad Habibi; Mirzadeh, Hamed

    2016-02-01

    Texture evolution in a newly developed severe plastic deformation technique, named multi-axial incremental forging and shearing (MAIFS), was studied applying the visco-plastic self-consistent crystal plasticity formulation by consideration of macroscopic deformation history. The simulated texture evolutions revealed that although shear-like texture had developed by the MAIFS process, texture components rotated around normal to mid-plane section. This could be ascribed to the complex deformation history that naturally develops during processing by the MAIFS process. The increased complexity of the deformation history in the MAIFS process, compared to the techniques that are solely based on the simple shear deformation, causes more activated slip planes, which in turn can result in an enhanced grain refinement ability of this processing technique.

  10. Cryomilled Aluminum Stabilized by Diamondoid Nanoparticles

    NASA Astrophysics Data System (ADS)

    Maung, Khinlay

    Nanocrystalline aluminum powder with an average grain size of 22nm was prepared via cryomilling. Hot Isostatic Pressing was used to consolidate the powder followed by hot extrusion to homogenize the consolidated material. The high homologous temperature processes tend to increase the average grain diameter beyond the nanoscle classification, which is less than 100 nm. Diamantane was added during cryomilling to enhance the thermal stability in nanocrystalline aluminum. The thermal stability test data show that aluminum reinforced with 1 wt% diamantane exhibit two to three fold better thermal stability than non-reinforced aluminum when annealed at 773K (0.84 Tm) for ten hours. A similar trend is shown for the samples consolidated at 693K. This finding is explained through Burke's model for grain growth in materials containing secondary particles to inhibit grain boundary motion. The mechanical properties of cryomilled aluminum stabilized by 0.5 wt% and 1 wt% diamantane particles are compared with cryomilled commercial purity (CP) aluminum with no diamantane after high strain rate deformation (trap extrusion). The grain size of cryomilled CP aluminum is 0.6 to 1.2 times larger than the samples containing diamantane. In contrast to Hall-petch predictions, cryomilled aluminum with diamantane has relatively lower flow stress while demonstrating a 2.7-3.7 time higher ductility compared to cryomilled CP aluminum. Possible reasons for this behavior are suggested in mechnical property section. A combination of higher temperature and pressure resulted in formation of Aluminum tris (Al(C9H6NO)3) precipitates from diamantane in the cryomilled aluminum matrix. The precipitates were formed during trap extrusion process but only seen in samples containing 1 wt% diamantane and HIP'ed at 521°C. Therefore, the HIP'ng temperature plays an important role in formation of these precipitates.

  11. Effect of pH with different purified aluminum species on coagulation performance and membrane fouling in coagulation/ultrafiltration process.

    PubMed

    Feng, Lijuan; Zhao, Shuang; Sun, Shenglei; Wang, Wenyu; Gao, Baoyu; Yue, Qinyan

    2015-12-30

    The influences of solution pH on coagulation/ultrafiltration (C-UF) process were investigated by using three purified Al species of polyaluminium chloride (PACl). A series of online-simulation experiments were developed to assess the coagulation removal efficiencies (turbidity, UV254), floc properties and membrane fouling in this paper. The results showed that change of pH had a significant impact on coagulation efficiencies, floc properties, membrane flux as well as the whole process. Under acidic condition, the hydrolysis action of aluminum salts was restrained which is bad for charge neutralization. While under alkaline region, absorption was the dominant mechanism to combine HA-Kaolin. Meanwhile, HA is apt to soluble by deprotonating under alkaline region which is hard to remove. These common effects made the experiment results complex. HA removal efficiency of Ala and Alb were higher than that of Alc, but the turbidity removal by Alc was slightly higher under the same pH condition. Flocs generated by Ala at pH 6 had advantages such as larger size and the most loosely structure which contributed the most to alleviating membrane fouling. Membrane fouling with Alb and Alc in alkaline range was more serious than that in acidic range.

  12. Measurement of tool forces in diamond turning

    SciTech Connect

    Drescher, J.; Dow, T.A.

    1988-12-01

    A dynamometer has been designed and built to measure forces in diamond turning. The design includes a 3-component, piezoelectric transducer. Initial experiments with this dynamometer system included verification of its predicted dynamic characteristics as well as a detailed study of cutting parameters. Many cutting experiments have been conducted on OFHC Copper and 6061-T6 Aluminum. Tests have involved investigation of velocity effects, and the effects of depth and feedrate on tool forces. Velocity has been determined to have negligible effects between 4 and 21 m/s. Forces generally increase with increasing depth of cut. Increasing feedrate does not necessarily lead to higher forces. Results suggest that a simple model may not be sufficient to describe the forces produced in the diamond turning process.

  13. Process for the production of metal nitride sintered bodies and resultant silicon nitride and aluminum nitride sintered bodies

    NASA Technical Reports Server (NTRS)

    Yajima, S.; Omori, M.; Hayashi, J.; Kayano, H.; Hamano, M.

    1983-01-01

    A process for the manufacture of metal nitride sintered bodies, in particular, a process in which a mixture of metal nitrite powders is shaped and heated together with a binding agent is described. Of the metal nitrides Si3N4 and AIN were used especially frequently because of their excellent properties at high temperatures. The goal is to produce a process for metal nitride sintered bodies with high strength, high corrosion resistance, thermal shock resistance, thermal shock resistance, and avoidance of previously known faults.

  14. ALUMINUM-CONTAINING POLYMERS

    DTIC Science & Technology

    ALUMINUM COMPOUNDS, *ORGANOMETALLIC COMPOUNDS, *POLYMERIZATION, *POLYMERS, ACRYLIC RESINS, ALKYL RADICALS, CARBOXYLIC ACIDS, COPOLYMERIZATION, LIGHT TRANSMISSION, STABILITY, STYRENES, TRANSPARENT PANELS.

  15. Spray Rolling Aluminum Strip

    SciTech Connect

    Lavernia, E.J.; Delplanque, J-P; McHugh, K.M.

    2006-05-10

    Spray forming is a competitive low-cost alternative to ingot metallurgy for manufacturing ferrous and non-ferrous alloy shapes. It produces materials with a reduced number of processing steps, while maintaining materials properties, with the possibility of near-net-shape manufacturing. However, there are several hurdles to large-scale commercial adoption of spray forming: 1) ensuring strip is consistently flat, 2) eliminating porosity, particularly at the deposit/substrate interface, and 3) improving material yield. Through this program, a new strip/sheet casting process, termed spray rolling, has been developed, which is an innovative manufacturing technique to produce aluminum net-shape products. Spray rolling combines the benefits of twin-roll casting and conventional spray forming, showing a promising potential to overcome the above hurdles associated with spray forming. Spray rolling requires less energy and generates less scrap than conventional processes and, consequently, enables the development of materials with lower environmental impacts in both processing and final products. Spray Rolling was developed as a collaborative project between the University of California-Davis, the Colorado School of Mines, the Idaho National Engineering and Environmental Laboratory, and an industry team. The following objectives of this project were achieved: (1) Demonstration of the feasibility of the spray rolling process at the bench-scale level and evaluation of the materials properties of spray rolled aluminum strip alloys; and (2) Demonstration of 2X scalability of the process and documentation of technical hurdles to further scale up and initiate technology transfer to industry for eventual commercialization of the process.

  16. A study on a thixoforming process using the thixotropic behavior of an aluminum alloy with an equiaxed microstructure

    NASA Astrophysics Data System (ADS)

    Jung, H. K.; Kang, C. G.

    2000-10-01

    Alloys with an equiaxed microstructure exhibit significantly lower flow resistance in the semisolid state than alloys with a dendritic microstructure. Their thixotropic behavior (solidlike in the unperturbed state and liquidlike during shearing) has been the basis for a thixoforming process. It is accepted today that thixoforming is a new net-shaped manufacturing technology in which the billet is heated to the semisolid state with coexisting solid-liquid phases. The thixoforming process has some industrial advantages, such as the successful fabrication of high-quality components with fewer inner defects, suitable for less machining, high productivity comparable to high-pressure die casting, and being an energy-saving system without the conventional melting process. It consists of inductive coil design, a billet reheating process, billet handling, filling into the die cavity, and solidification of the thixoformed part. This work presents an overview of all the detailed stages in the thixoforming process to manufacture the net-shaped product with good mechanical properties. An air compressor part with high strength has been fabricated by the thixoforming process.

  17. Aluminum recovery as a product with high added value using aluminum hazardous waste.

    PubMed

    David, E; Kopac, J

    2013-10-15

    The samples of hazardous aluminum solid waste such as dross were physically and chemically characterized. A relationship between density, porosity and metal content of dross was established. The paper also examines the chemical reactions involving aluminum dross in landfill and the negative consequences. To avoid environmental problems and to recovery the aluminum, a processing method was developed and aluminum was recovered as an added value product such as alumina. This method refers to a process at low temperature, in more stages: acid leaching, purification, precipitation and calcination. At the end of this process aluminum was extracted, first as Al(3+) soluble ions and final as alumina product. The composition of the aluminum dross and alumina powder obtained were measured by applying the leaching tests, using atomic absorption spectrometry (AAS) and chemical analysis. The mineralogical composition of aluminum dross samples and alumina product were determined by X-ray diffraction (XRD) and the morphological characterization was performed by scanning electron microscopy (SEM). The method presented in this work allows the use of hazardous aluminum solid waste as raw material to recover an important fraction from soluble aluminum content as an added value product, alumina, with high grade purity (99.28%).

  18. Aluminum and Young Artists.

    ERIC Educational Resources Information Center

    Anderson, Thomas

    1980-01-01

    The author suggests a variety of ways in which aluminum and aluminum foil can be used in elementary and junior high art classes: relief drawing and rubbing; printing; repousse; sculpture; mobiles; foil sculpture; and three dimensional design. Sources of aluminum supplies are suggested. (SJL)

  19. Aluminum plasmonic photocatalysis

    PubMed Central

    Hao, Qi; Wang, Chenxi; Huang, Hao; Li, Wan; Du, Deyang; Han, Di; Qiu, Teng; Chu, Paul K.

    2015-01-01

    The effectiveness of photocatalytic processes is dictated largely by plasmonic materials with the capability to enhance light absorption as well as the energy conversion efficiency. Herein, we demonstrate how to improve the plasmonic photocatalytic properties of TiO2/Al nano-void arrays by overlapping the localized surface plasmon resonance (LSPR) modes with the TiO2 band gap. The plasmonic TiO2/Al arrays exhibit superior photocatalytic activity boasting an enhancement of 7.2 folds. The underlying mechanisms concerning the radiative energy transfer and interface energy transfer processes are discussed. Both processes occur at the TiO2/Al interface and their contributions to photocatalysis are evaluated. The results are important to the optimization of aluminum plasmonic materials in photocatalytic applications. PMID:26497411

  20. Airmobile Shelter Analysis. Volume 2

    DTIC Science & Technology

    1994-02-01

    against wind loads. The roof is supported by lightweight aluminum trusses whiie the floor is supported by a system of beams and girders . Therefore, the...ranging from 28 to 74 feet. System 100 Clamshelters substitute aluminum trusses for the beams and provide spans of 94 to 200feet. Fabric for both...frames are constructed using hot dipped galvanized steel trusses (A36 steel) while the FSTFS uses extruded aluminum box beams (6061-T6). The fabric

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

    SciTech Connect

    Weiss, David C.; Gegal, Gerald A.

    2014-04-15

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

  2. Effect of some process parameters on geometric errors in twopoint incremental forming for Al-Cu-Mg Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Li, Xiaoqiang; Han, Kai; Yu, Honghan; Zhang, Yongsheng; Li, Dongsheng

    2016-08-01

    Two point incremental forming receives widespread study with its advantages of economy and flexibility in small batch products, such as aircraft parts. Aircraft parts, however, are rigorous in their shape errors. In this paper, one real airplane part is selected and formed with different process parameters to investigate the shape error level of part. Comparing the geometric errors caused by different process parameters, such as tool diameter, step size, feed rate and tool path, it is found that the geometric errors reduce as tool diameter increases. Meanwhile, the effect of step size is not linear. Influence law of feed rate is various with different other parameters. The bidirectional tool path, having opposite processing direction at adjacent layer, reduces the errors.

  3. Adsorption of aluminum and lead from wastewater by chitosan-tannic acid modified biopolymers: Isotherms, kinetics, thermodynamics and process mechanism.

    PubMed

    Badawi, M A; Negm, N A; Abou Kana, M T H; Hefni, H H; Abdel Moneem, M M

    2017-06-01

    Chitosan was reacted by tannic acid to obtain three modified chitosan biopolymer. Their chemical structures were characterized by FTIR and elemental analysis. The prepared biopolymers were used to adsorb Al(III) and Pb(II) metal ions from industrial wastewater. The factors affecting the adsorption process were biosorbent amount, initial concentration of metal ion and pH of the medium. The adsorption efficiency increased considerably with the increase of the biosorbent amount and pH of the medium. The adsorption process of biosorbent on different metal ions was fitted by Freundlich adsorption model. The adsorption kinetics was followed Pseudo-second-order kinetic model. The adsorption process occurred according to diffusion mechanism which was confirmed by the interparticle diffusion model. The modified biopolymers were efficient biosorbents for removal of Pb(II) and Al(III) metal ions from the medium.

  4. Numerical investigation on the growth process and size distribution of nanoparticles obtained through electrical explosion of aluminum wire

    NASA Astrophysics Data System (ADS)

    Bai, Jun; Shi, Zongqian; Jia, Shenli

    2017-02-01

    Numerical investigations on the formation process and the final size distribution of nanoparticles during electrical explosion of Al wire are carried out. Firstly, the formation of the atomic vapor clusters is investigated. It indicates that the Al wire does not reach its atomization conditions. The size of the atomic vapor clusters is obtained, and it increases with the temperature at explosion. Then the growth process of Al nanoparticles from the formed atomic vapor clusters is modeled and the size distribution is predicted. The size distribution at different temperatures indicates that the growth process of Al nanoparticles becomes inactive gradually as the temperature decreases. The investigation of the size distribution under different cooling rates indicates that the bigger cooling rate is favorable for the formation of Al nanoparticles with smaller size dispersion and lower average dimension. The size distribution of Al nanoparticles obtained by the model is qualitatively consistent with the experimental data, which demonstrates the feasibility of this model.

  5. Evaluation of the Effects of Rotary Degassing Process Variables on the Quality of A357 Aluminum Alloy Castings

    NASA Astrophysics Data System (ADS)

    Mostafaei, M.; Ghobadi, M.; Eisaabadi B., Ghasem; Uludağ, Muhammet; Tiryakioğlu, Murat

    2016-12-01

    The effects of rotary degassing process variables on the melt and casting quality have been investigated using reduced pressure test results and quality index calculations from tensile data. The results showed that the effectiveness of the rotary degassing process of Al alloys is highly dependent on the combination of rotational speed and the gas flow rate, and that the wrong combination of these factors may result in no improvement or even degradation in quality of castings. For the first time, it has been found that the effectiveness of the pouring and filling system to produce high-quality castings can be characterized numerically. This new method of quantifying the casting system is introduced as a new quality improvement tool for materials and process engineers.

  6. Thermomechanical Processing and Ambient Temperature Properties of a 6061 Aluminum 10 Volume Percent Alumina Metal Matrix Composite

    DTIC Science & Technology

    1990-03-01

    Submitted in partial fulfillment of the requirements for the degree of’ MASTER OF SCIENCE IN MECHANICAL ENGINEERING from the NAVAL POSTGRADUATE SCHOOL March... Mechanical Properties................. 15 3. Effects of Processing on Particle Size...........................16 C. AGE HARDENING STUDY...modulus * density - elevated temperature strength - thermal and electrical conductivities - corrosion and abrasion resistance. Furthermore, mechanical

  7. Optimization of Deposition Process and Microscopic Characterization of Highly Oriented Aluminum Nitride Thin Films for Bimorph Structures of Piezoelectric Tunable Capacitors

    NASA Astrophysics Data System (ADS)

    Nagano, Toshihiko; Nishigaki, Michihiko; Itaya, Kazuhiko; Kawakubo, Takashi

    2009-02-01

    Film deposition with RF sputtering to control residual stress in aluminum nitride (AlN) thin films has been investigated to fabricate the bimorph actuator for a piezoelectric tunable capacitor with low-voltage operation. The effects of conditions in sputtering and surface cleaning were studied both to obtain a preferable film orientation for piezoelectric actuation and to suppress structural deformation of the cantilever due to the residual stress in films. Microscopic analysis revealed that (0001)-oriented AlN and (111)-oriented Al films were epitaxially grown at each interface in the bimorph structure. The current-voltage (I-V) measurements showed a leakage current of less than 5 ×10-5 A m-2 in 500-nm thick AlN films up to 30 V. The effect of optimization of process parameters was demonstrated by the capacitance-voltage (C-V) characteristics of the folded-beam tunable capacitor, in which the suppression of residual stress in piezoelectric layers was shown to be effective to obtain low-voltage operation.

  8. 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

    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).

  9. QUALIFICATION OF A RADIOACTIVE HIGH ALUMINUM GLASS FOR PROCESSINGIN THE DEFENSE WASTE PROCESSING FACILITY AT THE SAVANNAH RIVER SITE

    SciTech Connect

    Bibler, N; John Pareizs, J; Tommy Edwards,T; Charles02 Coleman, C; Charles Crawford, C

    2008-01-29

    At the Savannah River Site (SRS) the Defense Waste Processing Facility (DWPF) has been immobilizing SRS's radioactive high level waste (HLW) sludge into a borosilicate glass for approximately eleven years. Currently the DWPF is immobilizing HLW sludge in Sludge Batch 4 (SB4). Each sludge batch is nominally two million liters of HLW and produces nominally five hundred stainless steel canisters 0.6 meters in diameter and 3 meters tall filled with the borosilicate glass. In SB4 and earlier sludge batches, the Al concentration has always been rather low, (less than 9.5 weight percent based on total dried solids). It is expected that in the future the Al concentrations will increase due to the changing composition of the HLW. Higher Al concentrations could introduce problems because of its known effect on the viscosity of glass melts and increase the possibility of the precipitation of nepheline in the final glass and decrease its durability. In 2006 Savannah River National Laboratory (SRNL) used DWPF processes to immobilize a radioactive HLW slurry containing 14 weight percent Al to ensure that this waste is viable for future DWPF processing. This paper presents results of the characterization of the high Al glass prepared in that demonstration. At SRNL, a sample of the processed high Al HLW slurry was mixed with an appropriate glass frit as performed in the DWPF to make a waste glass containing nominally 30% waste oxides. The glass was prepared by melting the frit and waste remotely at 1150 C. The glass was then characterized by: (1) determining the chemical composition of the glass including the concentrations of several actinide and U-235 fission products; (2) calculating the oxide waste loading of the glass based on the chemical composition and comparing it to that of the target; (3) determining if the glass composition met the DWPF processing constraints such as glass melt viscosity and liquidus temperature along with a waste form affecting constraint that

  10. Novel applications of microwaves in the metallurgical processing of a nickel-ferrous laterite ore and an aluminum industry waste

    NASA Astrophysics Data System (ADS)

    Samouhos, M.; Taxiarchou, M.; Kouvelos, E.

    2016-04-01

    Microwave radiation is a relatively new source of energy in the pyrometallurgical process. In this study, the application of microwaves in the carbothermic reductive roasting of a nickeliferous hematitic laterite ore and a red mud are investigated. The effective microwave heating (at temperatures above 900°C) of the aforementioned materials is attainable due to the relatively high values of their imaginary permittivity (ε")- In both two cases, the reduction of the included hematite was attempted, and the reduction degree was calculated as a function of: (a) the heating time and (b) the supplied microwave power. The mechanism of Fe+3 to Fe0 conversion was investigated using Mössbaurer spectroscopy revealing the formation of magnetite, fayalite and nano-structured metallic iron. Finally, it should be noted that that the gaseous products of the microwave pyrometallurgical process were analyzed using a mass spectroscopic technique, which is an important novelty.

  11. Examination of the physical processes associated with the keyhole region of variable polarity plasma arc welds in aluminum alloy 2219

    NASA Technical Reports Server (NTRS)

    Walsh, Daniel W.

    1987-01-01

    The morphology and properties of the Variable Polarity Plasma Arc (VPPA) weld composite zone are intimately related to the physical processes associated with the keyhole. This study examined the effects of oxide, halide, and sulfate additions to the weld plate on the keyhole and the weld pool. Changes in both the arc plasma character and the bead morphology were correlated to the chemical environment of the weld. Pool behavior was observed by adding flow markers to actual VPPA welds. A low temperature analog to the welding process was developed. The results of the study indicate that oxygen, even at low partial pressures, can disrupt the stable keyhole and weld pool. The results also indicate that the Marangoni surface tension driven flows dominate the weld pool over the range of welding currents studied.

  12. Femtosecond laser processing of fused silica and aluminum based on electron dynamics control by shaping pulse trains

    NASA Astrophysics Data System (ADS)

    Leng, Ni; Jiang, Lan; Li, Xin; Xu, Chuancai; Liu, Pengjun; Lu, Yongfeng

    2012-11-01

    The pulse train effects on femtosecond laser material processing are investigated from the viewpoint of electron dynamics on dielectrics with fused silica as a case study and metals with Al as a case study in air and water. During femtosecond laser (800 nm, 35 fs) pulse train (double pulses per train) processing of fused silica, a non-monotonic relationship between ablation size and pulse separation is observed with an abrupt rise in the range of 150-275 fs. It is assumed that this is due to the enhancement of photon-electron coupling efficiency and transition of the phase-change mechanism by adjusting the free electron density during pulse train ablation. Surface quality in Al is improved with less recast by designing the pulse energy distribution to adjust the electron/lattice temperature distribution. Furthermore, the positive effects on ablation quality by femtosecond pulse train technology are more significant in water than those in air.

  13. Improving Microstructure and Mechanical Properties for Large-Diameter 7075 Aluminum Alloy Ingots by a Forced Convection Stirring Casting Process

    NASA Astrophysics Data System (ADS)

    Qi, Mingfan; Kang, Yonglin; Zhu, Guoming; Li, Yangde; Li, Weirong

    2017-04-01

    A simple process so-called forced convection stirring casting (FCSC) was proposed to prepare large-diameter 7075 Al alloy ingots. The flow behavior, temperature, and composition fields of the melt in the FCSC process were simulated. The macromorphology, macrosegregation, microstructure, and mechanical properties of the ingots prepared by the FCSC were studied and compared with those prepared by normal casting (NC). The results showed that in the FCS device, the strong convection caused by the axial flow and circular flow rapidly promoted the uniformity of the temperature and composition fields of the melt. Microstructures of the FCSC ingots from the edge to the center were all nearly spherical grains, which were much finer and more uniform than that of the NC ingots. The rotation speed played an important role in the microstructure of the FCSC ingots, and the grains became finer and rounder as the speed increasing. The FCSC process effectively eliminated cracks, improved macrosegregation, and decreased the eutectic phase area fraction and the average grain boundary thickness of ingots. Mechanical properties of the ingots prepared by the FCSC are far better than that of the NC ingots.

  14. Improving Microstructure and Mechanical Properties for Large-Diameter 7075 Aluminum Alloy Ingots by a Forced Convection Stirring Casting Process

    NASA Astrophysics Data System (ADS)

    Qi, Mingfan; Kang, Yonglin; Zhu, Guoming; Li, Yangde; Li, Weirong

    2017-01-01

    A simple process so-called forced convection stirring casting (FCSC) was proposed to prepare large-diameter 7075 Al alloy ingots. The flow behavior, temperature, and composition fields of the melt in the FCSC process were simulated. The macromorphology, macrosegregation, microstructure, and mechanical properties of the ingots prepared by the FCSC were studied and compared with those prepared by normal casting (NC). The results showed that in the FCS device, the strong convection caused by the axial flow and circular flow rapidly promoted the uniformity of the temperature and composition fields of the melt. Microstructures of the FCSC ingots from the edge to the center were all nearly spherical grains, which were much finer and more uniform than that of the NC ingots. The rotation speed played an important role in the microstructure of the FCSC ingots, and the grains became finer and rounder as the speed increasing. The FCSC process effectively eliminated cracks, improved macrosegregation, and decreased the eutectic phase area fraction and the average grain boundary thickness of ingots. Mechanical properties of the ingots prepared by the FCSC are far better than that of the NC ingots.

  15. EBSD Study on Grain Boundary and Microtexture Evolutions During Friction Stir Processing of A413 Cast Aluminum Alloy

    NASA Astrophysics Data System (ADS)

    Shamanian, Morteza; Mostaan, Hossein; Safari, Mehdi; Szpunar, Jerzy A.

    2016-07-01

    The as-cast Al alloys contain heterogeneous distributions of non-deforming particles due to non-equilibrium solidification effects. Therefore, these alloys have poor tribological and mechanical behaviors. It is well known that using friction stir processing (FSP), very fine microstructure is created in the as-cast Al alloys, while their wear resistance can be improved. In this research work, FSP is used to locally refine a surface layer of the coarse as-cast microstructure of cast A413 Al alloy. The main objective of this study is to investigate the effect of FSP on microstructure and microtexture evolutions in A413 cast Al alloy. The grain boundary character distribution, grain structure, and microtexture evolutions in as-cast and friction stir processed A413 Al alloy are analyzed by electron back scatter diffraction technique. It is found that with the FSP, the fraction of low ∑boundary such as ∑3, 7, and 9 are increased. The obtained results show that there are no deformation texture components in the structure of friction stir processed samples. However, some of the main recrystallization texture components such as BR and cubeND are formed during FSP which indicate the occurrence of dynamic recrystallization phenomenon due to the severe plastic deformation induced by the rotation of tool.

  16. Spray Rolling Aluminum Strip for Transportation Applications

    SciTech Connect

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

    2005-02-01

    Spray rolling is a novel strip casting technology in which molten aluminum alloy is atomized and deposited into the roll gap of mill rolls to produce aluminum strip. A combined experimental/modeling approach has been followed in developing this technology with active participation from industry. The feasibility of this technology has been demonstrated at the laboratory scale and it is currently being scaled-up. This paper provides an overview of the process and compares the microstructure and properties of spray-rolled 2124 aluminum alloy with commercial ingot-processed material

  17. CATALYST ACTIVITY MAINTENANCE FOR THE LIQUID PHASE SYNTHESIS GAS-TO-DIMETHYL ETHER PROCESS PART II: DEVELOPMENT OF ALUMINUM PHOSPHATE AS THE DEHYDRATION CATALYST FOR THE SINGLE-STEP LIQUID PHASE SYNGAS-TO-DME PROCESS

    SciTech Connect

    Xiang-Dong Peng

    2002-05-01

    At the heart of the single-step liquid phase syngas-to-DME process (LPDME{trademark}) is a catalyst system that can be active as well as stable. In the Alternative Fuels I program, a dual-catalyst system containing a Cu-based commercial methanol synthesis catalyst (BASF S3-86) and a commercial dehydration material ({gamma}-alumina) was demonstrated. It provided the productivity and selectivity expected from the LPDME process. However, the catalyst system deactivated too rapidly to warrant a viable commercial process [1]. The mechanistic investigation in the early part of the DOE's Alternative Fuels II program revealed that the accelerated catalyst deactivation under LPDME conditions is due to detrimental interaction between the methanol synthesis catalyst and methanol dehydration catalyst [2,3]. The interaction was attributed to migration of Cu- and/or Zn-containing species from the synthesis catalyst to the dehydration catalyst. Identification of a dehydration catalyst that did not lead to this detrimental interaction while retaining adequate dehydration activity was elusive. Twenty-nine different dehydration materials were tested, but none showed the desired performance [2]. The search came to a turning point when aluminum phosphate was tested. This amorphous material is prepared by precipitating a solution containing Al(NO{sub 3}){sub 3} and H{sub 3}PO{sub 4} with NH{sub 4}OH, followed by washing, drying and calcination. The aluminum phosphate catalyst has adequate dehydration activity and good stability. It can co-exist with the Cu-based methanol synthesis catalyst without negatively affecting the latter catalyst's stability. This report documents the details of the development of this catalyst. These include initial leads, efforts in improving activity and stability, investigation and development of the best preparation parameters and procedures, mechanistic understanding and resulting preparation guidelines, and the accomplishments of this work.

  18. Virus inactivation in aluminum and polyaluminum coagulation.

    PubMed

    Matsui, Yoshihiko; Matsushita, Taku; Sakuma, Satoru; Gojo, Takahito; Mamiya, Teppei; Suzuoki, Hiroshi; Inoue, Takanobu

    2003-11-15

    Inorganic aluminum salts, such as aluminum sulfate, are coagulants that cause small particles, such as bacteria and viruses as well as inorganic particles, to destabilize and combine into larger aggregates. In this investigation, batch coagulation treatments of water samples spiked with Qbeta, MS2, T4, and P1 viruses were conducted with four different aluminum coagulants. The total infectious virus concentration in the suspension of floc particles that eventually formed by dosing with coagulant was measured after the floc particles were dissolved by raising the pH with an alkaline beef extract solution. The virus concentrations were extremely reduced after the water samples were dosed with aluminum coagulants. Viruses mixed with and adsorbed onto preformed aluminum hydroxide floc were, however, completely recovered after the floc dissolution. These results indicated that the aluminum coagulation process inactivates viruses. Virucidal activity was most prominent with the prehydrolyzed aluminum salt coagulant, polyaluminum chloride (PACl). Virucidal activity was lower in river water than in ultrapure water--natural organic matter in the river water depressed the virucidal activity. Mechanisms and kinetics of the virus inactivation were discussed. Our results suggest that intermediate polymers formed during hydrolysis of the aluminum coagulants sorbed strongly to viruses, either rendering them inactive or preventing infectivity.

  19. 40 CFR 421.20 - Applicability: description of the primary aluminum smelting subcategory.

    Code of Federal Regulations, 2010 CFR

    2010-07-01

    ... primary aluminum smelting subcategory. 421.20 Section 421.20 Protection of Environment ENVIRONMENTAL... CATEGORY Primary Aluminum Smelting Subcategory § 421.20 Applicability: description of the primary aluminum... production of aluminum from alumina in the Hall-Heroult process....

  20. 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.

  1. 40 CFR 421.20 - Applicability: description of the primary aluminum smelting subcategory.

    Code of Federal Regulations, 2012 CFR

    2012-07-01

    ... primary aluminum smelting subcategory. 421.20 Section 421.20 Protection of Environment ENVIRONMENTAL... CATEGORY Primary Aluminum Smelting Subcategory § 421.20 Applicability: description of the primary aluminum... production of aluminum from alumina in the Hall-Heroult process....

  2. 40 CFR 421.20 - Applicability: description of the primary aluminum smelting subcategory.

    Code of Federal Regulations, 2013 CFR

    2013-07-01

    ... primary aluminum smelting subcategory. 421.20 Section 421.20 Protection of Environment ENVIRONMENTAL... CATEGORY Primary Aluminum Smelting Subcategory § 421.20 Applicability: description of the primary aluminum... production of aluminum from alumina in the Hall-Heroult process....

  3. 40 CFR 421.20 - Applicability: description of the primary aluminum smelting subcategory.

    Code of Federal Regulations, 2011 CFR

    2011-07-01

    ... primary aluminum smelting subcategory. 421.20 Section 421.20 Protection of Environment ENVIRONMENTAL... CATEGORY Primary Aluminum Smelting Subcategory § 421.20 Applicability: description of the primary aluminum... production of aluminum from alumina in the Hall-Heroult process....

  4. 40 CFR 421.20 - Applicability: description of the primary aluminum smelting subcategory.

    Code of Federal Regulations, 2014 CFR

    2014-07-01

    ... primary aluminum smelting subcategory. 421.20 Section 421.20 Protection of Environment ENVIRONMENTAL... CATEGORY Primary Aluminum Smelting Subcategory § 421.20 Applicability: description of the primary aluminum... production of aluminum from alumina in the Hall-Heroult process....

  5. 76 FR 323 - Aluminum Extrusions From the People's Republic of China: Notice of Amended Preliminary...

    Federal Register 2010, 2011, 2012, 2013, 2014

    2011-01-04

    ... which are shapes and forms, produced by an extrusion process, made from aluminum alloys having metallic elements corresponding to the alloy series designations published by The Aluminum Association commencing...). Specifically, the subject merchandise made from aluminum alloy with an Aluminum Association series...

  6. Cathodoluminescence spectroscopy studies of aluminum gallium nitride and silicon device structures as a function of irradiation and processing

    NASA Astrophysics Data System (ADS)

    White, Brad Derek

    Electronic device performance is critically dependent on the presence of deep-level and shallow states in the electronic band gap. A uniform or localized distribution of defects throughout a device structure can adversely affect doping and carrier transport, and result in changes to device saturation current, threshold voltage, ohmic contact resistivity, and Schottky barrier properties, including leakage currents. Process-induced atomic intermixing effects at heterostructure interfaces can cause decreases in sheet density and mobility of channel layers. For the presence of all such effects, the spatial variation across a given wafer can result in significant variation in device performance depending on spatial position. Spatially-resolved cathodoluminescence spectroscopy (CLS) has been used to identify the presence of radiative point and extended defects in the semiconductor band gap produced by irradiation and processing conditions for Si and GaN-based devices. Changes in deep level emission in Al-SiO2-Si capacitor structures revealed a gradient in relative defect concentrations across the SiO2 film after x-ray irradiation, indicating interface-specific defect creation. CLS measurements also revealed changes in the near-band edge signatures of AlGaN-GaN high-electron mobility transistor (HEMT) structures subjected to 1.8 MeV proton irradiation. These changes were indicative of alloying of AlGaN and GaN at the charge confinement interface and relaxation of piezoelectric strain in the AlGaN film. Alloying was investigated with secondary-ion mass spectrometry, which confirmed a broadened interface after a high fluence of proton irradiation. Both mechanisms contributed to the measured degradation in HEMT channel transport properties. Ni-GaN Schottky barrier height decreases and ideality factor increases were observed at lower fluences than the degradation in HEMT channel figures. Additionally, 1.0 MeV protons resulted in ˜1.5 times higher damage than 1.8 MeV protons

  7. Thermal analysis of friction welding process in relation to the welding of YSZ-alumina composite and 6061 aluminum alloy

    NASA Astrophysics Data System (ADS)

    Uday, M. B.; Fauzi, M. N. Ahmad; Zuhailawati, H.; Ismail, A. B.

    2012-08-01

    The objective of this work is to establish an analytical data for heat generation by friction welding, based on different parameters of the contact condition between two dissimilar materials. The ceramic composite of Al2O3-YSZ and 6061 Al alloy, which is the example of joining materials by friction welding was used in the experiments. Alumina rods containing 0, 25 and 50 wt% yttria stabilized zirconia were produced by slip casting in Plaster of Paris molds and subsequently sintered at 1600 °C. The diameter of both the ceramic and metal rods was 16 mm. Rotational speeds for friction welding were between 630 and 2500 rpm. As a result, different data was evaluated for obtaining joint properties and operating conditions, and obtained results are useful in modeling the welding process and reliability joint under various conditions.

  8. Mechanical Properties and Microstructure of Thin Plates of A6061 Wrought Aluminum Alloy Using Rheology Forging Process with Electromagnetic Stirring

    NASA Astrophysics Data System (ADS)

    Jin, Chul Kyu; Bolouri, Amir; Kang, Chung Gil

    2014-06-01

    We propose the possibility of fabricating A6061 thin plates using the rheology forging process. Electromagnetic stirring (EMS) is used to fabricate a semi-solid slurry. A thin plate is formed by injecting the slurry into the forging die. When the punch speed used to compress the slurry is low, turbulent flow occurs. When the punch speed is high, laminar flow occurs, and the solid and liquid phases move simultaneously. For a pressure of 150 MPa or below, incomplete filling behavior and cracks occur. For a pressure of 200 MPa or above, a durable formed product can be obtained. However, the differences between the mechanical properties according to the application of EMS and pressure are slight. The microstructure of the slurry without EMS has an unclear distinction between the liquid phase and solid phase. However, the microstructure of the thin plates formed by using this slurry has a clear distinction between the liquid and solid with respect to the spheroid shapes. The tensile strength and elongation for a thin plate formed with a punch speed of 300 mm/s and pressure of 250 MPa with EMS slurry are 169 MPa and 11.0 pct, respectively. After T6 heat treatment, the tensile strength improves to 305 MPa.

  9. A Doping Lattice of Aluminum and Copper with Accelerated Electron Transfer Process and Enhanced Reductive Degradation Performance

    NASA Astrophysics Data System (ADS)

    Zhang, Lin; Gao, Xue; Zhang, Zhixuan; Zhang, Mingbo; Cheng, Yiqian; Su, Jixin

    2016-08-01

    Treatment of azo dye effluents has received increasing concerns over the years due to their potential harms to natural environment and human health. The present study described the degrading ability of the as-synthesized crystalline Al-Cu alloys for removal of high-concentration Acid Scarlet 3R in alkaline aqueous solutions and its degradation mechanism. Al-Cu alloy particles with Al/Cu ratios 19:1 were successfully synthesized by high-energy mechanical milling. Characterization results showed that 10 h mechanical alloying process could lead to the formation of crystalline Al(Cu) solid solution. Batch experiment results confirmed the excellent ability of Al-Cu alloy particles for the degradation of 3R in aqueous solution. Under a certain condition ([Al-Cu]0 = 2 g/L, [3R]0 = 200 mg/L, [NaCl]0 = 25 g/L, initial pH = 10.9), the 3R could be completely degraded within only 3 min. It was also found that the degradation reaction followed zero-order kinetics model with respect to the initial dye concentration. The intermediate compounds were identified by UV-vis, FT-IR and HPLC-MS, and a pathway was proposed. Additionally, post-treatment Al-Cu alloy particles were characterized by SEM and TEM, and the results showed that the degradation might be attributed to the corrosion effect of Al-Cu alloys.

  10. A Doping Lattice of Aluminum and Copper with Accelerated Electron Transfer Process and Enhanced Reductive Degradation Performance

    PubMed Central

    Zhang, Lin; Gao, Xue; Zhang, Zhixuan; Zhang, Mingbo; Cheng, Yiqian; Su, Jixin

    2016-01-01

    Treatment of azo dye effluents has received increasing concerns over the years due to their potential harms to natural environment and human health. The present study described the degrading ability of the as-synthesized crystalline Al-Cu alloys for removal of high-concentration Acid Scarlet 3R in alkaline aqueous solutions and its degradation mechanism. Al-Cu alloy particles with Al/Cu ratios 19:1 were successfully synthesized by high-energy mechanical milling. Characterization results showed that 10 h mechanical alloying process could lead to the formation of crystalline Al(Cu) solid solution. Batch experiment results confirmed the excellent ability of Al-Cu alloy particles for the degradation of 3R in aqueous solution. Under a certain condition ([Al-Cu]0 = 2 g/L, [3R]0 = 200 mg/L, [NaCl]0 = 25 g/L, initial pH = 10.9), the 3R could be completely degraded within only 3 min. It was also found that the degradation reaction followed zero-order kinetics model with respect to the initial dye concentration. The intermediate compounds were identified by UV-vis, FT-IR and HPLC-MS, and a pathway was proposed. Additionally, post-treatment Al-Cu alloy particles were characterized by SEM and TEM, and the results showed that the degradation might be attributed to the corrosion effect of Al-Cu alloys. PMID:27535800

  11. A Doping Lattice of Aluminum and Copper with Accelerated Electron Transfer Process and Enhanced Reductive Degradation Performance.

    PubMed

    Zhang, Lin; Gao, Xue; Zhang, Zhixuan; Zhang, Mingbo; Cheng, Yiqian; Su, Jixin

    2016-08-18

    Treatment of azo dye effluents has received increasing concerns over the years due to their potential harms to natural environment and human health. The present study described the degrading ability of the as-synthesized crystalline Al-Cu alloys for removal of high-concentration Acid Scarlet 3R in alkaline aqueous solutions and its degradation mechanism. Al-Cu alloy particles with Al/Cu ratios 19:1 were successfully synthesized by high-energy mechanical milling. Characterization results showed that 10 h mechanical alloying process could lead to the formation of crystalline Al(Cu) solid solution. Batch experiment results confirmed the excellent ability of Al-Cu alloy particles for the degradation of 3R in aqueous solution. Under a certain condition ([Al-Cu]0 = 2 g/L, [3R]0 = 200 mg/L, [NaCl]0 = 25 g/L, initial pH = 10.9), the 3R could be completely degraded within only 3 min. It was also found that the degradation reaction followed zero-order kinetics model with respect to the initial dye concentration. The intermediate compounds were identified by UV-vis, FT-IR and HPLC-MS, and a pathway was proposed. Additionally, post-treatment Al-Cu alloy particles were characterized by SEM and TEM, and the results showed that the degradation might be attributed to the corrosion effect of Al-Cu alloys.

  12. Decontamination and reuse of ORGDP aluminum scrap

    SciTech Connect

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

    1996-12-01

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

  13. FLOWSHEET FOR ALUMINUM REMOVAL FROM SLUDGE BATCH 6

    SciTech Connect

    Pike, J; Jeffrey Gillam, J

    2008-12-17

    Samples of Tank 12 sludge slurry show a substantially larger fraction of aluminum than originally identified in sludge batch planning. The Liquid Waste Organization (LWO) plans to formulate Sludge Batch 6 (SB6) with about one half of the sludge slurry in Tank 12 and one half of the sludge slurry in Tank 4. LWO identified aluminum dissolution as a method to mitigate the effect of having about 50% more solids in High Level Waste (HLW) sludge than previously planned. Previous aluminum dissolution performed in a HLW tank in 1982 was performed at approximately 85 C for 5 days and dissolved nearly 80% of the aluminum in the sludge slurry. In 2008, LWO successfully dissolved 64% of the aluminum at approximately 60 C in 46 days with minimal tank modifications and using only slurry pumps as a heat source. This report establishes the technical basis and flowsheet for performing an aluminum removal process in Tank 51 for SB6 that incorporates the lessons learned from previous aluminum dissolution evolutions. For SB6, aluminum dissolution process temperature will be held at a minimum of 65 C for at least 24 days, but as long as practical or until as much as 80% of the aluminum is dissolved. As planned, an aluminum removal process can reduce the aluminum in SB6 from about 84,500 kg to as little as 17,900 kg with a corresponding reduction of total insoluble solids in the batch from 246,000 kg to 131,000 kg. The extent of the reduction may be limited by the time available to maintain Tank 51 at dissolution temperature. The range of dissolution in four weeks based on the known variability in dissolution kinetics can range from 44 to more than 80%. At 44% of the aluminum dissolved, the mass reduction is approximately 1/2 of the mass noted above, i.e., 33,300 kg of aluminum instead of 66,600 kg. Planning to reach 80% of the aluminum dissolved should allow a maximum of 81 days for dissolution and reduce the allowance if test data shows faster kinetics. 47,800 kg of the dissolved

  14. Aspects of aluminum toxicity

    SciTech Connect

    Hewitt, C.D.; Savory, J.; Wills, M.R. )

    1990-06-01

    Aluminum is the most abundant metal in the earth's crust. The widespread occurrence of aluminum, both in the environment and in foodstuffs, makes it virtually impossible for man to avoid exposure to this metal ion. Attention was first drawn to the potential role of aluminum as a toxic metal over 50 years ago, but was dismissed as a toxic agent as recently as 15 years ago. The accumulation of aluminum, in some patients with chronic renal failure, is associated with the development of toxic phenomena; dialysis encephalopathy, osteomalacic dialysis osteodystrophy, and an anemia. Aluminum accumulation also occurs in patients who are not on dialysis, predominantly infants and children with immature or impaired renal function. Aluminum has also been implicated as a toxic agent in the etiology of Alzheimer's disease, Guamiam amyotrophic lateral sclerosis, and parkinsonism-dementia. 119 references.

  15. The Correlation of Stir Zone Texture Development with Base Metal Texture and Tool-Induced Deformation in Friction Stir Processing of Severely Deformed Aluminum

    NASA Astrophysics Data System (ADS)

    Sarkari Khorrami, M.; Kazeminezhad, Mohsen; Miyashita, Y.; Kokabi, A. H.

    2017-01-01

    The texture development during friction stir processing (FSP) of 1050 aluminum severely deformed at the strain magnitude of 2.32 was comprehensively discussed. It was observed that the component bar{B} of the ideal shear texture along with the cube texture was developed in the severely deformed base metal. The effects of base metal texture on the texture development of stir zone, thermo-mechanically affected zone, and heat-affected zone during FSP were examined. Also, the developed texture components in the vicinity of the FSP tool and the stir zone were correlated to the deformation induced by the rotating tool which consisted of pin and shoulder. The observed texture components in the longitudinal section of the stir zone were found coincided with the ideal shear ones, but different from those observed in the severely deformed base metal. It could be responsible for the fact that the material beneath the FSP tool is predominantly deformed and stirred by the shoulder rather than the pin. The independency of texture development in the stir zone from pin-induced deformation was also consistent with the observation associated with the stir zone geometry which was independent of the pin geometry. Microstructural evolutions in the regions located ahead of the FSP tool manifested the incident of static recovery and recrystallization as a result of the stored strain in the severely deformed base metal. These led to the development of almost random texture and the deterioration of base metal texture in this region. This suggested the independency of texture development in the stir zone from the texture of severely deformed base metal.

  16. Domestic aluminum resources: dilemmas of development

    SciTech Connect

    Staats, E.B.

    1980-07-17

    Concerns about supply disruptions and price gouging that could endanger aluminum production in the United States have spurred research in this country on processes to manufacture aluminum from ores other than bauxite. The United States has no large bauxite deposits but it has plentiful resources of other aluminum ores if the technology can be developed to use them economically. Sources of aluminium include alunite, anorthosite, dawsonite, and clay/acid. Miniplants for clay/nitric acid and clay/hydrochloric acid, gas-induced crystallization have been constructed.

  17. Fine Grain Aluminum Superplasticity

    DTIC Science & Technology

    1980-02-01

    time at elevated temperature for 7475 aluminum alloy 5 2 Optical micrographs of 7075 aluminum alloy after exposure to 5160C (960oF) for times...applied to Al-Zn-Mg-Cu ( 7075 Al) alloy. Subsequent developments by Waldman et al. (refs. 8-11) resulted in the demonstration that 7000 series alloys...a number of aluminum alloys. With such a fine grain structure, high temperature deformation character- istics approaching superplastic behavior

  18. Advanced Technology Lightweight Gondola System Experimental Fabrication Program.

    DTIC Science & Technology

    1981-07-01

    10400 10400 3. SECTION I SPECIFICATIONS FOR ALUMINUM STRUCTURES, The Aluminum Association, In., 750 Third Avenue, New York, New York. 50 5.3 17 - 4PH ...Material 6061-T6 Aluminum tubing Lower End Fitting Material 6061-T6 Aluminum bar Upper Fitting Material 17 - 4PH Cond 1025 Limit Load - 6.2 kips 7.2.2.4.1...Material 17 - 4PH Cond 1025 Thread 1-3/4-8UN-2B 2 PLIMIT - 2 (6.2) Limit Shear Stress f 2-lLMI) ( .) sy lTdh 7(l.75) (1.0) 85 f = 2.26 ksisy f = 1.5 f = 1.5

  19. Reducing aluminum dust explosion hazards: case study of dust inerting in an aluminum buffing operation.

    PubMed

    Myers, Timothy J

    2008-11-15

    Metal powders or dusts can represent significant dust explosion hazards in industry, due to their relatively low ignition energy and high explosivity. The hazard is well known in industries that produce or use aluminum powders, but is sometimes not recognized by facilities that produce aluminum dust as a byproduct of bulk aluminum processing. As demonstrated by the 2003 dust explosion at aluminum wheel manufacturer Hayes Lemmerz, facilities that process bulk metals are at risk due to dust generated during machining and finishing operations [U.S. Chemical Safety and Hazard Investigation Board, Investigation Report, Aluminum Dust Explosion Hayes Lemmerz International, Inc., Huntington, Indiana, Report No. 2004-01-I-IN, September 2005]. Previous studies have shown that aluminum dust explosions are more difficult to suppress with flame retardants or inerting agents than dust explosions fueled by other materials such as coal [A.G. Dastidar, P.R. Amyotte, J. Going, K. Chatrathi, Flammability limits of dust-minimum inerting concentrations, Proc. Saf. Progr., 18-1 (1999) 56-63]. In this paper, an inerting method is discussed to reduce the dust explosion hazard of residue created in an aluminum buffing operation as the residue is generated. This technique reduces the dust explosion hazard throughout the buffing process and within the dust collector systems making the process inherently safer. Dust explosion testing results are presented for process dusts produced during trials with varying amounts of flame retardant additives.

  20. Production of sodium-22 from proton irradiated aluminum

    DOEpatents

    Taylor, Wayne A.; Heaton, Richard C.; Jamriska, David J.

    1996-01-01

    A process for selective separation of sodium-22 from a proton irradiated minum target including dissolving a proton irradiated aluminum target in hydrochloric acid to form a first solution including aluminum ions and sodium ions, separating a portion of the aluminum ions from the first solution by crystallization of an aluminum salt, contacting the remaining first solution with an anion exchange resin whereby ions selected from the group consisting of iron and copper are selectively absorbed by the anion exchange resin while aluminum ions and sodium ions remain in solution, contacting the solution with an cation exchange resin whereby aluminum ions and sodium ions are adsorbed by the cation exchange resin, and, contacting the cation exchange resin with an acid solution capable of selectively separating the adsorbed sodium ions from the cation exchange resin while aluminum ions remain adsorbed on the cation exchange resin is disclosed.

  1. Aluminum Target Dissolution in Support of the Pu-238 Program

    SciTech Connect

    McFarlane, Joanna; Benker, Dennis; DePaoli, David W; Felker, Leslie Kevin; Mattus, Catherine H

    2014-09-01

    Selection of an aluminum alloy for target cladding affects post-irradiation target dissolution and separations. Recent tests with aluminum alloy 6061 yielded greater than expected precipitation in the caustic dissolution step, forming up to 10 wt.% solids of aluminum hydroxides and aluminosilicates. We present a study to maximize dissolution of aluminum metal alloy, along with silicon, magnesium, and copper impurities, through control of temperature, the rate of reagent addition, and incubation time. Aluminum phase transformations have been identified as a function of time and temperature, using X-ray diffraction. Solutions have been analyzed using wet chemical methods and X-ray fluorescence. These data have been compared with published calculations of aluminum phase diagrams. Temperature logging during the transients has been investigated as a means to generate kinetic and mass transport data on the dissolution process. Approaches are given to enhance the dissolution of aluminum and aluminosilicate phases in caustic solution.

  2. MTBE OXIDATION BY BIFUNCTIONAL ALUMINUM

    EPA Science Inventory

    Bifunctional aluminum, prepared by sulfating zero-valent aluminum with sulfuric acid, has a dual functionality of simultaneously decomposing both reductively- and oxidatively-degradable contaminants. In this work, the use of bifunctional aluminum for the degradation of methyl te...

  3. Analysis of Material Flow in Screw Extrusion of Aluminum

    SciTech Connect

    Haugen, Bjoern; Oernskar, Magnus; Welo, Torgeir; Wideroee, Fredrik

    2010-06-15

    Screw extrusion of aluminum is a new process for production of aluminum profiles. The commercial potential could be large. Little experimental and numerical work has been done with respect to this process.The material flow of hot aluminum in a screw extruder has been analyzed using finite element formulations for the non-Newtonian Navier-Stokes equations. Aluminum material properties are modeled using the Zener-Holloman material model. Effects of stick-slip conditions are investigated with respect to pressure build up and mixing quality of the extrusion process.The numerical results are compared with physical experiments using an experimental screw extruder.

  4. Real-time in-situ chemical sensing in aluminum gallium nitride/gallium nitride metal-organic chemical vapor deposition processes for advanced process control

    NASA Astrophysics Data System (ADS)

    Cho, Soon

    Gallium nitride and its alloys promise to be key materials for future semiconductor devices aimed at high frequency, high power electronic applications. However, manufacturing for such high performance products is challenged by reproducibility and material quality constraints that are notably more stringent than those required for optoelectronic applications. To meet this challenge, in-situ mass spectrometry was implemented as a real-time process- and wafer-state metrology tool in AlGaN/GaN/AlN metal-organic chemical vapor deposition processes on semi-insulating SiC substrate wafers. Dynamic chemical sensing through the process cycle, carried out downstream from the wafer, revealed generation of methane and ethane reaction byproducts, as well as other residual gas species. Real-time metrics were derived based on the chemical signals to predict/control material quality and thickness of critical layers within the heterostructure in real time during growth, and corresponding metrologies were used for real-time advanced process control. Using the methane/ethane ratio, GaN epilayer crystal quality was predicted in real time to 2--5% precision, which was verified by post-process x-ray diffraction. Moreover, the same real-time metric predicted material quality as indicated by post-process photoluminescence band-edge intensities to ˜5% precision. The methane/ethane ratio has a fundamental significance in terms of the intrinsic chemistry in that the two byproducts are believed to reflect two parallel reaction pathways leading to GaN-based material growth, namely the gas phase adduct formation route and the surface route for direct precursor decomposition, respectively. The fact that lower methane/ethane ratios consistently yield better material quality suggests that the surface pathway is preferred for high quality GaN growth. In addition, a metric based on methane and ethane signals integrated through the AlGaN growth period (˜1 min or less) enabled prediction of the cap

  5. Improvement of abrasion resistance in artificial seawater and corrosion resistance in NaCl solution of 7075 aluminum alloy processed by laser shock peening

    NASA Astrophysics Data System (ADS)

    Wang, Hao; Ning, Chengyi; Huang, Yihui; Cao, Zhenya; Chen, Xiaoxiao; Zhang, Wenwu

    2017-03-01

    As 7075 aluminum alloy is widely used in a humid environment, in order to enhance its abrasion resistance and electrochemical corrosion resistance, the paper studied the effect of laser shock peening on abrasion resistance in artificial seawater and corrosion resistance in 3.5% NaCl solution of 7075 aluminum alloy. Result shows that when specimens were treated once and twice with 7.17 GW/cm2 the abrasion loss would be reduced by 43.75% and 46.09% compare to untreated respectively, and the corrosion rate of 7075 aluminum alloy could be reduced as much as 50.32% by LSP treatment with 7.17 GW/cm2. What's more, the effects on the microhardness, microstructure and residual stress with different LSP impacts and power density were investigated to find out strengthening mechanism of laser shock peening, which were observed and measured by microhardness tester, optical microscope and X-ray diffraction (XRD) residual stress tester. In the entire laboratory tests, it is considered that LSP is a practical option to improve abrasion resistance in seawater and corrosion resistance of 7075 aluminum alloy.

  6. Effect of aluminum substitution on the structural and magnetic properties of cobalt ferrite synthesized by sol-gel auto combustion process

    NASA Astrophysics Data System (ADS)

    Aghav, P. S.; Dhage, Vinod N.; Mane, Maheshkumar L.; Shengule, D. R.; Dorik, R. G.; Jadhav, K. M.

    2011-12-01

    Aluminum substituted cobalt ferrite powders (CoFe2-xAlxO4) with varying composition from 0.0 to 1.0 in the step of 0.2 have been obtained by sol-gel auto combustion technique using citric acid as a fuel. The metal nitrate to fuel ratio was maintained 1:4 throughout the synthesis of CoFe2-xAlxO4. The thermal analysis of as prepared samples is done by TGA technique. The compositional stoichiometry of the prepared samples is confirmed by Energy dispersive X-ray analysis technique. Single phase cubic spinel structure and nano phase structure of the synthesized powders were confirmed by X-ray diffraction (XRD) and scanning electron microscopy (SEM). The crystallite size of 16-26 nm was obtained using Scherrer formula. SEM analysis shows the formation of uniform grain growth. The grain size obtained from SEM results is of the order of 30 nm. Maximum specific surface area was observed to be of the order of 52 m2/gm. The highest value of saturation magnetization and coercivity was observed for pure cobalt ferrite sample and it decreases as the aluminum content x increases. A strong co-relation between the saturation magnetization and aluminum content was observed. The decrease in magnetic properties is due to the substitution of aluminum ions in place of Fe3+.

  7. 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.

  8. FABRICATION OF URANIUM-ALUMINUM ALLOYS

    DOEpatents

    Saller, H.A.

    1959-12-15

    A process is presented for producing a workable article of a uranium- aluminum alloy in which the uranium content is between 14 and 70% by weight; aluminum powder and powdered UAl/sub 2/, UAl/sub 3/, UAl/sub 5/, or UBe/sub 9/ are mixed, and the mixture is compressed into the shape desired and sintered at between 450 and 600 deg C.

  9. High energy density aluminum battery

    SciTech Connect

    Brown, Gilbert M.; Paranthaman, Mariappan Parans; Dai, Sheng; Dudney, Nancy J.; Manthiram, Arumugan; McIntyre, Timothy J.; Sun, Xiao-Guang; Liu, Hansan

    2016-10-11

    Compositions and methods of making are provided for a high energy density aluminum battery. The battery comprises an anode comprising aluminum metal. The battery further comprises a cathode comprising a material capable of intercalating aluminum or lithium ions during a discharge cycle and deintercalating the aluminum or lithium ions during a charge cycle. The battery further comprises an electrolyte capable of supporting reversible deposition and stripping of aluminum at the anode, and reversible intercalation and deintercalation of aluminum or lithium at the cathode.

  10. Survey - Monomethylhydrazine Propellant/Material Compatibility

    DTIC Science & Technology

    1977-07-01

    Alloys Martin Marietta (Refs.l0, 20) rated 1100-0, 2014- T6 , and 2219 -T87 compatible with MMH for 300 hours at 135’C, no corrosion or MMH decomposition...Ti, 6061- T6 Al. The aluminum alloys show no susceptibility. The order of decreasing stress corrosion cracking promotion for the fuels is hydrazine...decomposition of propellant and no noticeable corrosion of the metal surfaces. The metals were aluminum alloys 1100, 2014, 6061; corrosion -resistant steels

  11. Methods for both coating a substrate with aluminum oxide and infusing the substrate with elemental aluminum

    SciTech Connect

    Choi, Jung-Pyung; Weil, Kenneth Scott

    2016-11-01

    Methods of aluminizing the surface of a metal substrate. The methods of the present invention do not require establishment of a vacuum or a reducing atmosphere, as is typically necessary. Accordingly, aluminization can occur in the presence of oxygen, which greatly simplifies and reduces processing costs by allowing deposition of the aluminum coating to be performed, for example, in air. Embodiments of the present invention can be characterized by applying a slurry that includes a binder and powder granules containing aluminum to the metal substrate surface. Then, in a combined step, a portion of the aluminum is diffused into the substrate and a portion of the aluminum is oxidized by heating the slurry to a temperature greater than the melting point of the aluminum in an oxygen-containing atmosphere.

  12. Is the Aluminum Hypothesis Dead?

    PubMed Central

    2014-01-01

    The Aluminum Hypothesis, the idea that aluminum exposure is involved in the etiology of Alzheimer disease, dates back to a 1965 demonstration that aluminum causes neurofibrillary tangles in the brains of rabbits. Initially the focus of intensive research, the Aluminum Hypothesis has gradually been abandoned by most researchers. Yet, despite this current indifference, the Aluminum Hypothesis continues to attract the attention of a small group of scientists and aluminum continues to be viewed with concern by some of the public. This review article discusses reasons that mainstream science has largely abandoned the Aluminum Hypothesis and explores a possible reason for some in the general public continuing to view aluminum with mistrust. PMID:24806729

  13. Anodizing Aluminum with Frills.

    ERIC Educational Resources Information Center

    Doeltz, Anne E.; And Others

    1983-01-01

    "Anodizing Aluminum" (previously reported in this journal) describes a vivid/relevant laboratory experience for general chemistry students explaining the anodizing of aluminum in sulfuric acid and constrasting it to electroplating. Additions to this procedure and the experiment in which they are used are discussed. Reactions involved are…

  14. Effect of Na2WO4 on Growth Process and Corrosion Resistance of Micro-arc Oxidation Coatings on 2A12 Aluminum Alloys in CH3COONa Electrolyte

    NASA Astrophysics Data System (ADS)

    Lin, Zhaoqing; Yu, Huijun; He, Siyu; Wang, Diangang; Chen, Chuanzhong

    2016-01-01

    Ceramic coatings were deposited on 2A12 aluminum alloys using micro-arc oxidation (MAO) technology in CH3COONa-Na2WO4 electrolyte. The MAO process was studied by recording the current-time curve. The influences of Na2WO4 concentrations on the coatings in CH3COONa electrolyte were investigated. The results show that the Na2WO4 concentrations affect the MAO process and performances of the coatings directly. Na2WO4 in excess is harmful for the formation of Al2O3 in this electrolyte. The corrosion resistance was enhanced with the decrease of Na2WO4 concentration.

  15. Aluminum recycling in the automotive industry. (Latest citations from the Aluminum Industry Abstracts database). Published Search

    SciTech Connect

    Not Available

    1994-06-01

    The bibliography contains citations concerning design and development of processes to recycle aluminum from automobiles. Scrap separation, shredding, and processing are covered including new equipment. Aluminum market information is included with respect to material selection for automobiles and new products developed from recycled material. References also discuss changes in automobile design to increase recycling oppertunities. (Contains a minimum of 107 citations and includes a subject term index and title list.)

  16. The Cleaning of Aluminum Frame Assembly Units

    SciTech Connect

    Shen, T H

    2001-05-16

    The Brulin immersion and the precision cleaning experiments have shown that neither the Brulin solution nor the precision cleaning in AstroPak causes the smut formation on aluminum surfaces. The acid-bath cleaning in GTC is the primary source of the smut formation. The current GTC acid formulation etches the aluminum matrix quite aggressively, but does not appear to appreciably attack the Si particles. Therefore, this acid-bath cleaning will leave the cast-aluminum part surfaces with many protruded Si particles, which could potentially cause smut problems in the cleaning process down-stream. To ensure the removal of all loose Si particles from the cast-aluminum parts, it is necessary to physically hand-wipe and vigorously wash the acid-bath cleaned surfaces. Furthermore, the casting porosity in alloy A356 could be another source in causing high swipe readings in the FAU parts.

  17. Dry lubricant films for aluminum forming.

    SciTech Connect

    Wei, J.; Erdemir, A.; Fenske, G. R.

    1999-03-30

    During metal forming process, lubricants are crucial to prevent direct contact, adhesion, transfer and scuffing of workpiece materials and tools. Boric acid films can be firmly adhered to the clean aluminum surfaces by spraying their methanol solutions and provide extremely low friction coefficient (about 0.04). The cohesion strengths of the bonded films vary with the types of aluminum alloys (6061, 6111 and 5754). The sheet metal forming tests indicate that boric acid films and the combined films of boric acid and mineral oil can create larger strains than the commercial liquid and solid lubricants, showing that they possess excellent lubricities for aluminum forming. SEM analyses indicate that boric acid dry films separate the workpiece and die materials, and prevent their direct contact and preserve their surface qualities. Since boric acid is non-toxic and easily removed by water, it can be expected that boric acid films are environmentally friendly, cost effective and very efficient lubricants for sheet aluminum cold forming.

  18. Macrodeformation Twins in Single-Crystal Aluminum

    NASA Astrophysics Data System (ADS)

    Zhao, F.; Wang, L.; Fan, D.; Bie, B. X.; Zhou, X. M.; Suo, T.; Li, Y. L.; Chen, M. W.; Liu, C. L.; Qi, M. L.; Zhu, M. H.; Luo, S. N.

    2016-02-01

    Deformation twinning in pure aluminum has been considered to be a unique property of nanostructured aluminum. A lingering mystery is whether deformation twinning occurs in coarse-grained or single-crystal aluminum at scales beyond nanotwins. Here, we present the first experimental demonstration of macrodeformation twins in single-crystal aluminum formed under an ultrahigh strain rate (˜106 s-1 ) and large shear strain (200%) via dynamic equal channel angular pressing. Large-scale molecular dynamics simulations suggest that the frustration of subsonic dislocation motion leads to transonic deformation twinning. Deformation twinning is rooted in the rate dependences of dislocation motion and twinning, which are coupled, complementary processes during severe plastic deformation under ultrahigh strain rates.

  19. Modeling dissolution in aluminum alloys

    NASA Astrophysics Data System (ADS)

    Durbin, Tracie Lee

    2005-07-01

    Aluminum and its alloys are used in many aspects of modern life, from soda cans and household foil to the automobiles and aircraft in which we travel. Aluminum alloy systems are characterized by good workability that enables these alloys to be economically rolled, extruded, or forged into useful shapes. Mechanical properties such as strength are altered significantly with cold working, annealing, precipitation-hardening, and/or heat-treatments. Heat-treatable aluminum alloys contain one or more soluble constituents such as copper, lithium, magnesium, silicon and zinc that individually, or with other elements, can form phases that strengthen the alloy. Microstructure development is highly dependent on all of the processing steps the alloy experiences. Ultimately, the macroscopic properties of the alloy depend strongly on the microstructure. Therefore, a quantitative understanding of the microstructural changes that occur during thermal and mechanical processing is fundamental to predicting alloy properties. In particular, the microstructure becomes more homogeneous and secondary phases are dissolved during thermal treatments. Robust physical models for the kinetics of particle dissolution are necessary to predict the most efficient thermal treatment. A general dissolution model for multi-component alloys has been developed using the front-tracking method to study the dissolution of precipitates in an aluminum alloy matrix. This technique is applicable to any alloy system, provided thermodynamic and diffusion data are available. Treatment of the precipitate interface is explored using two techniques: the immersed-boundary method and a new technique, termed here the "sharp-interface" method. The sharp-interface technique is based on a variation of the ghost fluid method and eliminates the need for corrective source terms in the characteristic equations. In addition, the sharp-interface method is shown to predict the dissolution behavior of precipitates in aluminum

  20. 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.

  1. 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.

  2. Precipitation hardening in aluminum alloy 6022

    SciTech Connect

    Miao, W.F.; Laughlin, D.E.

    1999-03-05

    Although the precipitation process in Al-Mg-Si alloys has been extensively studied, the understanding of the hardening process is still incomplete, since any change in composition, processing and aging practices, etc., could affect the precipitation hardening behavior. In this paper, hardness measurements, differential scanning calorimetry and transmission electron microscopy have been utilized to study the precipitation hardening behavior in aluminum alloy 6022.

  3. Microstructure of SiC-Si-Al2O3 composites derived from silicone resin - metal aluminum filler compounds by low temperature reduction process

    NASA Astrophysics Data System (ADS)

    Narisawa, M.; Abe, Y.

    2011-06-01

    Concentrated slurry of a silicone resin with low carbon content, 3 μm aluminum particles and ethanol were prepared. After casting, addition of cross-linking agent and drying, silicone resin-aluminum composite with thick sheet form was obtained. The prepared sheet was heat-treated at 933 or 1073K with various holding times to characterize formed phases during the heat treatments. XRD patterns and FT-IR spectra revealed free Si formation and existence of Si-O-Si bond at 933K. The Si-O-Si bond, however, disappeared and silicon carbide was formed at 1073K. SEM observation indicated formation of cracks bridged with a number of tiny struts at 933K and conversion to wholly porous structure at 1073K.

  4. Energy Assessment Helps Kaiser Aluminum Save Energy and Improve Productivity

    SciTech Connect

    2008-07-01

    The Kaiser Aluminum plant in Sherman, Texas, adjusted controls and made repairs to a furnace for a simple payback of 1 month. Kaiser adopted DOE's Process Heating Assessment and Survey Tool (PHAST) software as the corporate diagnostic tool and has used it to evaluate process heating systems at five other aluminum plants.

  5. Interactions of satellite-speed helium atoms with satellite surfaces. 2: Energy distributions of reflected helium atoms

    NASA Technical Reports Server (NTRS)

    Liu, S. M.; Knuth, E. L.

    1976-01-01

    Energy transfer in collisions of satellite-speed (7,000 m/sec) helium atoms with a cleaned 6061-T6 satellite-type aluminum surface was investigated using the molecular-beam technique. The amount of energy transferred was determined from the measured energy of the molecular-beam and the measured spatial and energy distributions of the reflected atoms. Spatial distributions of helium atoms scattered from a 6061-T6 aluminum surface were measured. The scattering pattern exhibits a prominent backscattering, probably due to the gross surface roughness and/or the relative lattice softness of the aluminum surface. Energy distributions of reflected helium atoms from the same surface were measured for six different incidence angles. For each incidence angle, distributions were measured at approximately sixty scattering positions. At a given scattering position, the energy spectra of the reflected helium atoms and the background gas were obtained using the retarding-field energy analyzer.

  6. Preliminary Investigation of Zircaloy-4 as a Research Reactor Cladding Material

    SciTech Connect

    Brian K Castle

    2012-05-01

    As part of a scoping study for the ATR fuel conversion project, an initial comparison of the material properties of Zircaloy-4 and Aluminum-6061 (T6 and O-temper) is performed to provide a preliminary evaluation of Zircaloy-4 for possible inclusion as a candidate cladding material for ATR fuel elements. The current fuel design for the ATR uses Aluminum 6061 (T6 and O temper) as a cladding and structural material in the fuel element and to date, no fuel failures have been reported. Based on this successful and longstanding operating history, Zircaloy-4 properties will be evaluated against the material properties for aluminum-6061. The preliminary investigation will focus on a comparison of density, oxidation rates, water chemistry requirements, mechanical properties, thermal properties, and neutronic properties.

  7. Low Temperature Aluminum Dissolution Of Sludge Waste

    SciTech Connect

    Keefer, M.T.; Hamm, B.A.; Pike, J.A.

    2008-07-01

    High Level Waste (HLW) at the Savannah River Site (SRS) is currently stored in aging underground storage tanks. This waste is a complex mixture of insoluble solids, referred to as sludge, and soluble salts. Continued long-term storage of these radioactive wastes poses an environmental risk. The sludge is currently being stabilized in the Defense Waste Processing Facility (DWPF) through a vitrification process immobilizing the waste in a borosilicate glass matrix for long-term storage in a federal repository. Without additional treatment, the existing volume of sludge would produce nearly 8000 canisters of vitrified waste. Aluminum compounds, along with other non-radioactive components, represent a significant portion of the sludge mass currently planned for vitrification processing in DWPF. Removing the aluminum from the waste stream reduces the volume of sludge requiring vitrification and improves production rates. Treating the sludge with a concentrated sodium hydroxide (caustic) solution at elevated temperatures (>90 deg. C) to remove aluminum is part of an overall sludge mass reduction effort to reduce the number of vitrified canisters, shorten the life cycle for the HLW system, and reduce the risk associated with the long term storage of radioactive wastes at SRS. A projected reduction of nearly 900 canisters will be achieved by performing aluminum dissolution on six targeted sludge batches; however, a project to develop and install equipment will not be ready for operation until 2013. The associated upgrades necessary to implement a high temperature process in existing facilities are costly and present many technical challenges. Efforts to better understand the characteristics of the sludge mass and dissolution kinetics are warranted to overcome these challenges. Opportunities to further reduce the amount of vitrified waste and increase production rates should also be pursued. Sludge staged in Tank 51 as the next sludge batch for feed to DWPF consisted

  8. Clinical biochemistry of aluminum

    SciTech Connect

    King, S.W.; Savory, J.; Wills, M.R.

    1981-05-01

    Aluminum toxicity has been implicated in the pathogenesis of a number of clinical disorders in patients with chronic renal failure on long-term intermittent hemodialysis treatment. The predominant disorders have been those involving either bone (osteomalacic dialysis osteodystrophy) or brain (dialysis encephalopathy). In nonuremic patients, an increased brain aluminum concentration has been implicated as a neurotoxic agent in the pathogenesis of Alzheimer's disease and was associated with experimental neurofibrillary degeneration in animals. The brain aluminum concentrations of patients dying with the syndrome of dialysis encephalopathy (dialysis dementia) are significantly higher than in dialyzed patients without the syndrome and in nondialyzed patients. Two potential sources for the increased tissue content of aluminum in patients on hemodialysis have been proposed: (1) intestinal absorption from aluminum containing phosphate-binding gels, and (2) transfer across the dialysis membrane from aluminum in the water used to prepare the dialysate. These findings, coupled with our everyday exposure to the ubiquitous occurrence of aluminum in nature, have created concerns over the potential toxicity of this metal.

  9. Electrically Conductive Anodized Aluminum Surfaces

    NASA Technical Reports Server (NTRS)

    Nguyen, Trung Hung

    2006-01-01

    Anodized aluminum components can be treated to make them sufficiently electrically conductive to suppress discharges of static electricity. The treatment was conceived as a means of preventing static electric discharges on exterior satin-anodized aluminum (SAA) surfaces of spacecraft without adversely affecting the thermal-control/optical properties of the SAA and without need to apply electrically conductive paints, which eventually peel off in the harsh environment of outer space. The treatment can also be used to impart electrical conductivity to anodized housings of computers, medical electronic instruments, telephoneexchange equipment, and other terrestrial electronic equipment vulnerable to electrostatic discharge. The electrical resistivity of a typical anodized aluminum surface layer lies between 10(exp 11) and 10(exp 13) Omega-cm. To suppress electrostatic discharge, it is necessary to reduce the electrical resistivity significantly - preferably to < or = 10(exp 9) Omega-cm. The present treatment does this. The treatment is a direct electrodeposition process in which the outer anodized surface becomes covered and the pores in the surface filled with a transparent, electrically conductive metal oxide nanocomposite. Filling the pores with the nanocomposite reduces the transverse electrical resistivity and, in the original intended outer-space application, the exterior covering portion of the nanocomposite would afford the requisite electrical contact with the outer-space plasma. The electrical resistivity of the nanocomposite can be tailored to a value between 10(exp 7) and 10(exp 12) Omega-cm. Unlike electrically conductive paint, the nanocomposite becomes an integral part of the anodized aluminum substrate, without need for adhesive bonding material and without risk of subsequent peeling. The electrodeposition process is compatible with commercial anodizing production lines. At present, the electronics industry uses expensive, exotic

  10. Wastewater sludge dewaterability enhancement using hydroxyl aluminum conditioning: Role of aluminum speciation.

    PubMed

    Cao, Bingdi; Zhang, Weijun; Wang, Qiandi; Huang, Yangrui; Meng, Chenrui; Wang, Dongsheng

    2016-11-15

    Chemical conditioning is one of the most important processes for improve the performance of sludge dewatering device. Aluminum salt coagulant has been widely used in wastewater and sludge treatment. It is generally accepted that pre-formed speciation of aluminum salt coagulants (ASC) has an important influence on coagulation/flocculation performance. In this study, the interaction mechanisms between sludge particles and aluminum salt coagulants with different speciation of hydroxy aluminum were investigated by characterizing the changes in morphological and EPS properties. It was found that middle polymer state aluminum (Alb) and high polymer state aluminum (Alc) performed better than monomer aluminum and oligomeric state aluminum (Ala) in reduction of specific resistance to filtration (SRF) and compressibility of wastewater sludge due to their higher charge neutralization and formed more compact flocs. Sludge was significantly acidified after addition Ala, while pH was much more stable under Alb and Alc conditioning due to their hydrolysis stability. The size of sludge flocs conditioned with Alb and Alc was small but flocs structure was denser and more compact, and floc strength is higher, while that formed from Ala is relatively large, but floc structure was loose, floc strength is relatively lower. Scanning environmental microscope analysis revealed that sludge flocs conditioned by Alb and Alc (especially PAC2.5 and Al13) exhibited obvious botryoidal structure, this is because sludge flocs formed by Alb and Alc were more compact and floc strength is high, it was easy generated plentiful tiny channels for water release. In addition, polymeric aluminum salt coagulant (Alb, Alc) had better performance in compressing extracellular polymeric substances (EPS) structure and removing sticky protein-like substances from soluble EPS fraction, contributing to improvement of sludge filtration performance. Therefore, this study provides a novel solution for improving sludge

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

    PubMed

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

    2016-04-01

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

  12. Recommended Aluminum Pipe Welding Procedures for Corps of Engineers Construction.

    DTIC Science & Technology

    1984-09-01

    tungsten -arc welding process) (4) Use of the extended land joint configuration; O-s (5) Use of current limits set by the Aluminum Association and ALCOA. ~0...Design Used for the 1-In. Schedule 10 Pipe 9 3 Typical Metal Weld Made Using Gas Tungsten -Arc Welding 11 4 Typical Small-Diameter Pipe Tensile Test...aluminum pipe commonly Approach used in military applications (Table 1). The gas Available literature on aluminum welding was tungsten -arc welding

  13. Cast Aluminum Bonding Study

    DTIC Science & Technology

    1988-05-01

    fabricated using P?-’r;est11 bur)ld II19 te(hnll I Oly with 6 cIsL nqs. The cast a lumi num alloy used was A357 . The sur- face preparation was phosphoric acid...from a cast aluminum alloy designated A357 . The bonding surfaces of the adherends were prepared using PAA. One primer and two adhesives considered...System, Cast Aluminum Lap Shear 18 11 Bond Area of 350°F Adhesive System, Cast Aluminum Lap Shear 19 vi LIST OF TABLES TABLE PAGE 1 A357 Chemical

  14. CHARACTERIZATION AND ALUMINUM DISSOLUTION DEMONSTRATION WITH A 3 LITER TANK 51H SAMPLE

    SciTech Connect

    Hay, M; John Pareizs, J; Cj Bannochie, C; Michael Stone, M; Damon Click, D; Daniel McCabe, D

    2008-02-29

    A 3-liter sludge slurry sample was sent to SRNL for demonstration of a low temperature aluminum dissolution process. The sludge was characterized before and after the aluminum dissolution. Post aluminum dissolution sludge settling and the stability of the decanted supernate were also observed. The characterization of the as-received 3-liter sample of Tank 51H sludge slurry shows a typical high aluminum HM sludge. The XRD analysis of the dried solids indicates Boehmite is the predominant crystalline form of aluminum in the sludge solids. However, amorphous phases of aluminum present in the sludge would not be identified using this analytical technique. The low temperature (55 C) aluminum dissolution process was effective at dissolving aluminum from the sludge. Over the three week test, {approx}42% of the aluminum was dissolved out of the sludge solids. The process appears to be selective for aluminum with no other metals dissolving to any appreciable extent. At the termination of the three week test, the aluminum concentration in the supernate had not leveled off indicating more aluminum could be dissolved from the sludge with longer contact times or higher temperatures. The slow aluminum dissolution rate in the test may indicate the dissolution of the Boehmite form of aluminum however; insufficient kinetic data exists to confirm this hypothesis. The aluminum dissolution process appears to have minimal impact on the settling rate of the post aluminum dissolution sludge. However, limited settling data were generated during the test to quantify the effects. The sludge settling was complete after approximately twelve days. The supernate decanted from the settled sludge after aluminum dissolution appears stable and did not precipitate aluminum over the course of several months. A mixture of the decanted supernate with Tank 11 simulated supernate was also stable with respect to precipitation.

  15. Lightweight Aluminum/Nano composites for Automotive Drive Train Applications

    SciTech Connect

    Chelluri, Bhanumathi; Knoth, Edward A.; Schumaker, Edward J.

    2012-12-14

    During Phase I, we successfully processed air atomized aluminum powders via Dynamic Magnetic Compaction (DMC) pressing and subsequent sintering to produce parts with properties similar to wrought aluminum. We have also showed for the first time that aluminum powders can be processed without lubes via press and sintering to 100 % density. This will preclude a delube cycle in sintering and promote environmentally friendly P/M processing. Processing aluminum powders via press and sintering with minimum shrinkage will enable net shape fabrication. Aluminum powders processed via a conventional powder metallurgy process produce too large a shrinkage. Because of this, sinter parts have to be machined into specific net shape. This results in increased scrap and cost. Fully sintered aluminum alloy under this Phase I project has shown good particle-to-particle bonding and mechanical properties. We have also shown the feasibility of preparing nano composite powders and processing via pressing and sintering. This was accomplished by dispersing nano silicon carbide (SiC) powders into aluminum matrix comprising micron-sized powders (<100 microns) using a proprietary process. These composite powders of Al with nano SiC were processed using DMC press and sinter process to sinter density of 85-90%. The process optimization along with sintering needs to be carried out to produce full density composites.

  16. Corrosion Inhibitors for Aluminum.

    ERIC Educational Resources Information Center

    Muller, Bodo

    1995-01-01

    Describes a simple and reliable test method used to investigate the corrosion-inhibiting effects of various chelating agents on aluminum pigments in aqueous alkaline media. The experiments that are presented require no complicated or expensive electronic equipment. (DDR)

  17. Walnut Hulls Clean Aluminum

    NASA Technical Reports Server (NTRS)

    Colberg, W. R.; Gordon, G. H.; Jackson, C. H.

    1984-01-01

    Hulls inflict minimal substrate damage. Walnut hulls found to be best abrasive for cleaning aluminum surfaces prior to painting. Samples blasted with walnut hulls showed no compressive stress of surface.

  18. Aluminum-lithium target behavior

    SciTech Connect

    McDonell, W.R.

    1989-10-01

    Information on physical properties and irradiation behavior of aluminum-lithium target alloys employed for the production of tritium in Savannah River reactors has been reviewed to support development of technology for the New Production Reactor (NPR). Phase compositions and microstructures, thermal conductivity, mechanical properties, and constituent diffusion phenomena of the alloys, established in prior site studies, are presented. Irradiation behavior, including distributions of product tritium and helium and related exposure limits due to swelling and cracking of the target alloys is discussed, along with gas release processes occurring during subsequent product recovery operations. The property review supports designation of the aluminum-lithium alloys as ideally well-suited target materials for low-temperature, tritium-producing reactors, demonstrated over 35 years of Savannah River reactor operation. Low temperature irradiation and reaction with lithium in the alloy promotes tritium retention during reactor exposure, and the aluminum provides a matrix from which the product is readily recovered on heating following irradiation. 33 refs., 26 figs., 8 tabs.

  19. Analysis of peel strength of consisting of an aluminum sheet, anodic aluminum oxide and a copper foil laminate composite

    NASA Astrophysics Data System (ADS)

    Shin, Hyeong-Won; Lee, Hyo-Soo; Jung, Seung-Boo

    2017-01-01

    Laminate composites consisting of an aluminum sheet, anodic aluminum oxide, and copper foil have been used as heat-spreader materials for high-power light-emitting diodes (LEDs). These composites are comparable to the conventional structure comprising an aluminum sheet, epoxy adhesives, and copper foil. The peel strength between the copper foil and anodic aluminum oxide should be more than 1.0 kgf/cm in order to be applied in high-power LED products. We investigated the effect of the anodic aluminum oxide morphology and heat-treatment conditions on the peel strength of the composites. We formed an anodic aluminum oxide layer on a 99.999% pure aluminum sheet using electrochemical anodization. A Ti/Cu seed layer was formed using the sputtering direct bonding copper process in order to form a copper circuit layer on the anodic aluminum oxide layer by electroplating. The developed heat spreader, composed of an aluminum layer, anodic aluminum oxide, and a copper circuit layer, showed peel strengths ranging from 1.05 to 3.45 kgf/cm, which is very suitable for high-power LED applications.

  20. Aluminum powder applications

    SciTech Connect

    Gurganus, T.B.

    1995-08-01

    Aluminum powders have physical and metallurgical characteristics related to their method of manufacture that make them extremely important in a variety of applications. They can propel rockets, improve personal hygiene, increase computer reliability, refine exotic alloys, and reduce weight in the family sedan or the newest Air Force fighter. Powders formed into parts for structural and non-structural applications hold the key to some of the most exciting new developments in the aluminum future.

  1. CORROSION PROTECTION OF ALUMINUM

    DOEpatents

    Dalrymple, R.S.; Nelson, W.B.

    1963-07-01

    Treatment of aluminum-base metal surfaces in an autoclave with an aqueous chromic acid solution of 0.5 to 3% by weight and of pH below 2 for 20 to 50 hrs at 160 to 180 deg C produces an extremely corrosion-resistant aluminum oxidechromium film on the surface. A chromic acid concentration of 1 to 2% and a pH of about 1 are preferred. (D.C.W.)

  2. Corrosion Protection of Aluminum

    DOEpatents

    Dalrymple, R. S.; Nelson, W. B.

    1963-07-01

    Treatment of aluminum-base metal surfaces in an autoclave with an aqueous chromic acid solution of 0.5 to 3% by weight and of pH below 2 for 20 to 50 hrs at 160 to 180 deg C produces an extremely corrosion-resistant aluminum oxidechromium film on the surface. A chromic acid concentration of 1 to 2% and a pH of about 1 are preferred.

  3. Aluminum phosphate ceramics for waste storage

    SciTech Connect

    Wagh, Arun; Maloney, Martin D

    2014-06-03

    The present disclosure describes solid waste forms and methods of processing waste. In one particular implementation, the invention provides a method of processing waste that may be particularly suitable for processing hazardous waste. In this method, a waste component is combined with an aluminum oxide and an acidic phosphate component in a slurry. A molar ratio of aluminum to phosphorus in the slurry is greater than one. Water in the slurry may be evaporated while mixing the slurry at a temperature of about 140-200.degree. C. The mixed slurry may be allowed to cure into a solid waste form. This solid waste form includes an anhydrous aluminum phosphate with at least a residual portion of the waste component bound therein.

  4. Spatial Mechanical Response and Strain Gradient Evolution of Friction Stir Welded Aluminum-2139

    DTIC Science & Technology

    2012-02-01

    Background Aluminum alloys are becoming increasingly desirable structural metals for replacing steel due to their lower density, 2.67 and 7.87 g/cm 3... aluminum alloys. FSW is an optimal process for welding aluminum , in comparison to conventional welding techniques that are difficult to fuse together...due to the aluminum oxide (Al2O3) formed on the surface (3). FSW reduces the cracks and voids that are formed during other joining processes. FSW

  5. Aluminum-stabilized Nb[sub 3]Sn superconductor

    DOEpatents

    Scanlan, R.M.

    1988-05-10

    Disclosed are an aluminum-stabilized Nb[sub 3]Sn superconductor and process for producing same, utilizing ultrapure aluminum. Ductile components are co-drawn with aluminum to produce a conductor suitable for winding magnets. After winding, the conductor is heated to convert it to the brittle Nb[sub 3]Sn superconductor phase, using a temperature high enough to perform the transformation but still below the melting point of the aluminum. This results in reaction of substantially all of the niobium, while providing stabilization and react-in-place features which are beneficial in the fabrication of magnets utilizing superconducting materials. 4 figs.

  6. Aluminum-stabilized Nb/sub 3/Sn superconductor

    DOEpatents

    Scanlan, R.M.

    1984-02-10

    This patent discloses an aluminum-stabilized Nb/sub 3/Sn superconductor and process for producing same, utilizing ultrapure aluminum. Ductile components are co-drawn with aluminum to produce a conductor suitable for winding magnets. After winding, the conductor is heated to convert it to the brittle Nb/sub 3/Sn superconductor phase, using a temperature high enough to perform the transformation but still below the melting point of the aluminum. This results in reaction of substantially all of the niobium, while providing stabilization and react-in-place features which are beneficial in the fabrication of magnets utilizing superconducting materials.

  7. Air-Impregnated Nanoporous Anodic Aluminum Oxide Layers for Enhancing the Corrosion Resistance of Aluminum.

    PubMed

    Jeong, Chanyoung; Lee, Junghoon; Sheppard, Keith; Choi, Chang-Hwan

    2015-10-13

    Nanoporous anodic aluminum oxide layers were fabricated on aluminum substrates with systematically varied pore diameters (20-80 nm) and oxide thicknesses (150-500 nm) by controlling the anodizing voltage and time and subsequent pore-widening process conditions. The porous nanostructures were then coated with a thin (only a couple of nanometers thick) Teflon film to make the surface hydrophobic and trap air in the pores. The corrosion resistance of the aluminum substrate was evaluated by a potentiodynamic polarization measurement in 3.5 wt % NaCl solution (saltwater). Results showed that the hydrophobic nanoporous anodic aluminum oxide layer significantly enhanced the corrosion resistance of the aluminum substrate compared to a hydrophilic oxide layer of the same nanostructures, to bare (nonanodized) aluminum with only a natural oxide layer on top, and to the latter coated with a thin Teflon film. The hydrophobic nanoporous anodic aluminum oxide layer with the largest pore diameter and the thickest oxide layer (i.e., the maximized air fraction) resulted in the best corrosion resistance with a corrosion inhibition efficiency of up to 99% for up to 7 days. The results demonstrate that the air impregnating the hydrophobic nanopores can effectively inhibit the penetration of corrosive media into the pores, leading to a significant improvement in corrosion resistance.

  8. Constraints on formation processes of two coarse-grained calcium- aluminum-rich inclusions: a study of mantles, islands and cores

    USGS Publications Warehouse

    Meeker, G.P.

    1995-01-01

    Many coarse-grained calcium- aluminum-rich inclusions (CAIs) contain features that are inconsistent with equilibrium liquid crystallization models of origin. Spinel-free islands (SFIs) in spinel-rich cores of Type B CAIs are examples of such features. One model previously proposed for the origin of Allende 5241, a Type B1 CAI containing SFIs, involves the capture and assimilation of xenoliths by a liquid droplet in the solar nebula (El Goresy et al, 1985; MacPherson et al 1989). This study reports new textural and chemical zoning data from 5241 and identifies previously unrecognized chemical zoning patterns in the melilite mantle and in a SFI. -from Author

  9. ALUMINUM AND CHROMIUM LEACHING WORKSHOP WHITEPAPER

    SciTech Connect

    McCabe, D; Jeff Pike, J; Bill Wilmarth, B

    2007-04-25

    A workshop was held on January 23-24, 2007 to discuss the status of processes to leach constituents from High Level Waste (HLW) sludges at the Hanford and Savannah River Sites. The objective of the workshop was to examine the needs and requirements for the HLW flowsheet for each site, discuss the status of knowledge of the leaching processes, communicate the research plans, and identify opportunities for synergy to address knowledge gaps. The purpose of leaching of non-radioactive constituents from the sludge waste is to reduce the burden of material that must be vitrified in the HLW melter systems, resulting in reduced HLW glass waste volume, reduced disposal costs, shorter process schedules, and higher facility throughput rates. The leaching process is estimated to reduce the operating life cycle of SRS by seven years and decrease the number of HLW canisters to be disposed in the Repository by 1000 [Gillam et al., 2006]. Comparably at Hanford, the aluminum and chromium leaching processes are estimated to reduce the operating life cycle of the Waste Treatment Plant by 20 years and decrease the number of canisters to the Repository by 15,000-30,000 [Gilbert, 2007]. These leaching processes will save the Department of Energy (DOE) billions of dollars in clean up and disposal costs. The primary constituents targeted for removal by leaching are aluminum and chromium. It is desirable to have some aluminum in glass to improve its durability; however, too much aluminum can increase the sludge viscosity, glass viscosity, and reduce overall process throughput. Chromium leaching is necessary to prevent formation of crystalline compounds in the glass, but is only needed at Hanford because of differences in the sludge waste chemistry at the two sites. Improving glass formulations to increase tolerance of aluminum and chromium is another approach to decrease HLW glass volume. It is likely that an optimum condition can be found by both performing leaching and improving

  10. Thermodynamic analysis of contamination by alloying elements in aluminum recycling.

    PubMed

    Nakajima, Kenichi; Takeda, Osamu; Miki, Takahiro; Matsubae, Kazuyo; Nakamura, Shinichiro; Nagasaka, Tetsuya

    2010-07-15

    In previous studies on the physical chemistry of pyrometallurgical processing of aluminum scrap, only a limited number of thermodynamic parameters, such as the Gibbs free energy change of impurity reactions and the variation of activity of an impurity in molten aluminum, were taken into account. In contrast, in this study we thermodynamically evaluated the quantitative removal limit of impurities during the remelting of aluminum scrap; all relevant parameters, such as the total pressure, the activity coefficient of the target impurity, the temperature, the oxygen partial pressure, and the activity coefficient of oxidation product, were considered. For 45 elements that usually occur in aluminum products, the distribution ratios among the metal, slag, and gas phases in the aluminum remelting process were obtained. Our results show that, except for elements such as Mg and Zn, most of the impurities occurred as troublesome tramp elements that are difficult to remove, and our results also indicate that the extent to which the process parameters such as oxygen partial pressure, temperature, and flux composition can be changed in aluminum production is quite limited compared to that for iron and copper production, owing to aluminum's relatively low melting point and strong affinity for oxygen. Therefore, the control of impurities in the disassembly process and the quality of scrap play important roles in suppressing contamination in aluminum recycling.

  11. 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.

  12. Electrolytic production of high purity aluminum using ceramic inert anodes

    DOEpatents

    Ray, Siba P.; Liu, Xinghua; Weirauch, Douglas A.; DiMilia, Robert A.; Dynys, Joseph M.; Phelps, Frankie E.; LaCamera, Alfred F.

    2002-01-01

    A method of producing commercial purity aluminum in an electrolytic reduction cell comprising ceramic inert anodes is disclosed. The method produces aluminum having acceptable levels of Fe, Cu and Ni impurities. The ceramic inert anodes used in the process may comprise oxides containing Fe and Ni, as well as other oxides, metals and/or dopants.

  13. Electrolytic production of high purity aluminum using inert anodes

    DOEpatents

    Ray, Siba P.; Liu, Xinghua; Weirauch, Jr., Douglas A.

    2001-01-01

    A method of producing commercial purity aluminum in an electrolytic reduction cell comprising inert anodes is disclosed. The method produces aluminum having acceptable levels of Fe, Cu and Ni impurities. The inert anodes used in the process preferably comprise a cermet material comprising ceramic oxide phase portions and metal phase portions.

  14. Numerical Simulation and Chaotic Analysis of an Aluminum Holding Furnace

    NASA Astrophysics Data System (ADS)

    Wang, Ji-min; Zhou, Yuan-yuan; Lan, Shen; Chen, Tao; Li, Jie; Yan, Hong-jie; Zhou, Jie-min; Tian, Rui-jiao; Tu, Yan-wu; Li, Wen-ke

    2014-12-01

    To achieve high heat efficiency, low pollutant emission and homogeneous melt temperature during thermal process of secondary aluminum, taking into account the features of aluminum alloying process, a CFD process model was developed and integrated with heat load and aluminum temperature control model. This paper presented numerical simulation of aluminum holding furnaces using the customized code based on FLUENT packages. Thermal behaviors of aluminum holding furnaces were investigated by probing into main physical fields such as flue gas temperature, velocity, and concentration, and combustion instability of aluminum holding process was represented by chaos theory. The results show that aluminum temperature uniform coefficient firstly decreases during heating phase, then increases and reduces alternately during holding phase, lastly rises during standing phase. Correlation dimension drops with fuel velocity. Maximal Lyapunov exponent reaches to a maximum when air-fuel ratio is close to 1. It would be a clear comprehension about each phase of aluminum holding furnaces to find new technology, retrofit furnace design, and optimize parameters combination.

  15. Aluminum, parathyroid hormone, and osteomalacia

    SciTech Connect

    Burnatowska-Hledin, M.A.; Kaiser, L.; Mayor, G.H.

    1983-01-01

    Aluminum exposure in man is unavoidable. The occurrence of dialysis dementia, vitamin D-resistant osteomalacia, and hypochromic microcytic anemia in dialysis patients underscores the potential for aluminum toxicity. Although exposure via dialysate and hyperalimentation leads to significant tissue aluminum accumulation, the ubiquitous occurrence of aluminum and the severe pathology associated with large aluminum burdens suggest that smaller exposures via the gastrointestinal tract and lungs could represent an important, though largely unrecognized, public health problem. It is clear that some aluminum absorption occurs with the ingestion of small amounts of aluminum in the diet and medicines, and even greater aluminum absorption is seen in individuals consuming large amounts of aluminum present in antacids. Aluminum absorption is enhanced in the presence of elevated circulating parathyroid hormone. In addition, elevated PTH leads to the preferential deposition of aluminum in brain and bone. Consequently, PTH is likely to be involved in the pathogenesis of toxicities in those organs. PTH excess also seems to lead to the deposition of aluminum in the parathyroid gland. The in vitro demonstration that aluminum inhibits parathyroid hormone release is consistent with the findings of a euparathyroid state in dialysis patients with aluminum related vitamin D-resistant osteomalacia. Nevertheless, it seems likely that hyperparathyroidism is at least initially involved in the pathogenesis of aluminum neurotoxicity and osteomalacia; the increases in tissue aluminum stores are followed by suppression of parathyroid hormone release, which is required for the evolution of osteomalacia. Impaired renal function is not a prerequisite for increased tissue aluminum burdens, nor for aluminum-related organ toxicity. Consequently, it is likely that these diseases will be observed in populations other than those with chronic renal disease.

  16. 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.

  17. Fatal aluminum phosphide poisoning.

    PubMed

    Anger, F; Paysant, F; Brousse, F; Le Normand, I; Develay, P; Gaillard, Y; Baert, A; Le Gueut, M A; Pepin, G; Anger, J P

    2000-03-01

    A 39-year-old man committed suicide by ingestion of aluminum phosphide, a potent mole pesticide, which was available at the victim's workplace. The judicial authority ordered an autopsy, which ruled out any other cause of death. The victim was discovered 10 days after the ingestion of the pesticide. When aluminum phosphide comes into contact with humidity, it releases large quantities of hydrogen phosphine (PH3), a very toxic gas. Macroscopic examination during the autopsy revealed a very important asphyxia syndrome with major visceral congestion. Blood, urine, liver, kidney, adrenal, and heart samples were analyzed. Phosphine gas was absent in the blood and urine but present in the brain (94 mL/g), the liver (24 mL/g), and the kidneys (41 mL/g). High levels of phosphorus were found in the blood (76.3 mg/L) and liver (8.22 mg/g). Aluminum concentrations were very high in the blood (1.54 mg/L), brain (36 microg/g), and liver (75 microg/g) compared to the usual published values. Microscopic examination revealed congestion of all the organs studied and obvious asphyxia lesions in the pulmonary parenchyma. All these results confirmed a diagnosis of poisoning by aluminum phosphide. This report points out that this type of poisoning is rare and that hydrogen phosphine is very toxic. The phosphorus and aluminum concentrations observed and their distribution in the different viscera are discussed in relation to data in the literature.

  18. Aluminum and aluminum alloys as sources of hydrogen for fuel cell applications

    NASA Astrophysics Data System (ADS)

    Soler, Lluís; Macanás, Jorge; Muñoz, Maria; Casado, Juan

    Production of hydrogen using aluminum and aluminum alloys with aqueous alkaline solutions is studied. This process is based on aluminum corrosion, consuming only water and aluminum which are cheaper raw materials than other compounds used for in situ hydrogen generation, such as chemical hydrides. In principle, this method does not consume alkali because the aluminate salts produced in the hydrogen generation undergo a decomposition reaction that regenerates the alkali. As a consequence, this process could be a feasible alternative for hydrogen production to supply fuel cells. Preliminary results showed that an increase of base concentration and working solution temperature produced an increase of hydrogen production rate using pure aluminum. Furthermore, an improvement of hydrogen production rates and yields was observed varying aluminum alloys composition and increasing their reactive surface, with interesting results for Al/Si and Al/Co alloys. The development of this idea could improve yields and reduce costs in power units based on fuel cells which use hydrides as raw material for hydrogen production.

  19. Technological, Economic, and Environmental Optimization of Aluminum Recycling

    NASA Astrophysics Data System (ADS)

    Ioana, Adrian; Semenescu, Augustin

    2013-08-01

    The four strategic directions (referring to the entire life cycle of aluminum) are as follows: production, primary use, recycling, and reuse. Thus, in this work, the following are analyzed and optimized: reducing greenhouse gas emissions from aluminum production, increasing energy efficiency in aluminum production, maximizing used-product collection, recycling, and reusing. According to the energetic balance at the gaseous environment level, the conductive transfer model is also analyzed through the finished elements method. Several principles of modeling and optimization are presented and analyzed: the principle of analogy, the principle of concepts, and the principle of hierarchization. Based on these principles, an original diagram model is designed together with the corresponding logic diagram. This article also presents and analyzes the main benefits of aluminum recycling and reuse. Recycling and reuse of aluminum have the main advantage that it requires only about 5% of energy consumed to produce it from bauxite. The aluminum recycling and production process causes the emission of pollutants such as dioxides and furans, hydrogen chloride, and particulate matter. To control these emissions, aluminum recyclers are required to comply with the National Emission Standards for Hazardous Air Pollutants for Secondary Aluminum Production. The results of technological, economic, and ecological optimization of aluminum recycling are based on the criteria function's evaluation in the modeling system.

  20. Mercury-free dissolution of aluminum-clad fuel in nitric acid

    DOEpatents

    Christian, Jerry D.; Anderson, Philip A.

    1994-01-01

    A mercury-free dissolution process for aluminum involves placing the aluminum in a dissolver vessel in contact with nitric acid-fluoboric acid mixture at an elevated temperature. By maintaining a continuous flow of the acid mixture through the dissolver vessel, an effluent containing aluminum nitrate, nitric acid, fluoboric acid and other dissolved components are removed.