Experimental and Numerical Analysis of Residual Stress in Cast Aluminum Alloy after FSP Process

2015 ◽  
Vol 651-653 ◽  
pp. 1563-1568 ◽  
Author(s):  
Marek Stanisław Węglowski ◽  
Piotr Sedek ◽  
Carter Hamilton
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Process Zone ◽  
Cast Aluminum Alloy ◽  
Stress Profile ◽  
Cast Aluminum ◽  
Tensile Stresses ◽  
Residual Stress Profile ◽  
Experimental Profile ◽  
Experimental Values

The effect of FSP modification of cast aluminum alloy AlSi9Mg on residual stress are presented. The numerical results are compared with the residual stresses experimentally measured by the trepanation method. Experimental results show that the residual tensile stresses are higher on the advancing side than on the retreating side. The simulation successfully captures the asymmetric behavior of the residual stress profile, and the predicted maximum residual stress values show relatively good agreement with the experimental values. The simulated profile, however, is more narrow than the experimental profile, yielding a smaller region of residual tensile stresses around the process zone than experimentally observed

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

2000 ◽  
Vol 123 (4) ◽  
pp. 547-551 ◽  
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.

Improvement of Fatigue Properties in a Cast Aluminum Alloy by Roller Burnishing and Friction Stir Processing

2014 ◽  
Vol 891-892 ◽  
pp. 662-667 ◽  
Author(s):  
Yuki Nakamura ◽  
Masaki Nakajima ◽  
Hiroaki Masuda ◽  
Toshifumi Kakiuchi ◽  
Yoshihiko Uematsu
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Friction Stir Processing ◽  
Compressive Residual Stress ◽  
Fatigue Tests ◽  
Fatigue Properties ◽  
Cast Aluminum Alloy ◽  
Cast Aluminum ◽  
Bending Fatigue ◽  
Friction Stir

Roller burnishing (RB) and friction stir processing (FSP) were applied to a cast aluminum alloy, AC4CH-T6 (equivalent to A356-T6), to improve the fatigue properties. In roller burnished specimens, Vickers hardness was increased until the depth of 60μm compared with that of the as-cast specimens, resulting in work-hardening by RB. The compressive residual stress on the surface of the roller burnished specimens was also increased from 35MPa to 132MPa. In order to investigate the effect of RB on the fatigue properties, rotary bending fatigue tests have been performed using the roller burnished and the as-cast specimens. The roller burnished specimens exhibited higher fatigue strength than the untreated specimens. It is due to the increase in hardness and compressive residual stress by RB. In addition, plane bending fatigue tests have been performed using the friction stir processed and untreated specimens. Fatigue strengths of the friction stir processed specimens were highly improved compared with untreated specimens as the results of the elimination of casting defects by FSP. However, the crack growth rates of the friction stir processed specimens were faster than those of untreated specimens. It is due to the softening of the material by heat input during the FSP.

THE PROCESS OF NANOMODIFYING CAST ALUMINUM ALLOY INGOTS FOR COMPONENTS OF AEROSPACE VEHICLES

2019 ◽  
Vol 20 (2) ◽  
pp. 268-276
Author(s):  
G. G. Krushenko ◽  
◽  
V. P. Nazarov ◽  
S. N. Reshetnikova ◽  
G. V. Dvirnyi ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Cast Aluminum Alloy ◽  
Cast Aluminum ◽  
Aerospace Vehicles

Machining Performance and Health Effects of Cutting Fluid Application in Drilling of A390.0 Cast Aluminum Alloy

2007 ◽  
Vol 9 (2) ◽  
pp. 137-146 ◽  
Author(s):  
Anshu D. Jayal ◽  
A.K. Balaji ◽  
Richard Sesek ◽  
Adam Gaul ◽  
Dean R. Lillquist
Keyword(s):  
Aluminum Alloy ◽  
Health Effects ◽  
Cutting Fluid ◽  
Cast Aluminum Alloy ◽  
Cast Aluminum ◽  
Machining Performance

Modelling precipitation hardening in an A356+0.5 wt%Cu cast aluminum alloy

2021 ◽  
pp. 141450
Author(s):  
Anass Assadiki ◽  
Vladimir A. Esin ◽  
Rémi Martinez ◽  
Warren J. Poole ◽  
Georges Cailletaud
Keyword(s):  
Aluminum Alloy ◽  
Precipitation Hardening ◽  
Cast Aluminum Alloy ◽  
Cast Aluminum

scholarly journals Influence of residual stress profile and surface microstructure on fatigue life of a 15-5PH

2018 ◽  
Vol 213 ◽  
pp. 623-629 ◽  
Author(s):  
F. Valiorgue ◽  
V. Zmelty ◽  
M. Dumas ◽  
V. Chomienne ◽  
C. Verdu ◽  
...  
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Surface Microstructure ◽  
Stress Profile ◽  
Residual Stress Profile

scholarly journals Cross-Sectional Mapping of Residual Stresses by Measuring the Surface Contour After a Cut

2000 ◽  
Vol 123 (2) ◽  
pp. 162-168 ◽  
Author(s):  
M. B. Prime
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Stress Measurement ◽  
Superposition Principle ◽  
New Method ◽  
Contour Method ◽  
Stress Profile ◽  
Relaxation Methods ◽  
Cross Sectional ◽  
Residual Stress Profile

A powerful new method for residual stress measurement is presented. A part is cut in two, and the contour, or profile, of the resulting new surface is measured to determine the displacements caused by release of the residual stresses. Analytically, for example using a finite element model, the opposite of the measured contour is applied to the surface as a displacement boundary condition. By Bueckner’s superposition principle, this calculation gives the original residual stresses normal to the plane of the cut. This “contour method” is more powerful than other relaxation methods because it can determine an arbitrary cross-sectional area map of residual stress, yet more simple because the stresses can be determined directly from the data without a tedious inversion technique. The new method is verified with a numerical simulation, then experimentally validated on a steel beam with a known residual stress profile.

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