Tensile, fatigue, and corrosion fatigue behavior of high performance die cast aluminum alloy

Abstract Effect of anodization on the thermal performance of naturally cooled heat sinks in power electronic devices made of die-cast aluminum alloy A380 and machined aluminum alloy 6061 was investigated experimentally and numerically. Various types of anodization were examined with different thickness of anodic aluminum oxide layer (AAO), pore size distributions, and surface coloring conditions. A customized natural convection and thermal radiation experimental chamber was built to measure the cooling capacity and heat sink temperatures. A 3D numerical model was also developed and validated against the collected data to provide more details into the contribution of the radiation heat transfer. The total emittance of the anodized samples was determined by a Fourier transform infrared reflectometer (FTIR) spectroscopy method. The results show a significant improvement in total hemispherical emissivity from 0.14 to 0.92 in anodized die-cast aluminum samples. This increase resulted in a considerable reduction in overall thermal resistance, up to 15%; where up to 41% of the total heat dissipation was contributed by thermal radiation. In spite of the rather distinguishable surface morphologies, the measurements suggested that thermal emissivity of the anodized die-cast Al A380 and Al alloy 6061 samples were in the same range.

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G030093 Fatigue behavior of AC4CH cast aluminum alloy microstructurally modified by friction stir processing at low strain rate

The Proceedings of Mechanical Engineering Congress Japan ◽

10.1299/jsmemecj.2011._g030093-1 ◽

2011 ◽

Vol 2011 (0) ◽

pp. _G030093-1-_G030093-5

Author(s):

Yoshihiko UEMATSU ◽

Toshifumi KAKIUCHI ◽

Yasunari TOZAKI

Keyword(s):

Aluminum Alloy ◽

Strain Rate ◽

Friction Stir Processing ◽

Fatigue Behavior ◽

Cast Aluminum Alloy ◽

Cast Aluminum ◽

Friction Stir ◽

Low Strain Rate

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Fatigue Behavior and Damage Mechanism of a Cast Aluminum Alloy in Very High Cycle Regime

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.706 ◽

2011 ◽

Vol 264-265 ◽

pp. 706-711

Author(s):

Hong Qian Xue ◽

E. Bayraktar ◽

Claude Bathias

Keyword(s):

Aluminum Alloy ◽

Fatigue Crack ◽

Fatigue Fracture ◽

Loading Condition ◽

Fatigue Behavior ◽

Axial Loading ◽

Cast Aluminum Alloy ◽

Cast Aluminum ◽

Fatigue Fracture Surface ◽

Very High

An improved understanding of fatigue behavior of a cast aluminum alloy (2-AS5U3G-Y35) in very high cycle regime was developed through ultrasonic fatigue test in axial and torsion loading, cyclic loading in axial and torsion at 35 Hz and 20kHz with R=-1 was used respectively to demonstrate the effect of loading condition. S-N curves obtained show that fatigue failure occurred in range of 105 -1010 cycles in axial or torsion loading, the asymptote of S-N curve is inclined gently, but no fatigue limit under torsion and axial loading condition. Fatigue fracture surface shows fatigue crack essentially initiated from the surface of the specimens subjected to cyclic torsion load, it is different from the fatigue fracture characteristic in axial loading which fatigue crack initiate from subsurface defect in very high cycle regime. Fatigue initiation is on the maximum shear plane, the overall crack orientation is observed on a typical spiral 45° to the fracture plane, which is the maximum principle stress plane, however, shear strip are very clear in the torsion fatigue fracture surface, the torsion fracture is actually in shear fracture.

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Influence of Aging Temperatures and Times on Mechanical Properties of Vacuum High Pressure Die Cast Aluminum Alloy A356

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.445.277 ◽

2012 ◽

Vol 445 ◽

pp. 277-282 ◽

Cited By ~ 5

Author(s):

Xue Zhi Zhang ◽

Kazi Ahmmed ◽

Meng Wang ◽

Henry Hu

Keyword(s):

Mechanical Properties ◽

Aluminum Alloy ◽

Thermal Treatment ◽

Tensile Properties ◽

Intermetallic Phase ◽

Aged Alloy ◽

Cast Aluminum Alloy ◽

Cast Aluminum ◽

Die Cast ◽

Wide Range

In this study a number of thermal treatment schemes over a wide range of temperatures between 120˚ to 350˚ C and times (30 120 minutes) have been experimented in an effort to understand the effect of thermal treatment on tensile properties of vacuum die cast modified aluminum alloy A356. The results show that, the morphology of eutectic silicon has a sound effect on the tensile properties of the tested alloy. The content of magnesium-based intermetallic phases, their morphology and distribution throughout the matrix affect the mechanical properties of the aged alloy as well. The reduction in the strengths of the alloy treated at 350°C for two hours should be at least attributed partly to the absence of the magnesium-based intermetallic phase. However the presence of sufficient amount of magnesium intermetallic phase had played important role in strengthening the alloy thermally treated at 200°C for 90 minutes.

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Influence of Cutting Parameters on Residual Stresses Induced by Milling in Pressure Die-Cast Aluminum Alloy Components

Journal of Manufacturing Science and Engineering ◽

10.1115/1.1383552 ◽

2000 ◽

Vol 123 (4) ◽

pp. 547-551 ◽

Cited By ~ 6

Author(s):

T. Berruti ◽

G. Ubertalli

Keyword(s):

Residual Stress ◽

Aluminum Alloy ◽

Cutting Speed ◽

Depth Of Cut ◽

Cast Aluminum Alloy ◽

Feed Speed ◽

Cast Aluminum ◽

X Ray ◽

Die Cast ◽

Experimental Apparatus

Residual stress states, induced by milling in a die cast aluminum alloy component, have been determined by means of X-ray diffraction. Samples have been cut from an automotive engine sump, fabricated by pressure die-casting. The X-ray experimental apparatus has been calibrated by detecting stresses on a sample bent under imposed external deformations. Different samples (cut from the sump) have been tested after milling operations with each one characterized by different cutting speed, feed speed and depth of cut in order to evaluate their influence on the final residual stress state. Results have been analyzed taking into account surface morphologies after milling, as revealed by scanning electron microscopy.

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