Development of a High Strength Cast Aluminium Alloy for Possible Automotive Applications

2013 ◽  
Vol 765 ◽  
pp. 54-58 ◽  
Author(s):  
M.C. Shaji ◽  
Kuriakkattil Kunjayyappan Ravikumar ◽  
M. Ravi ◽  
K. Sukumaran
Keyword(s):  
Mechanical Properties ◽  
Aluminium Alloy ◽  
Automotive Industry ◽  
Low Cost ◽  
High Strength ◽  
Microstructural Refinement ◽  
Cast Aluminium ◽  
Cu Alloys ◽  
High Integrity ◽  
Automobile Components

Al-Si-Cu alloys of the 319 type are age hardenable alloys and offer a good combination of mechanical properties with excellent castability, corrosion resistance and low cost, making these alloys attractive for the automotive industry. The mechanical properties of Al-Si-Cu alloys can be improved by minor alloying additions. The paper describes the attempts to develop a high strength cast aluminium alloy by the addition of Mg to 319 alloy for producing high integrity automobile components. The importance of optimizing the addition of Mg and optimization of the heat treatment parameters, especially the ageing temperature for achieving high strength, are explained. The increase in UTS is accompanied by a decrease in elongation. The elongation is proposed to be increased by the microstructural refinement that can be achieved by squeeze casting.

scholarly journals Effect of Solidification Rates at Sand Casting on the Mechanical Joinability of a Cast Aluminium Alloy

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1304
Author(s):  
Moritz Neuser ◽  
Olexandr Grydin ◽  
Anatolii Andreiev ◽  
Mirko Schaper
Keyword(s):  
Mechanical Properties ◽  
Aluminium Alloy ◽  
Aluminium Alloys ◽  
High Strength ◽  
Casting Process ◽  
Sand Casting ◽  
Minimum Thickness ◽  
Cast Aluminium ◽  
Microstructure Parameters ◽  
Alloys Of The Al

Implementing the concept of mixed construction in modern automotive engineering requires the joining of sheet metal or extruded profiles with cast components made from different materials. As weight reduction is desired, these cast components are usually made from high-strength aluminium alloys of the Al-Si (Mn, Mg) system, which have limited weldability. The mechanical joinability of the cast components depends on their ductility, which is influenced by the microstructure. High-strength cast aluminium alloys have relatively low ductility, which leads to cracking of the joints. This limits the range of applications for cast aluminium alloys. In this study, an aluminium alloy of the Al-Si system AlSi9 is used to investigate relationships between solidification conditions during the sand casting process, microstructure, mechanical properties, and joinability. The demonstrator is a stepped plate with a minimum thickness of 2.0 mm and a maximum thickness of 4.0 mm, whereas the thickness difference between neighbour steps amounts to 0.5 mm. During casting trials, the solidification rates for different plate steps were measured. The microscopic investigations reveal a correlation between solidification rates and microstructure parameters such as secondary dendrite arm spacing. Furthermore, mechanical properties and the mechanical joinability are investigated.

Metodología para el desarrollo de trayectorias en la aplicación por el proceso de soldadura GMAW en un robot industrial

2019 ◽  
pp. 1-4
Author(s):  
Josué Rafael Sánchez-Lerma ◽  
Luis Armando Torres-Rico ◽  
Héctor Huerta-Gámez ◽  
Ismael Ruiz-López
Keyword(s):  
Mechanical Properties ◽  
Automotive Industry ◽  
Industrial Robot ◽  
Welding Process ◽  
High Strength ◽  
Test Material ◽  
Advantages And Disadvantages ◽  
Application Characteristics ◽  
Joining Process ◽  
Gmaw Welding

This paper proposes the development of the methodology to be carried out for the metal joining process through the GMAW welding process in the Fanuc LR Mate 200iD industrial robot. The parameters or properties were considered for the application to be as efficient as possible, such parameters as speed of application, characteristics of the filler material, gas to be used as welding protection. The GMAW welding process can be applied semiautomatically using a hand gun, in which the electrode is fed by a coil, or an automatic form that includes automated equipment or robots. The advantages and disadvantages of the GMAW welding process applied in a manual and automated way were commented. The mechanical properties of the materials to which said welding can be applied were investigated; The materials with which this type of welding can be worked are the high strength materials, which are used in the automotive industry, for the forming of sheet metal. To know the properties of the material, destructive tests were carried out on the test material to be used, as well as the mechanical properties of the welding.

Mechanical Properties of Nanocrystalline Materials Produced by In Situ Consolidation Ball Milling

2008 ◽  
Vol 579 ◽  
pp. 15-28 ◽  
Author(s):  
Carl C. Koch ◽  
Khaled M. Youssef ◽  
Ron O. Scattergood
Keyword(s):  
Mechanical Properties ◽  
Ball Milling ◽  
Nanocrystalline Materials ◽  
Preparation Method ◽  
High Strength ◽  
Al Alloys ◽  
Ductile Metals ◽  
Cu Alloys ◽  
Bulk Nanocrystalline

This paper reviews a method, “in situ consolidation ball milling” that provides artifactfree bulk nanocrystalline samples for several ductile metals such as Zn, Al and Al alloys, and Cu and Cu alloys. The preparation method is described in this paper and examples of the mechanical behavior of nanocrystalline materials made by this technique are given. It is found that in such artifact-free metals, combinations of both high strength and good ductility are possible.

scholarly journals Advanced High Strength Steel in Auto Industry: an Overview

2014 ◽  
Vol 4 (4) ◽  
pp. 686-689 ◽  
Author(s):  
N. Baluch ◽  
Z. M. Udin ◽  
C. S. Abdullah
Keyword(s):  
Automotive Industry ◽  
High Strength Steel ◽  
Low Cost ◽  
High Strength ◽  
Direct Result ◽  
Advanced High Strength Steel ◽  
Geometrical Form ◽  
Cost Efficient ◽  
Safety Attributes ◽  
Selection Of

The world’s most common alloy, steel, is the material of choice when it comes to making products as diverse as oil rigs to cars and planes to skyscrapers, simply because of its functionality, adaptability, machine-ability and strength. Newly developed grades of Advanced High Strength Steel (AHSS) significantly outperform competing materials for current and future automotive applications. This is a direct result of steel’s performance flexibility, as well as of its many benefits including low cost, weight reduction capability, safety attributes, reduced greenhouse gas emissions and superior recyclability. To improve crash worthiness and fuel economy, the automotive industry is, increasingly, using AHSS. Today, and in the future, automotive manufacturers must reduce the overall weight of their cars. The most cost-efficient way to do this is with AHSS. However, there are several parameters that decide which of the AHSS types to be used; the most important parameters are derived from the geometrical form of the component and the selection of forming and blanking methods. This paper describes the different types of AHSS, highlights their advantages for use in auto metal stampings, and discusses about the new challenges faced by stampers, particularly those serving the automotive industry.

Structure, mechanical properties, and stress corrosion behaviour of high strength spray deposited 7000 series aluminium alloy

1991 ◽  
Vol 7 (5) ◽  
pp. 447-451 ◽  
Author(s):  
R. Mächler ◽  
P. J. Uggowitzer ◽  
C. Solenthaler ◽  
R. M. Pedrazzoli ◽  
M. O. Speidel
Keyword(s):  
Mechanical Properties ◽  
Aluminium Alloy ◽  
Stress Corrosion ◽  
Corrosion Behaviour ◽  
High Strength

Tensile properties of the FFF-processed thermoplastic polyurethane (TPU) elastomer

2021 ◽  
Author(s):  
Budi Arifvianto ◽  
Teguh Nur Iman ◽  
Benidiktus Tulung Prayoga ◽  
Rini Dharmastiti ◽  
Urip Agus Salim ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Low Cost ◽  
Thermoplastic Polyurethane ◽  
High Strength ◽  
Tensile Tests ◽  
Uniaxial Tensile ◽  
Fused Filament Fabrication ◽  
Raster Angle ◽  
Manufacturing Techniques

Abstract Fused filament fabrication (FFF) has become one of the most popular, practical, and low-cost additive manufacturing techniques for fabricating geometrically-complex thermoplastic polyurethane (TPU) elastomer. However, there are still some uncertainties concerning the relationship between several operating parameters applied in this technique and the mechanical properties of the processed material. In this research, the influences of extruder temperature and raster orientation on the mechanical properties of the FFF-processed TPU elastomer were studied. A series of uniaxial tensile tests was carried out to determine tensile strength, strain, and elastic modulus of TPU elastomer that had been printed with various extruder temperatures, i.e., 190–230 °C, and raster angles, i.e., 0–90°. Thermal and chemical characterizations were also conducted to support the analysis in this research. The results obviously showed the ductile and elastic characteristics of the FFF-processed TPU, with specific tensile strength and strain that could reach up to 39 MPa and 600%, respectively. The failure mechanisms operating on the FFF-processed TPU and the result of stress analysis by using the developed Mohr’s circle are also discussed in this paper. In conclusion, the extrusion temperature of 200 °C and raster angle of 0° could be preferred to be applied in the FFF process to achieve high strength and ductile TPU elastomer.

scholarly journals Effect of Microstructure and Texture on Mechanical Properties of Resistance Spot Welded High Strength Steel 22MnB5 and 5A06 Aluminium Alloy

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 685
Author(s):  
Xiaoqing Jiang ◽  
Shujun Chen ◽  
Jinlong Gong ◽  
Zhenyang Lu
Keyword(s):  
Mechanical Properties ◽  
Shear Strength ◽  
Aluminium Alloy ◽  
High Strength Steel ◽  
High Strength ◽  
Welding Parameters ◽  
Tensile Shear Strength ◽  
Tensile Shear ◽  
Resistance Spot ◽  
Effect Of Microstructure

The present study aims to investigate the effect of microstructure and texture on mechanical properties of resistance spot welding of high strength steel 22MnB5 and 5A06 aluminium alloy as a function of welding parameters. The pseudo-nugget zones (NZs) at the steel side have undergone full recrystallisation with a fine-grained ferrite structure containing a small amount of retained austenite and a high hardness of approximately 500 HV, which is a 35% increase in hardness compared to the base material (BM) with fine lath martensitic structure. The NZs at the Al side contain both a recrystallisation texture and shear texture. Higher tensile shear strength with increasing weld time could be linked to the random texture at the Al side. The highest tensile shear strength was achieved at an intermetallic layer thickness of 4 mm.

scholarly journals Effect of reinforcements on polymer matrix bio-composites – an overview

2018 ◽  
Vol 25 (6) ◽  
pp. 1039-1058 ◽  
Author(s):  
Sumit Das Lala ◽  
Ashish B. Deoghare ◽  
Sushovan Chatterjee
Keyword(s):  
Mechanical Properties ◽  
Low Cost ◽  
Natural Fibers ◽  
High Strength ◽  
Low Density ◽  
Intrinsic Properties ◽  
Environment Friendly ◽  
Complex Shapes ◽  
Strength And Durability ◽  
Comprehensive Study

AbstractThe inherent properties of bio-composites such as biodegradability, environment friendly, low cost of production, high strength and durability make them a suitable replacement to traditional materials such as glass and nylon. Bio-polymers are finding wide applications due to their intrinsic properties such as low density, low thermal conductivity, corrosion resistance and ease of manufacturing complex shapes. This paper aims toward a comprehensive study on polymer bio-composites. The review mainly focuses on types of reinforcements such as natural fibers, seed shells, animal fibers, cellulose, bio-polymers, bio-chemicals and bioceramics which enhance the mechanical properties, such as tensile strength, compressive strength, flexural strength, Young’s modulus and creep behavior, of the composites. The pertinent study carried out in this review explores an enormous potentiality of the composites toward a wide variety of applications.

Effect of FSP on Strength and Fracture Toughness of Aluminium Alloy 7000

2018 ◽  
Vol 877 ◽  
pp. 20-25
Author(s):  
P.K. Mandal
Keyword(s):  
Mechanical Properties ◽  
Fracture Toughness ◽  
Aluminium Alloy ◽  
Axial Force ◽  
Weight Ratio ◽  
High Strength ◽  
Hardness Measurement ◽  
Traverse Speed ◽  
Age Hardening ◽  
Friction Stir

The cast Al-Zn-Mg 7000 alloy has become one of the most potential structural materials in many engineering fields such as aircraft body, automotive casting due to their high strength to weight ratio, strong age hardening ability, competitive weight savings, attractive mechanical properties and improvement of thermal properties. The cast aluminium alloy has been modified of surface layer through a solid-state technique is called friction stir process (FSP). But basic principle has been followed by friction stir welding (FSW). This process can be used to locally refine microstructures and eliminate casting defects in selected locations, where mechanical properties improvements can enhance component performance and service life. However, some specified process parameters have adopted during experimental works. Those parameters are tool rotation speed (720 rpm), plate traverse speed (80 mm/min), axial force (15 kN), and tool design (i.e., pin height 3.5 mm and pin diameter 3.0 mm), respectively. The main mechanism behind this process likely to axial force and frictional force acting between the tool shoulder and workpiece results in intense heat generation and plastically soften the process material. The specified ratio of rotational speed (720 rpm) to traverse speed (80 mm/min) is considered 9 as low heat input during FSP and its entails low Zn vaporization problem results as higher fracture toughness of aluminium alloy. It is well known that the stirred zone (SZ) consists of refine equiaxed grains produced due to dynamic recrystallization. FSP has been proven to innovatively enhancing of various properties such as formability, hardness and fracture toughness (32.60 MPa√m). The hardness and fracture toughness of double passes AC+FSP aluminium alloy had been investigated by performing Vicker’s hardness measurement and fracture toughness (KIC)(ASTM E-399 standard) tests. Detailed observations with optical microscopy, Vicker’s hardness measurement, SEM, TEM, and DTA analysis have conducted to analyse microstructure and fracture surfaces of double passes FSP aluminium alloy.

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