A Comparative Assessment of Austempered Ductile Iron as a Substitute in Weight Reduction Applications

2008 ◽  
Author(s):  
Ashwin Polishetty ◽  
Sarat Singamneni ◽  
Guy Littlefair
Keyword(s):  
Ductile Iron ◽  
High Performance ◽  
Material Selection ◽  
Weight Ratio ◽  
Cost Savings ◽  
High Strength ◽  
Good Choice ◽  
Comparative Assessment ◽  
Austempered Ductile Iron ◽  
Machining Characteristics

Manufacturing engineering has had to undergo drastic changes in the approach to material selection in order to meet new design challenges. In the automotive industry, researchers in their effort to reduce emissions and satisfy environmental regulations, have shifted their focus to new emerging materials such as high-strength aluminium alloys, metal matrix composites, plastics, polymers and of late, Austempered Ductile Iron (ADI). ADI is a good choice for design where the criterion is high performance at reduced weight and cost. The unique, ausferrite microstructure gives the material desirable material properties and an edge over other materials. A comparative study of ADI in terms of materials properties and machining characteristics with other materials is desirable to highlight the potential of the material. This paper focuses on a comparative assessment of material and machining characteristics of ADI for different applications. The properties under consideration are machinability, weight and cost savings and versatility. ADI has a higher strength-to-weight ratio than aluminium making it a ready alternative for material selection. In terms of machinability, there are some problems associated with machining of ADI due to its work hardening nature. This paper attempts to identify the possible potential applications of ADI, by critically reviewing specific applications such as machinability, overall economics and service.

High-Performance Linear Cable Transmission

2008 ◽  
Vol 130 (6) ◽  
Author(s):  
Joan Savall ◽  
Javier Martín ◽  
Alejo Avello
Keyword(s):  
High Performance ◽  
Weight Ratio ◽  
High Strength ◽  
Negative Effects ◽  
Low Friction ◽  
Alternative Design ◽  
Cable Length ◽  
High Stiffness ◽  
Length Changes

Cable transmissions offer several advantages such as high stiffness to weight ratio, high strength, low friction, and absence of backlash, which makes them appropriate for demanding mechanical applications. However, while extensively used as rotational transmissions, there are only a few examples of linear cable transmissions in the literature. The reason is that the up-to-date designs are based on a cable layout that leads to cable length changes during movement. This, in turn, produces negative effects such as transmission nonlinearity and cable fatigue. In this paper, an alternative design for linear cable transmissions is presented. The new design overcomes the aforementioned problems through a proper cable layout. Different applications of the new transmission are reported, validating the proposed design.

scholarly journals Fused Filament Fabrication of PEEK: A Review of Process-Structure-Property Relationships

Polymers ◽  
2020 ◽  
Vol 12 (8) ◽  
pp. 1665 ◽  
Author(s):  
Ali Reza Zanjanijam ◽  
Ian Major ◽  
John G. Lyons ◽  
Ugo Lafont ◽  
Declan M. Devine
Keyword(s):  
High Performance ◽  
Space Station ◽  
Weight Ratio ◽  
High Strength ◽  
Structure Property ◽  
Fused Filament Fabrication ◽  
Space Applications ◽  
Structure Property Relationships ◽  
Complex Design ◽  
Process Structure

Poly (ether ether ketone) (PEEK) is a high-performance engineering thermoplastic polymer with potential for use in a variety of metal replacement applications due to its high strength to weight ratio. This combination of properties makes it an ideal material for use in the production of bespoke replacement parts for out-of-earth manufacturing purposes, in particular on the International Space Station (ISS). Additive manufacturing (AM) may be employed for the production of these parts, as it has enabled new fabrication pathways for articles with complex design considerations. However, AM of PEEK via fused filament fabrication (FFF) encounters significant challenges, mostly stemming from the semi crystalline nature of PEEK and its associated high melting temperature. This makes PEEK highly susceptible to changes in processing conditions which leads to a large reported variation in the literature on the final performance of PEEK. This has limited the adaption of FFF printing of PEEK in space applications where quality assurance and reproducibility are paramount. In recent years, several research studies have examined the effect of printing parameters on the performance of the 3D-printed PEEK parts. The aim of the current review is to provide comprehensive information in relation to the process-structure-property relationships in FFF 3D-printing of PEEK to provide a clear baseline to the research community and assesses its potential for space applications, including out-of-earth manufacturing.

Turning of Austempered Ductile Iron with ceramic tools

2020 ◽  
pp. 095440542095715 ◽  
Author(s):  
A Fernández-Valdivielso ◽  
LN López de Lacalle ◽  
P Fernández-Lucio ◽  
H González
Keyword(s):  
Heat Treatment ◽  
Tool Wear ◽  
Ductile Iron ◽  
High Strength ◽  
Cutting Parameters ◽  
Precise Determination ◽  
Machining Process ◽  
Austempered Ductile Iron ◽  
Machining Time ◽  
Ceramic Tools

Austempered ductile iron castings (ADI) are characterized by the high strength and resistance to fatigue, impact, and wear. ADI mechanical properties are obtained by performing a heat treatment on ductile iron casting. Thus, the so-called ausferrite microstructure is achieved. However, heat treatment significantly affects ductile casting machinability. A precise determination of ADI microstructure, on the one hand, and to choose correct machining process parameters and tool wear control on the other, are essential to optimize cutting processes and for the introduction of ceramic inserts. Ceramics are an alternative to carbide tools. In this paper, ceramic tools for the dry turning of ADI castings are studied. Thus, different technical ceramics were analyzed, identifying the dominant wear mechanism and evolution. Tool wear rate magnitude was determined indirectly by the variation of cutting force along machining time. Finally, different tests helped to study ceramics wear sensitivity with respect to cutting parameters. Mixed ceramics of Al2O3 with TiC showed the best performance, followed by SiAlON ones.

Assessment of Machining Characteristics of Austempered Ductile Iron

2010 ◽  
Vol 97-101 ◽  
pp. 2036-2039 ◽  
Author(s):  
Ashwin Polishetty ◽  
Guy Littlefair
Keyword(s):  
Surface Texture ◽  
Ductile Iron ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Austempered Ductile Iron ◽  
Spheroidal Graphite ◽  
Surface Texture Analysis ◽  
Machining Characteristics ◽  
Stage Heat Treatment ◽  
Cutting Speeds

Austempered Ductile Iron (ADI) is a modified Spheroidal Graphite Iron (SGI) produced by applying a two-stage heat treatment cycle of austenitising and austempering. The microstructure of ADI also known as “ausferrite” consists of ferrite, austenite and graphite nodules. Machining ADI using conventional techniques is often problematic due to the microstructural phase transformation from austenite to martensite. Machining trials consisted of drilling ADI-Grades900, 1050, 1200 and 1400 using inserted (TiAlN PVD coated) type drills. The cutting parameters selected were; cutting speeds [m/min] of 30 and 40; penetration rates [mm/rev] of 0.1 and 0.2; to a constant depth of 20mm. The machining characteristics of ADI are evaluated through surface texture analysis and microhardness analysis. These results indicate that microhardness is modified during machining and surface texture is improved using a cutting fluid.

A Preliminary Study on Cell Wall Architecture of Titanium Foams

2009 ◽  
Vol 1188 ◽  
Author(s):  
Nihan Tuncer ◽  
Luc Salvo ◽  
Eric Maire ◽  
Gürsoy Arslan
Keyword(s):  
Weight Ratio ◽  
Cost Savings ◽  
High Strength ◽  
Processing Parameters ◽  
Inert Atmosphere ◽  
Theoretical Density ◽  
Space Holder ◽  
Wide Range ◽  
Powder Characteristics ◽  
Foamed Metals

AbstractBio-inspired architectures, especially metallic foams, have been receiving an increasing interest for the last 10 years due to their unusual mechanical properties. Among commonly dealt foamed metals, like aluminum and steel, titanium possesses a distinctive place because of its high strength-to-weight ratio, excellent corrosion resistance and biocompatibility. In this study, Ti foams were produced by a very simple and common method, sintering under inert atmosphere with fugitive space holder. Removal of the space holder was conducted by dissolution in hot deionized water which makes it possible to minimize contamination of Ti. Sintering of remaining Ti skeleton at 1300 °C offered a wide range of properties and cost savings. The effects of the processing parameters such as sintering temperature and powder characteristics on the 3D foam architecture were investigated by using X-ray microtomography (μ-CT). Use of bimodal Ti powders caused a decrease in final theoretical density when compared to the ones prepared with the same amount of space holder but with monomodal Ti powders. It was also observed that the use of bimodal Ti powders decreased compressive strength, by introducing pores into the cell walls, when compared to the ones having the same theoretical density.

Investigation of Residual Stresses Distribution in Titanium Weldments

2014 ◽  
Vol 777 ◽  
pp. 171-175 ◽  
Author(s):  
Shao Pin Song ◽  
Anna M. Paradowska ◽  
Ping Sha Dong
Keyword(s):  
Residual Stresses ◽  
High Performance ◽  
Weight Ratio ◽  
Welding Process ◽  
High Strength ◽  
Naval Research ◽  
Office Of Naval Research ◽  
And Performance ◽  
Superior Corrosion Resistance ◽  
The University

Titanium and its alloys have increasingly become a material of choice for applications in high-performance structures due to their superior corrosion resistance and high strength-to-weight ratio. However, in contrast to conventional steel alloys, there exist little design and manufacturing experience in the heavy fabrication industry with large welded structures made of titanium materials. In addressing the above concern, the University of New Orleans funded by Office of Naval Research (ONR) initiated program on investigation of manufacturability and performance of a titanium mid-ship section. The uniqueness of this program is its focus upon a representative full-size mid-ship section upon which relevant scientific and technological challenges are simulated and experimentally validated. This paper reports the measurements of residual stresses using neutron diffraction in titanium T-joints. The residual stresses were measured using Engin-X at ISIS (UK) and the Kowari Strain Scanner at ANSTO (Australia). This experimental research was used to validate our in house predictions and significantly improved the knowledge and understanding of the welding process of titanium alloys.

scholarly journals Recent studies on particulate reinforced AZ91 magnesium composites fabricated by Stir casting – A review

2020 ◽  
Vol 4 (2) ◽  
pp. 115-126
Author(s):  
Anil K. Matta ◽  
Naga S. S. Koka ◽  
Sameer K. Devarakonda
Keyword(s):  
High Performance ◽  
Matrix Material ◽  
Weight Ratio ◽  
High Strength ◽  
Casting Process ◽  
Stir Casting ◽  
Critical Conditions ◽  
Matrix Composites ◽  
The Matrix ◽  
Magnesium Composites

Magnesium Metal Matrix Composites (Mg MMC) have been the focus of consideration by many researchers for the past few years. Many applications of Mg MMCs were evolved in less span of time in the automotive and aerospace sector to capture the benefit of high strength to weight ratio along with improved corrosion resistance. However, the performance of these materials in critical conditions is significantly influenced by several factors including the fabrication methods used for processing the composites. Most of the papers addressed all the manufacturing strategies of Mg MMC but no paper was recognized as a dedicated source for magnesium composites prepared through stir casting process. Since stir casting is the least expensive and most common process in the preparation of composites, this paper reviews particulate based Mg MMCs fabricated with stir casting technology. AZ91 series alloys are considered as the matrix material while the effect of different particle reinforcements, sizes , weight fractions on mechanical and tribological responses are elaborated in support with micro structural examinations. Technical difficulties and latest innovations happened during the last decade in making Mg MMCs as high performance material are also presented.

Processing, Properties, and Uses of Lightweight Glass Fiber/Aluminum Hybrid Structures

2022 ◽  
pp. 101-120
Author(s):  
Noureddine Ramdani ◽  
Mohammed Seddik Razali
Keyword(s):  
Glass Fiber ◽  
High Performance ◽  
Weight Ratio ◽  
High Strength ◽  
Fiber Reinforced ◽  
Metallic Structures ◽  
Reinforced Plastics ◽  
Industrial Sectors ◽  
Glass Fiber Reinforced ◽  
Processing Properties

The replacement of heavy metallic structures by high-performance lightweight composite materials is a prominent solution to fulfill the continuous demand in different industrial sectors. Lightweight structures based on aluminum-glass fiber reinforced plastics (GFRP) sandwich panels have been increasingly utilized in the shipbuilding, automotive, and aerospace industries for their striking mechanical and physical properties. These advantageous properties have resulted from the combination of the high tensile and flexural strengths, increased hardness, and the improved wear-resistance of aluminum laminate with the unique properties of lightweight stiffness and high strength weight ratio of glass fiber-reinforced. In this chapter, the various processing approaches, properties, and applications of these sandwich structures are summarized from a wide range of literature.

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