Deformation Of Aluminum Alloy Research Articles

Research Progress on the Microstructure Evolution Mechanisms of Al-Mg Alloys by Severe Plastic Deformation.

Al-Mg alloys are widely used as important engineering structural materials in aerospace engineering, transportation systems, and structural constructions due to their low density, high specific strength, corrosion resistance, welding capability, fatigue strength, and cost-effectiveness. However, the conventional Al-Mg alloys can no longer fully satisfy the demands of practical production due to difficulties caused by many defects. The high strength of Al-Mg alloys as non-heat treatment precipitation-strengthened alloys is achieved primarily by solid solution strengthening along with work hardening rather than precipitation strengthening. Therefore, severe plastic deformation (SPD) techniques can be often used to produce ultrafine-grained structures to fabricate ultra-high strength aluminum alloys. However, this approach often achieves the strengthening of material at the cost of reduced ductility. This paper comprehensively summarizes the various approaches of ultrafine/nanocrystalline materials for enhancing their plasticity, elaborates on the creation of a bimodal microstructure within the alloy, and discusses the formation of a nanotwin microstructure within the alloy and the incorporation of dispersed nanoparticles. The mechanisms underlying both the strengthening and toughening during large plastic deformation in aluminum alloys are summarized, and the future research direction of high-performance ultrafine crystalline and nanocrystalline Al-Mg aluminum alloys is prospected.

High-speed face milling features of deformable aluminum alloys

High-speed face milling features of deformable aluminum alloys

Analysis of the properties and features of high-strength deformable aluminium alloys of Al-Li, Al-Cu-Mn systems used in the aerospace industry in manufacture of welded structures (Review)

Analysis of the properties and features of high-strength deformable aluminium alloys of Al-Li, Al-Cu-Mn systems used in the aerospace industry in manufacture of welded structures (Review)

CHANGES IN THE STRUCTURE AND PROPERTIES OF ALUMINIUM ALLOYS WHEN MODIFIED WITH POWDER COMPOSITIONS

Purpose. To determine the effect of modification with powder compositions on the structure and mechanical properties of cast and deformed aluminium alloys. Research methods. Metallographic analysis, stereometric metallography, testing of strength and plastic properties of cast alloys AL4, AL4C of the Al-Si system and deformed alloys 1545 of the Al-Mg-Sc system, 2219 of the Al-Cu-Mn system in their original and modified state. Results. Meltings of AL4, AL4C, 1545, 2219 alloys were carried out in the initial state and with melt treatment with a complex nano-disperse modifier of magnesium silicide Mg2Si and silicon carbide SiC with a particle size of 50...100 nm. The optimal content of Mg2Si+SiC (0.10%) for increasing σ0.2 of aluminium alloys was determined. A 1.6-fold reduction in the grain structure of cast alloys was achieved. The dependence of the particle size and the amount of the modifier on the mechanical properties of the alloys was established. In industrial experiments, the most effective particle size of Mg2Si+SiC was established for increasing σ0.2 of AL4, AL4C alloy from 115 to 260 MPa in the as-cast state. The increase in the strength properties of the modified alloys is 44 % compared to the original state. Scientific novelty. Further development, insight into the influence of melt modification on the parameters of the structure and properties of aluminium alloys was obtained. The use of nanodispersed complex modifier Mg2Si+SiС with a particle size of 50...100 nm is proposed. It has been confirmed that the use of complex nanodisperse modifiers allows you to actively influence the structure and mechanical properties of aluminium alloys. Practical value. It has been experimentally proven that the rational amount of the introduced complex modifier is 0.10% of the mass of the melt. A significant grinding of the grain structure and an increase in the strength properties of cast and deformed aluminium alloys were achieved as a result of the modification.

Improving the quality of cold-rolled deformable aluminum alloy billets

A mode of high-speed recrystallization annealing has been developed to increase technological plasticity while maintaining the strength of sheet cold-rolled blanks made of deformable aluminum alloys that are not strengthened by heat treatment. Problem. Cold deformation of cold-rolled plates is achieved by recrystallization annealing in hooded furnaces. However, such annealing often does not provide the technological plasticity for defect-free stamping of products and, as a result, has significant rejects. Hooded furnaces are not suitable for improving the deformation of individual billets. In addition, for products with complex configurations that operate in harsh environments, the requirements for rolled aluminum are increased, which is also not possible to realize in open hearth furnaces. These problems can be solved by high-speed continuous parting heat treatment. Goal. The aim is development of a high-speed recrystallization annealing regime for increasing technological plasticity while maintaining the strength of cold-rolled sheet billets from deformable aluminum alloys. Methodology. The object of the study was thin-sheet (1 mm) billets from cold-rolled aluminum alloys AD1, AMts, AMg3. Strip blanks were subjected to high-speed continuous recrystallization annealing using contact heating. The metal was heated at a rate of 5 ºC/c to temperatures from 250 to 400 ºC with an interval of 50 ºC with a holding time of 5 - 15 min at the heating temperature and cooling in air. The quality of the annealing was judged by the nature of the obtained structure and indicators of mechanical properties. The ability to extract metal in different states was evaluated by the Eriksen method. Result. The least energy-consuming modes of continuous high-speed annealing of workpieces from the studied alloys were developed to obtain increased plasticity indicators (while maintaining strength) and improve cold pressure processing in the manufacture of products of complex configuration. Practical value. High-speed recrystallization annealing provides reduction of defects, saving of metal, improvement of productivity in the production of thin-sheet items by the method of cold deformation with deep and complex drawing.

Constitutive equation and microstructural evolution of one distinctive Al–based hybrid composite reinforced by nano–AlN and micro–TiC particles during hot compression

In this study, an (8.2AlN + 4TiC)/Al–0.3Fe–0.1Mn composite was successfully fabricated for elevated– temperature applications by the liquid–solid reaction method, and the high–temperature performance (hot workability) of the composite was evaluated by unidirectional hot deformation experimentation. The tested temperatures and strain rates were 350–500 °C and 0.001–1 s−1, respectively. The results indicated that the peak stress of the composite was as high as 226 MPa at 350 °C and 1.0 s−1, which was significantly higher than the reported strength values of commercial deformed aluminum alloys or other particle–reinforced Al matrix composites under the same experimental conditions. Although the flow stress of the composite decreased with the increase of deformation temperature and the decrease of strain rate, the peak stress remained at 82 MPa under the experimental conditions of 500 °C and 0.001 s−1. This reflected the excellent high–temperature synergistic strengthening effect of the in–situ nanosized AlN and submicron TiC particles. Based on the true stress–true strain curve, the hot deformation constitutive equation of the composite was established and fitted. The relative microstructural evolution of the composite during hot deformation was characterized by electron backscattering diffraction (EBSD) and transmission electron microscopy (TEM). It was found that the Orowan strengthening and load–transfer strengthening effect of the nanosized AlN and submicron TiC particles were the main reasons for their high–temperature strengthening, and the softening effect of the composite could be attributed to dynamic recovery (DRV) and continuous dynamic recrystallization (CDRX), accompanied by partial discontinuous dynamic recrystallization (DDRX). This study provided a new strategy for the design of heat–resistant Al alloys and their high–temperature strengthening and softening mechanism. This study may provide new insights for designing and achieving good workability in Al–based composites for elevated temperature applications.

Investigation on the formability and deformation mechanism of aluminum alloy thin-walled parts at cryogenic temperature

Due to the poor ductility of aluminum alloy sheet at room temperature, which results in the difficulty in forming complex thin-walled parts, a novel forming method for thin-walled parts at cryogenic temperatures is proposed in this research, at which its strength and ductility are significantly improved. In this work, the cryogenic forming tests of the typical aluminum alloy thin-walled part were carried out, the formability and forming quality of the parts were evaluated, and the mechanism of the increase of strength-ductility at cryogenic temperature was discussed. The results of these experiments indicate that compared to room temperature, the formability of 2024-O aluminum alloy sheet at cryogenic temperature is significantly improved; the maximum forming height of aluminum alloy thin-walled part increases by 21.5% to 96 mm at − 180 ℃; in addition, the quality of parts formed at cryogenic temperature is better, whose maximum thinning rate is only half of the corresponding value at room temperature, and the hardness increases by 8.6%. It can be seen from the microstructure that when aluminum alloy deforming at low temperature, the dynamic recovery is restrained, the accumulation of dislocations leads to the increase of resistance to dislocation’s motion. The deformation of aluminum alloy at low temperature is more uniform, the work hardening ability is significantly improved, and its strength and ductility are enhanced. This study proves the feasibility of forming aluminum alloy thin-walled parts at cryogenic temperature, and provides a new idea for high-quality forming of complex thin-walled parts.

Investigation of the effect of ultrasonic treatment during crystallization on the structure and properties of deformable aluminum alloys

The article presents the methodology and results of the study of the effect of ultrasonic treatment of the melt of deformable aluminum alloys during crystallization on the structure and properties of the formed ingots: the dependence of the grain score, porosity, size and distribution of inclusions of intermetallides on the amplitude of ultrasound radiation and the frequency of vibrations, as well as the distance to the waveguide. In addition, data on the analysis of the transformation of iron‑containing phases (α‑AlFeSi and β‑AlFeSi) under the action of ultrasound and dissolution of titanium waveguides during ultrasonic treatment of aluminum melt are presented.

Study on the microscopic mechanism of age-strengthened high damage tolerance Al–Cu–Mg alloys

In this paper, the effect of the heat treatment process on mechanical properties is systematically investigated, and the optimal aging process is obtained. Transmission Electron Microscopy (TEM) was employed to investigate the microstructure and clarify the microstructural evolution during aging. We found that the σb, σ0.2, δ, and Hardness of Al–Cu–Mg alloys exhibited 476.2 ± 4.4 MPa, 376.2 ± 6.2 MPa, 14.9 ± 0.5%, and 151.2 ± 1.5HV after T6 heat treatment(solution treatment + aging treatment of deformed aluminum alloy), respectively. The TEM results indicated that the precipitate evolution is α-Al→GPB→S'→S during aging. When the ratio of the fractions of the GP: S phase is 10.58, Al–Cu–Mg alloy got the best mechanical properties.

Study on the Influence of Erbium and Preheating Process on Mechanical Properties of As-Cast 7055 Aluminum Alloy.

Although 7055 aluminum alloy is a deformed aluminum alloy and shows excellent mechanical properties after recrystallization and large deformation, through this method, its application range is enriched if rare earth is added, and the rare earth phase dispersion is promoted by heat treatment. This article used optical microscopy, scanning electron microscopy energy dispersive spectroscopy (SEM-EDS), X-ray diffraction (XRD), micro Vickers hardness, and room temperature stretching methods to study the as-cast 7055-xEr (x = 0 wt.%, 0.2 wt.%, 0.4 wt.%, 0.6 wt.%, 0.8 wt.%) aluminum alloy after being subjected to 460 °C × 3 h homogenization and 410 °C × 1 h solid solution + 150 °C × 12 h aging treatment for the changes in its microstructure and properties. The results indicated that: when 0.2 wt.%Er was added to 7055 aluminum alloy after a solution at 410 °C × 1 h and aging at 150 °C × 12 h, the dendrite structure was significantly reduced, the grain thinning was obvious, and the distribution was uniform; the Al8Cu4Er phase appeared in the lamellar eutectic η-Mg(Zn,Al,Cu)2 structure at grain boundaries, and the hardness reached 168.8 HV. The yield strength, tensile strength, and elongation were 542.12 MPa, 577.67 MPa, and 8.36%, respectively.

Nonlinear unloading-reloading behavior and macro/micro models during multi-pass cyclic hot compression of aluminum alloys

Unloading-reloading behavior is of crucial importance in multi-pass forming of metal materials, the nonlinear of which creates challenges for the analysis of springback and residual stress of the precision manufacture components. Especially for the hot bulk-formed material at elevated temperature, the thermal-mechanical coupling effect makes the unloading-reloading process more complicated and thus more difficult to model and control, which remains to be solved. In this paper, the unloading-reloading behavior dependent on strain rate and deformation temperature and its model of hot compressive deformed aluminum alloys at elevated temperature were studied from the macroscopic and microscopic perspectives. The effect of deformation temperature, strain rate and strain on the unloading-reloading behavior of hot compressive deformed aluminum alloys were revealed, and corresponding micro-mechanism was elucidated and then discussed. Macroscopically, a strain-, strain rate- and temperature-dependent nonlinear macroscopic model describing unloading–reloading process was established, which can be used to describe the unloading stress relaxation and predict springback during multi-pass hot bulk forming. Microscopically, it is suggested that the relaxations of back stress and forest dislocation hardening stress collectively affect the unloading stress relaxation, due to the decrease of mobile and immobile (forest) dislocation density in unloading, while the dislocation-related behavior before yield, i.e. the dislocations’ bowing-out under pinning, affects the reloading behavior. Based on the micro-mechanism, a physically-based micro-model for describing unloading–reloading was constructed which further is used to clarify the physical mechanism of internal stress relaxation and inelastic strain recovery under multi-pass hot compression deformation. The comparison of the calculation results of the models with those of experiments indicated that the established unloading–reloading macroscopic and microscopic models are able to predict the stress–strain response upon the unloading–reloading loop of multi-pass cyclic hot compression deformation.

Особливості використання гуми як конструкційного матеріалу під час створення вузлів стикування систем термостатування

Explosive bolts are widely used as actuating devices in the spacecraft separation systems. Explosive bolt body is divided into parts as a result of engagement of the pyromixture placed inside. Activated explosive bolts have negative mechanical effect on the interface elements and sensitive electronic devices installed nearby owing to explosive behavior of the pyromixture combustion, generating shock front with high pressure and velocities, impacts and collisions of the structural units. Cumulative effect of the above factors on the separated objects is called pyroshock. For separation systems with increased requirements to external actions and cleanliness, authors developed a shear explosive bolt or pyrobolt, divided into parts, cutting the body walls in segments, which are set in motion by action of the pressure of gases, released as a result of pyrocartridge activation. The basic sources of pyroshock for these shear explosive bolts with segments are: combustion of pyromixture, internal impacts of structural units against the bolt body; cutting of body wall in segments, release of preliminary deformed interface after activation. Structural solutions are presented to reduce the pyroshock per each of the components. Vibration impulsive loading during pyromixture combustion is reduced by optimization of explosive quantity, finding its minimum to provide the reliable activation of the device. To reduce the impact on the explosive bolt elements and shock front interface the rubber gasket is installed in the path of shock wave distribution, partially disseminating and absorbing its kinetic energy. Damper, made of easily deformable aluminum alloy, is also installed to decrease the internal impact of the rod against the explosive bolt body. Functional testing of the device, using the pendulum suspension and measuring separation speed and vibration impulsive loading, showed that body parts of the shear explosive bolt with segments are separated without significant impact loads and discharge of high-temperature gases and debris, providing reliable separation of compartments and units without damaging the sensitive equipment. Obtained values of the mechanical momentum, I = 0,4÷0,7 N•s and shock load spectrum – g-load 1950 g at the frequency range up to 5000 Hz, meet the up-to-date requirements to pyrotechnical devices. Key words: explosive bolt, pyroshock, shock wave, pyrocartridge, high-temperature gases, damper.

Optimization of Welding Process Parameter for Gap Response in Aluminum GMAW Using Taguchi Method

A gap is generated in the weld joint due to dimensional error of welded parts and thermal deformation in aluminum alloy’s gas metal arc welding (GMAW) process of aluminum alloy. The optimum welding conditions corresponding to different gaps in the weld joint are required in the field. In this study, the welding conditions were optimized using Taguchi’s design of experiment method in response to gaps. Al5083-O with a thickness of 4.0 mm was used as the base material, and GMAW was performed on the T-fillet joints. An alternating current (AC) pulse was used for the welding process, and the welding experiment was performed for different gap sizes. Three levels of wire feed rate (WFR), electrode negative ratio (EN ratio), and teaching point (T.P) were selected as welding parameters, and 3 gap sizes (0, 0.5, and 1.0 mm) were selected as noise factors. Other welding conditions were fixed at a welding speed of 40 cm/min, a work angle of 40 degrees, a push of 10 degrees, the contact tip to work distance (CTWD) of 15 mm, and a shielding gas of 100 % Ar. The weld sizes such leg length, penetration depth, and throat thickness were measured using the cross-section. The maximum weld size that satisfies the minimum heat input was selected as the target value. Based on signal-to-noise ratio analysis, WFR, EN ratio, and T.P were selected as optimal levels of 11 m/min, 20 %, and 0 mm, respectively.

Optimization of Plasma Electrolytic Oxidation Technological Parameters of Deformed Aluminum Alloy D16T in Flowing Electrolyte

The prospects of plasma electrolytic oxidation (PEO) technology applied for surface hardening of aluminum alloys are substantiated. The work aims to optimize the technological process of PEO for aluminum in flowing electrolyte. The design of the equipment and the technological process of the PEO for aluminum deformed alloy D16T in flowing silicate–alkaline electrolyte have been developed. Oxide coatings were formed according to various technological parameters of the PEO process. The properties of the oxide coatings were evaluated, respectively, by measurements of coating thickness, geometric dimensions of the samples, microhardness, wear tests, and optical and scanning electron microscopy. To study the influence of the technological parameters of the PEO process of forming oxide coatings on geometrical, physical, and mechanical properties, planning of the experiment was used. According to the results of the conducted experiments, a regression equation of the second order was obtained and the response surfaces were constructed. We determined the optimal values of the technological parameters of the PEO process: component concentration ratio (Na2SiO3/KOH), current density, flow rate, and electrolyte temperature, which provide the oxide coating with minimal wear and sufficiently high physical and mechanical properties and indicators of the accuracy of the shape of the parts. The research results showed that the properties of oxide coatings mainly depend on almost all constituent modes of the PEO process. Samples with Al2O3 oxide coating were tested during dry friction according to the “ring–ring” scheme. It was established that the temperature in the friction zone of aluminum samples with an oxide coating is lower compared to steel samples without a coating, and this indicates high frictional heat resistance of the oxide coating.

Simulation of strain induced abnormal grain growth in aluminum alloy by coupling crystal plasticity and phase field methods

A mesoscale modeling methodology is proposed to predict the strain induced abnormal grain growth in the annealing process of deformed aluminum alloys. Firstly, crystal plasticity finite element (CPFE) analysis is performed to calculate dislocation density and stored deformation energy distribution during the plastic deformation. A modified phase field (PF) model is then established by extending the continuum field method to consider both stored energy and local interface curvature as driving forces of grain boundary migration. An interpolation mapping approach is adopted to transfer the stored energy distribution from CPFE to PF efficiently. This modified PF model is implemented to a hypothetical bicrystal firstly for verification and then the coupled CPFE-PF framework is further applied to simulating the 2D synthetic polycrystalline microstructure evolution in annealing process of deformed AA3102 aluminum alloy. Results show that the nuclei with low stored energy embedded within deformed matrix tend to grow up, and abnormal large grains occur when the deformation is close to the critical plastic strain, attributing to the limited number of recrystallized nuclei and inhomogeneity of the stored energy.

Investigating the Mechanical Properties of Aluminum Alloy Ultra-Fine Grained Metals by Fluid-Solid Coupling Method

This research examines the mechanical characteristics of metal materials using the FSC (Fluid-solid coupling) technique. It primarily investigates the formation of a regular FSC non-smooth surface by the 7A05 deformed aluminum alloy after laser treatment. The mechanical characteristics of the manufactured aluminum alloy ultrafine grained metal materials are investigated by altering various laser settings, coupling patterns, and cell distribution modes. The findings demonstrate that the tensile strength of aluminum alloy increases by 37.21% and 44.14%, and the fracture strength increases by 38.69% and 46.73%, respectively, when the chip thickness compression ratio is 1.2 and 2.2. According to the study, extruding aluminum alloy improves its Vickers hardness, tensile strength, friction, and wear qualities to varying degrees.

Coupled quantitative modeling of microstructural evolution and plastic flow during continuous dynamic recrystallization

Continuous dynamic recrystallization (cDRX) dominates microstructural evolution during the hot working of metallic materials with high stacking fault energy (SFE), such as aluminum alloys. However, in reality, a lack of quantitative and visual modeling of the process hinders its widespread application in the hot working process. In this study, using a recently developed multilevel cellular automaton (MCA) that integrates the newly established cell switching rules and topology deformation technique, a novel mesoscale MCA-cDRX model was constructed to investigate the evolution of both microstructures and macroscopic mechanical response in the hot working of AA7075 aluminum alloy. By considering the evolution of dislocation density and the orientation angle of the local cells as the primary clues, the plastic flow, recrystallization kinetics, features of subgrain size and high-angle grain boundaries, and influence of initial matrix characteristics on the cDRX mechanism were analyzed. The model predictions are consistent with the experimental data. Quantitative analysis confirms that the incubation time for the initiation of subgrain formation is significantly short. The fine-grain matrix and high initial volume fraction of low-angle grain boundaries can significantly accelerate the progress of cDRX owing to a stronger accumulation of dislocations in the dislocation cell walls through the climb and cross-slip mechanisms in the deformed aluminum alloy. The subgrain size is dependent on the Zener-Hollomon parameter. The developed simulation framework offers an effective means to allow the visualization of the cDRX.

Конструкційні алюмінієві сплави систем Al−Cu−Mg і Al−Zn−Mg−Cu в літакобудуванні. Огляд

A review of scientific and technical information on structural deformable aluminum alloys, Al-Cu-Mg (series 2xxx) and Al-Zn-Mg-Cu (series 7xxx) systems was conducted. Their chemical and phase composition, alloying methods, mechanical and operational properties, influence of technological factors were analyzed. Examples of the use of these alloys in aircraft construction are given. It is shown that among the alloys of the Al-Cu-Mg system (D1, B65, D16, D16ч, 1163, D19, etc.), the strongest is D16 and its improved modifications D16ч and 1163, the mechanical properties of which in the heat-hardened state are equal to low-carbon steels. Alloys D16, D16оч, 1163 have high strength characteristics at 20 0С and elevated temperatures, especially in the form of sheets and pressed parts. Therefore, it is a common material for the manufacture of aircraft skins in the engine area, which is subject to heating. However, an increase in strength leads to a decrease in plasticity. Alloys based on the Al-Zn-Cu-Mg system (В95, В95пч, В95оч, В96, В96Ц, В96Ц1, В96Ц3, В94, В93, В92, etc.) are the most high-strength among deformable aluminum alloys, so they are widely used in responsible power elements of aircraft and rocket engineering in the form of pressed and forged products. The strongest of them is B96Ц, especially its modification B96Ц1, in which, unlike the B95 alloy, manganese and chromium are partially or completely replaced by zirconium. The B95 alloy has high compressive strength and is used to cover the upper surface of aircraft wings, which is in a compressed state during flight. The inner surface of the wing is made of D16, D16ч, 1163 alloys that withstand tensile loads in flight. In terms of strength, the B95 alloy exceeds the similar characteristics of the D16 alloy by 20-25%, and in terms of yield strength by 40%. Replacing the D16 alloy with B95 makes it possible to reduce the weight of the aircraft to 5 tons. Almost all the large-sized stamped parts for the world’s largest turboprop An-22 “Antey” transport aircraft are made from the B93 forging alloy, which is alloyed with iron and heat-treated according to the T1 regime.The main disadvantage of high-strength alloys of the Al-Cu-Mg and Al-Zn-Mg-Cu systems is their tendency to degrade, which is caused by the action of various types of loads and corrosive environments during aircraft and flight basing and is accompanied by the development of fatigue or corrosion-fatigue cracks. Alternative points of view regarding the causes of these phenomena and ways of improving the properties of products made of these alloys by alloying, thermal and deformation treatments are considered. Keywords: deformable structural aluminum alloys; aircraft construction, chemical and phase composition, alloying, mechanical properties, corrosion resistance, heat treatment.

Non-destructive evaluation from deformed aluminum alloy 6063 and silicon carbides black and green reinforced aluminium alloy based composites

In this work, tensile mechanical properties of the aluminum alloy 6063 (AA6063) with reinforced silicon carbides (SiC) black and green aluminium based composites and the deformed specimens are analyzed using nondestructive evaluation (NDE) of ultrasonic inspections. The specimens making of various weight proportions and its manufacturing of stir casting technique. After tensile test the deformed specimens measure the surfaces using scanning electron microscope (SEM) and Energy Dispersive X-ray spectrum (EDX). Also, conduct the salt spray test of the deformed specimens and compare the surfaces at before and after the deformation. The deformed specimen for NDE was observed interruption, twinning and debonding in onset of plastic deformation of the matrix interfaces. However, the interaction moment was significantly influence by the load bearing capacity from the reinforcement to the matrix. The result was showed that AA6063 with SiC black and green composites are better tensile mechanical properties and better surface integrity was investigated. Furthermore, the regression analysis shows that the variations of interfaces on AA6063 with SiC black and green composites and the factors influenced by the tensile properties, salt spray test and ultrasonic test are found significant and the MMCs are the specific applications of automotive industries.

Modeling of casting technology of large-sized ingots from deformable aluminum alloys

An industrial technology for semi-continuous casting of large-sized ingots from wrought aluminum alloy 1580 has been developed through the use of complex modeling, including computer modeling and physical modeling. The ProCAST and ANSYS software packages equipped with the FLUENT module were used for computer modeling. The physical modeling was carried out on a laboratory semi-continuous casting unit (SCCU), which represents a tenfold reduced physical model of an industrial casting unit for the vertical semi-continuous casting of ingots from aluminum alloys. An aluminum-magnesium alloy with the addition of 0.05% (wt.) of scandium was used as the object of modeling. The results of computer modeling were tested at the SCCU, and then computer modeling was carried out for casting a large ingot. According to the modes obtained in the simulation, an ingot with a section of 1310 × 560 mm was cast under industrial conditions, which had a good surface quality with the absence of casting defects. In the microstructure of an industrial ingot and an ingot cast on the SCCU, there were no primary intermetallic compounds Al3(Sc, Zr), which makes it possible to strengthen the alloy upon annealing. To check the manufacturability during rolling, billets with a size of 40 × 120 × 170 mm were cut from these ingots, which were hot-rolled to a thickness of 5 mm, and then cold rolled to a thickness of 1 mm. The rolling results revealed good workability of the alloy, which was reflected in the high quality of the surface and the absence of cracks at the edges of the rolled stock. The mechanical properties of sheets obtained from both ingots were at the same level, which proves the reliability of casting modes for ingots obtained by complex modeling and the validity of their use for industrial conditions of the semi-continuous casting of large ingots from aluminum alloys.