Abstract
A promising technology for integration of top-down nanomanufacturing is equal channel angular pressing, a process transforming metallic materials into nanostructured or ultra-fine grained materials with significantly enhanced performance characteristics. To bridge the gap between process potential and actual manufacturing output a novel prototype system identified as indexing equal channel angular pressing (IX-ECAP) was developed to capitalize on sustainable engineering opportunities of transforming spent or scrap engineering elements into key engineering commodities by recycling 4043 aluminium alloy welding rod residuals. A resolution III fractional factorial split-plot experiment assessed significance of predictors on the response, microhardness, with multiple linear regression used for model development. Five process parameters involving pressing temperature, number of passes, pressing speed, back pressure, and vibration were studied. Microhardness conversions allowed theoretical determination of grain sizes employing Hall-Petch relationships. IX-ECAP offered a viable solution whereby processing of discrete variable length work pieces proved very successful.
Highlights
Materials development, especially metallic systems, has been directed at attaining the highest performance characteristics per unit weight of material
To bridge the gap between process potential and actual manufacturing output a novel prototype system identified as indexing equal channel angular pressing (IX-ECAP) was developed to capitalize on sustainable engineering opportunities of transforming spent or scrap engineering elements into key engineering commodities by recycling 4043 aluminium alloy welding rod residuals
Based on the original plan three replicates were to be conducted for the 1⁄4 fractional factorial split-plot (FFSP) design
Summary
Especially metallic systems, has been directed at attaining the highest performance characteristics per unit weight of material. This scenario is especially critical to industries such as aerospace, automotive, rail, and maritime. Each of these respective applications requires high performance materials of lightweight construction (Azushima et al, 2008). A key objective is the attainment of even higher material strength while at the same time retaining excellent ductility These two performance characteristics are mutually exclusive whereby increased strength is achieved at the expense of ductility and vice versa. With a focus on performance gains from diverse applications of nanotechnology these mutually exclusive restrictions are being challenged and overcome (Valiev, Alexandrov, Zhu, & Lowe, 2002)
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