Alloy A356 Research Articles

Fatigue analysis of alloy wheel using cornering fatigue test and its weight optimization

Aluminium alloys are widely used to manufacture alloy wheels for automobiles. Alloy wheels differ from steel wheels in that they possess high strength to weight ratio, better heat conductivity as well as these wheels have a superior aesthetic look. The present work focusses on the application of corner fatigue test and the simulation of wheel rim in order to reduce its the weight and increase the fatigue life of an aluminium alloy A356 wheel. CATIA V5R19 was used to model the wheel rim, and the fatigue analysis was carried out using Ansys 17. The results of the finite element analysis study indicated that the stress generated in the optimised alloy wheel rim was significantly below the actual yield stress of the aluminium alloy. A mass reduction of 200 gm was achieved through the finite element analysis by proper application of stresses on the wheel rim. The overall weight reduction of 1 kg has contributed to the cost reduction as well as decreased fuel consumption for the automobile.

Influence of NbC addition in aluminium alloy A380 on microstructure at semi-solid processing temperature

Influence of NbC addition in aluminium alloy A380 on microstructure at semi-solid processing temperature

Permeability Measurements of 3D Microstructures Generated by Phase Field Simulation of the Solidification of an Al-Si Alloy during Chill Casting

The permeability of the semi-solid state is important for the compensation of volume shrinkage during solidification, since insufficient melt feeding can cause casting defects such as hot cracks or pores. Direct measurement of permeability during the dynamical evolution of solidification structures is almost impossible, and numerical simulations are the best way to obtain quantitative values. Equiaxed solidification of the Al-Si-Mg alloy A356 was simulated on the microscopic scale using the phase field method. Simulated 3D solidification structures for different stages along the solidification path were digitally processed and scaled up to generate 3D models by additive manufacturing via fused filament fabrication (FFF). The Darcy permeability of these models was determined by measuring the flow rate and the pressure drop using glycerol as a model fluid. The main focus of this work is a comparison of the measured permeability to results from computational fluid flow simulations in the phase field framework. In particular, the effect of the geometrical constraint due to isolated domain walls in a unit cell with a periodic microstructure is discussed. A novel method to minimize this effect is presented. For permeability values varying by more than two orders of magnitude, the largest deviation between measured and simulated permeabilities is less than a factor of two.

Double-Ligand Strategy to Construct an Inhibitor-Loaded Zn-MOF and Its Corrosion Protection Ability for Aluminum Alloy 2A12

A promising double-ligand strategy for the delivery of active corrosion inhibitors by a Zn(II)-based metal-organic framework (Zn-MOF) is developed. Zn-MOF compounds were synthesized by a facile one-pot solvothermal method and characterized. The Zn-MOF is based on the corrosion inhibitor benzotriazole (BTA) and 2,5-furandicarboxylic acid (H2FDA) ligand, which is a promising renewable building block alternative to terephthalic or isophthalic acid. The crystal structure and morphology are characterized by single-crystal X-ray diffraction analysis, powder X-ray diffraction analysis (PXRD), Fourier transform infrared spectroscopy (FT-IR), and scanning electron microscopy (SEM). The synthesized MOF crystallites are in the trigonal space group R3c with the cell parameters in a three-dimensional (3D) anionic framework. Their ability to inhibit the corrosion process of aluminum alloy 2A12 in NaCl solution was also evaluated by immersion tests in solutions with and without a MOF. The postcorrosion analysis was performed by SEM and X-ray photoelectron spectroscopy (XPS). Additional information about the inhibition efficiency was obtained by electrochemical impedance spectroscopy (EIS). The results suggest that the as-synthesized MOF can release the inhibitors and form protective layers effectively on the surface of the aluminum alloy. The use of inhibitor-loaded MOF nanocontainers provides promising opportunities for the smart delivery of inhibitors and effective corrosion protection of 2A12 aluminum alloys.

An Investigation on Constitutive Model of Aluminum Alloy 2A12 by Isothermal Hot Compression

The plasticity flow behavior of 2A12 aluminum alloy under a wide range of temperatures ranging from 300°C to 450°C and strain rates ranging from 0.01s-1 to 1s-1 was studied by isothermal hot compression testing. The plastic behavior shows a peak stress in stress strain curve. At the beginning stage of deformation, the stress increases with strain rapidly, then flow stress decreases showing softening characteristics. The results show that the peak stress increases with the strain rate showing rate hardening, while decreases with the temperature showing heat softening. The strain flow stress curve was modeled by a novel function which consist an exponential and linear term with hardening coefficient, peak stress and softening modulus. The coupling effect of strain rate and temperature on the peak stress was studied by an Arrhenius-type equation. The effect of strain rate and temperature on hardening coefficient, peak stress and softening modulus was discussed and modeled by linear equations.

Less-loading hydroforming process for large-size hollow components of aluminum alloy

To overcome the problem of welding distortion on conventional multiple segment structures, and the problem of requiring large-scale forming equipment and severe thinning occurs in high-pressure hydroforming process, a novel less-loading hydroforming process is proposed for manufacturing large-size hollow components in this paper. The geometrical relationship of the tube blank during less-loading hydroforming process is firstly discussed. Then, experiment and numerical simulation are conducted to investigate the forming behavior of a large-size tubular component of aluminum alloy 5A06 with rectangular cross-section. It is found that the needed internal pressure, die closing force, and axial force for the less-loading hydroforming are significantly reduced, which are about 1/22, 1/8 and 1/28 of those required in high-pressure hydroforming, respectively. During the less-loading hydroforming process, the tube blank is firstly deformed by bending to fill the die corners, and then deformed by circumferential compression. Moreover, the compression deformation characteristics make the thickness increase. However, a too large circumferential compression and/or an insufficient supporting pressure will cause a wrinkle defect. These results provide insights for less-loading and approaching uniform manufacturing of large-size hollow components.

Re-evaluation of the mechanical properties and creep resistance of commercial magnesium die-casting alloy AE44

This paper presents a re-evaluation of the room temperature mechanical properties and high temperature creep resistance of magnesium die-casting alloy AE44 (Mg-4Al-4RE) in light of the influence of minor Mn addition. It is shown that the Mn-containing AE44 exhibits distinct age hardening response upon direct ageing (T5) due to the precipitation of nanoscale Al-Mn particles, as reported previously in a similar alloy. The T5 ageing leads to a significant improvement in strength with similar ductility. Consequently, the T5-aged AE44 has a remarkably better strength-ductility combination than most Mg die-casting alloys and even the Al die-casting alloy A380. Minor Mn addition is also shown to be critical for the creep resistance of AE44 whereas the influence of the RE constituent is not as significant as previously thought, which reaffirms that precipitation hardening of the α-Mg matrix is more important than grain boundary reinforcement by intermetallic phases for the creep resistance of die-cast Mg alloys. The findings in this work could provide new application perspectives for AE44, particularly in the automotive industry.

Studies on Tribological and Statistical Modeling for Al/ZrO2 MMC’s

Abstract: In recent era early growth and remarkable development with regards of composite materials has become a need of designing area on account of consideration to the drawbacks over conventional materials in improving material properties which includes viz, stiffness, density, toughness, and strength.This research focuses on utilizing the stir casting method of forming better metal matrix composite by using ZrO2 as reinforcing material thereby developing a composite material.Current study investigates Al357 alloy is fortified with different percentage of ZrO2 (3%, 5% and 7%) is concocted by the stir casting and studied for a microstructure, mechanical and the statistical modelling of wear analysis. Wear tracks of the as-cast alloy and its composites were examined using SEM. From the results it was concluded that compared to as-cast alloy A357/ 7 % ZrO2 displayed better properties compared followed by 5% and 3% composites. Keywords: MMC’S; ZrO2; Aluminium 357 alloy; Hardness test; Statistical Analysis.

Grinding of High-Strength Materials

The joint research of scientists of two countries deals with cylindrical and surface grinding with abrasive wheels of heat-resistant steel Inconel 625 (KhN77TYu GOST 5632 – 72 Russian Federation standard), (analogues include Hastalloy, N07080, Alloy 80A, Nimonic 80A, 2.4952 ASTM B637/ASME SB637, UNS N07080). The article shows the results of studies of the features of high-temperature steel during grinding with a fastened abrasive. The results of experiments are given to determine the optimal characteristics of grinding wheels, grinding modes, cooling-lubricant fluids. Experimental data about geometric accuracy, surface roughness, resistance of wheels are demonstrated as well. The ways to prevent from defects during cylindrical and surface grinding of high-strength steel are proposed. The recommendations to increase the tool resistance and output of the process are given.

Microstructure and Mechanical Properties of Aluminum Cast Alloy A356 reinforced with Dual-Size B4C Particles

The paper details the studies carried out on a dual-size particulate composite prepared by stir casting using A 356 aluminum alloy and B4C powders. Three composite compositions, viz., A356 plus 2% B4C (44µm size and 105µm size in 1:1 ratio), 4% B4C (3:1 ratio), and 6% B4C (1:3 ratio) were cast in finger molds, from which test specimens were prepared for hardness and tensile tests as well as for metallography. Vickers hardness tests, tensile tests and microstructure analysis using an optical microscope were conducted. The results obtained indicated that the B4C particles were evenly distributed in the alloy matrix. EDS also revealed the presence of B4C in all the three composites. In general, the hardness and tensile strengths increased with increase in concentration B4C powders. While the increase in hardness was increases less than 15%, there was significant increase (more than 35 %) in tensile strength. However, the ductility represented by % elongation, which was already very low in A 356 cast alloy (24.2%,), further decreased in composites. Tensile fractography results shows inter crystalline fracture where the breakage in the B4C particle instead of deboning were observed.

Achieving high-strength metallurgical bonding between A356 aluminum and copper through compound casting

Due to stable surface oxides on the solid copper surface and the ease of forming Al 2 O 3 films at the aluminum melt surface, it is difficult to achieve high-strength metallurgical bonding between the two materials through compound casting. In this research, a novel surface coating method for the copper inserts, namely hot-dip Sn-coating, has been applied. Through this method, a high-quality bond between a cast aluminum alloy A356 and commercially pure copper was achieved through a gravity compound casting process. Tensile tests showed that a maximum ultimate tensile strength (UTS) of 90.8 MPa could be obtained for the bimetal interface. Microstructures formed in the aluminum/copper interface were studied by optical- and scanning electron microscopy, while a sessile drop wetting test was used to study the wettability between the aluminum melt and Sn-coated copper substrates. The effects of Sn-coating on the wettability and the formation of interfacial microstructure were discussed. • Continuous metallurgical bond was achieved in aluminum/copper compound castings. • Sn-coating of copper significantly improved wetting between aluminum and copper. • Ultimate tensile strength of 90.8 MPa was measured for the Al/Cu castings. • Effect of the Sn coating layer was discussed.

Retraction: Investigation on mechanical properties of aluminium alloy A356 by reinforcing with TiB2 & WC composites (IOP Conf. Ser.: Mater. Sci. Eng. 1145 012110)

This article (and all articles in the proceedings volume relating to the same conference) has been retracted by IOP Publishing following an extensive investigation in line with the COPE guidelines. This investigation has uncovered evidence of systematic manipulation of the publication process and considerable citation manipulation.IOP Publishing respectfully requests that readers consider all work within this volume potentially unreliable, as the volume has not been through a credible peer review process.IOP Publishing regrets that our usual quality checks did not identify these issues before publication, and have since put additional measures in place to try to prevent these issues from reoccurring. IOP Publishing wishes to credit anonymous whistleblowers and the Problematic Paper Screener [1] for bringing some of the above issues to our attention, prompting us to investigate further.[1] Cabanac G, Labbé C and Magazinov A 2021 arXiv:2107.06751v1 Retraction published: 23 February 2022

Investigation on mechanical properties of aluminium alloy A356 by reinforcing with TiB2 & WC composites

In this project, Aluminium metal matrix hybrid composites are processed through stir casting methodology. A356 is reinforced with ceramic particle-like Titanium diboride (TiB2) and Tungsten carbide (WC) in varying weight percentages of 92.5% A356 and TiB2 5% WC 2.5% of Sample 1, A356 90% TiB2 5% WC 5% of Sample 2, A356 100% of Sample 3 through stir casting technique. Under the Vickers hardness test, the Sample consisting of 90% A356 + 5% TiB2+ 5% WC exhibited superior results. Under the Tensile test, the Sample of 90% A356 + 5% TiB2 + 5% WC exhibited higher tensile strength when compared with the remaining two Samples. It is because the ceramic reinforcement particulates are harder than the A356 matrix material. Then the fractured Samples were examined under SEM and fracture mechanisms were studied.

Nano-yttrium-containing precipitates of T6 heat-treated A356.2 alloy when trace yttrium (Y less than 0.100 wt%) added

To investigate the effect of yttrium (Y) on microstructure refinement and mechanical properties of aluminum alloy A356.2, the different trace contents of Y (0 wt%, 0.025 wt%, 0.050 wt%, 0.075 wt%, or 0.100 wt%) were introduced into the liquid alloy. The alloys were fabricated in a preheated permanent mold, and subsequently treated by a T6 heat treatment. The results of tensile testing indicate that the yield strength (YS), the ultimate tensile strength (UTS) and the elongation (El) of the A356.2 alloy are improved by the Y additions. The YS dependence on grain size for the test alloys follows the Hall–Petch equation, which gives $${\text{YS}} = - 354.1 + {2875}{\text{.2}}d^{ - 1/2}$$ with a correlation of R2 = 0.83. As 0.050 wt% Y is added, the optimum values of the YS, UTS and El are achieved after T6 heat treatment. The secondary phases were identified by X-ray diffraction (XRD) which mainly consisted as Si, Mg2Si and Al3Y. The scanning electron microscope (SEM) and energy-dispersive spectrometer (EDS) analyses reveal the presence of the nano-sized Al3Y particles on the surface of the Si phase. The A356.2 alloy with the Y addition is strengthened by the dendritic refinement, and the presence of the micron- and nano-sized Al3Y precipitates.

Investigation of Stresses Induced Due to the Mismatch of the Coefficients of Thermal Expansion of the Matrix and the Strengthening Particle in Aluminum-Based Composites

An experimental and theoretical investigation of the strength properties of aluminum alloys strengthened by dispersed nanoparticles, as well as the determination of the significance of various mechanisms responsible for the strengthening of the material, was carried out. Results of experimental investigation demonstrate that the hardening of aluminum alloy A356 by Al2O3 and ScF3 nanoparticles leads to an increase in the yield strength, ultimate tensile strength, and plasticity. Despite the similar size of Al2O3 and ScF3 nanoparticles, the physicomechanical properties of nanoparticles significantly affect the possibility of increasing the mechanical properties of the A356 aluminum alloy. A physicomathematical model of the occurrence of thermal stresses was developed caused by the mismatch of the coefficients of thermal expansion (CTEs) of the matrix and strengthening particles on the basis of the fundamental principles of mechanics of a deformable solid and taking into account the elastic properties of not only the matrix, but also the particle. The forming of thermal stresses induced due to the mismatch of the coefficients of thermal expansion of the matrix and the strengthening particle in aluminum-based composites was investigated. In the case of thermal deformation of dispersion-hardened alloys, when the CTE of the matrix and particles noticeably differ, an additional stress field is created in the vicinity of the strengthening particle. Thermal stresses increase the effective particle size. This phenomenon can significantly affect the result of the assessment of the yield strength. The strengthening caused by thermal mismatch makes the largest contribution to the yield strength improvement. The yield strength increments due to Nardon×Prewo and Orowan mechanisms are much lower.

Modeling and simulation studies of 100 cc motor cycle engine cylinder with groove and perforated fin design using different materials

The modeling and simulation studies of 100 cc motor cycle engine cylinder with fins are carried out to analyze the heat transfer rate of the engine block. The engine cylinder with fins is modeled using Autodesk Fusion360 having different groove widths of 10 mm, 7.5 mm, 5 mm and 2.5 mm size and different perforation diameters in the fins such as 4 mm, 3 mm and 2 mm. The materials used for modeling in these studies are aluminium cast alloy A356, AA 1060, AA2014-T6, cast iron with 2% nickel, magnesium alloy AM60A-F and Sintered Aluminium Powder (SAP). It is observed that engine cylinder made of cast iron with fins having groove width of 2.5 mm and cylindrical perforation diameter of 4 mm in the fins is most suitable for better heat transfer rate compared to other materials used in this study.

Cooling control for castings by adopting skeletal sand mold design

The cooling control of the melt during the casting process is of great significance. A comprehensive closed-loop cooling control of castings by adopting a skeletal sand mold design was proposed. The skeletal sand mold consisting of an adaptive shell, functional cavities and a support was designed and created based on the finite difference meshes of a casting. It was applied to a round wall test casting. Two kinds of skeletal sand molds, one with lattice support and the other with enforcing ribs for this casting were designed and printed out by the 3D printing (3DP) method. Aluminum alloy A356 was cast by using these two sand molds. The first mold was cooled by natural convection, the other one by water spray cooling. Two sound castings were obtained. The sand mold temperature, cooling curves, microstructures, mechanical properties, residual stress and deformation were measured, compared and discussed. Water spray cooling hastened the cooling rate by 62%, increased the content of Mg and Cu in the α-Al matrix, improved the mechanical properties, and altered the surface residual stress state.

Industrial suitable and digitally recordable application of ultrasound for the enviromentally friendly degassing of aluminium melts before tilt casting

Aluminium casting alloys are important for numerous industrial applications. Due to the high affinity of aluminium melts for the absorption of hydrogen, hydrogen-related porosity is regarded as one of the main defects affecting the quality of castings. The use of rotor degassing and/or chemical degassing tablets prior to casting are state of the art to reduce the hydrogen content of the melt but require the use of additional substances and are often difficult to digitize. Due to its purely physical operating principle ultrasonic degassing (USD) is considered an environmentally friendly alternative to the established procedures and allows digital process monitoring. However, its small primary treatment zone, the cavitation zone, is the reason why the USD has so far been denied widespread industrial use. The approach presented here aims at an USD of aluminium casting alloy A356 in the basin prior to tilt casting. Here the melting volumes are sufficiently small. By using Particle Image Velocimetry (PIV) analyses, CFD simulation and casting tests, this case of application was systematically investigated. It could be shown that the approach followed contributes to a significant reduction of the hydrogen dissolved in the melt by more than 50 % resulting in an increase of mechanical properties, especially elongation.

Processing and characterization of vertical twin roll cast aluminium alloy sheets of A356, A6061 and A6005

Aluminum alloys A356, A606 and A6005 were twin roll cast in sheets 3 mm thickness using a vertical twin roll caster. Microstructure, hardness and wear characteristics of the cast sheets were investigated. VTRC processed sheets showed finer grain size depending upon the solidification range of alloy. It was observed that hardness values of VTRC alloys were significantly higher than those of corresponding ingot cast alloy products. Approximate Hall-Petch calculations show possibilities of additional strengthening mechanisms other than grain boundary for VTRC processed alloys. Extensive wear studies were performed using a pin on disc wear testing machine. The parameters like wear constant, specific wear rate and average friction coefficient were determined to understand the wear behaviour. The wear results show that all the alloy sheets exhibit wear in the mild wear regime.

Microstructure and Properties of As-Cast and Heat-Treated 2017A Aluminium Alloy Obtained from Scrap Recycling

The continuous increase in the consumption of aluminium and its alloys has led to an increase in the amount of aluminium scrap. Due to environmental protection, and to reduce the costs of manufacturing aluminum in recent years, a lot of research is devoted to recycling of aluminum alloys. The paper presents the results of research concerning the possibility of manufacturing standardized alloy 2017A from commercial and post-production scrap by continuous casting. Obtained from recycling process ingots were subjected to analysis of chemical composition and intermetallic phase composition. Based on the results of light microscopy (LM), scanning electron microscopy + electron dispersive spectroscopy (SEM + EDS), and X-ray diffraction (XRD) the following phases in the as-cast state were identified: θ-Al2Cu, β-Mg2Si, Al7Cu2Fe, Q-Al4Cu2Mg8Si7, and α-Al15(FeMn)3(SiCu)2. During solution heat treatment most of the primary precipitates of intermetallic phases, like θ-Al2Cu, β-Mg2Si, and Q-Al4Cu2Mg8Si7, were dissolved in the solid solution α-Al, and during natural and artificial aging they precipitate as strengthening phases θ-Al2Cu and Q-Al4Cu2Mg8Si7 with high dispersion. The highest hardness—150.3 HB—of 2017A alloy was obtained after solution heat treatment from 510 °C and aging at 175 °C. In the static tensile test the mechanical (Rm and Rp0.2) and plastic (A5) properties were determined for 2017A alloy in the cast state and after T4 heat treatment. The highest strength properties—tensile strength Rm = 450.5 MPa and yield strength R0.2 = 268.7 MPa with good relative elongation A5 = 14.65%, were obtained after solution heat treatment at 510 °C/6 h/water quenching and natural aging at 25 °C for 70 h. The alloy manufactured from recycled scrap is characterized by relatively high mechanical properties.