The End-to-End Simulation of Semi-Continuous Casting and Subsequent Hot Rolling with Account of Microstructure

Basing on the developed methodology for data transfer between the ProCAST and Deform-3D software products, which allows exporting geometry, temperature, residual stresses and microstructure of the casting, it is simulated semi-continuous casting of ingots from aluminum alloy 5182 into a direct chill mold and their following hot rolling in a reversing rolling stand to with aim to study microstructure the evolution.

Characterization of Plastic Anisotropy of AA5182-O Sheets During Prestraining and Subsequent Annealing

This paper described the effects of prestraining and annealing on plastic anisotropy (r-value) of aluminum alloy 5182-O sheets including two prestrain paths and two annealing conditions. During the prestraining and annealing processes, r-value changed depending on prestrain paths and annealing conditions. Although there were slight changes of the normal anisotropy coefficient, r¯, during prestraining and annealing processes, the planar anisotropy coefficient, Δr, increased significantly, especially for the uniaxial prestrain condition. This could accelerate the development of earing during a sheet forming operation. Also, the corresponding sheet textures in rolling direction (RD)/TD plane after prestraining and annealing processes were observed through electron backscatter diffraction (EBSD) analysis to explain the r-value changes, where the viscoplastic self-consistent (VPSC) model was used to correlate the determined texture to measured r-values. It is found that the sheet texture also had significant changes relating to the prestrain paths and annealing conditions resulting in varied r-values.

High Speed Twin-Roll Casting of Al-Mg Alloys

The disadvantages of the conventional twin-roll caster for aluminum alloy are low casting speeds and limited choices of alloys that are castable by this processing. It is known that strip casting of aluminum alloy 5182 is very difficult because of their wider freezing zones. The vertical-type high-speed twin-roll caster used in the present study was devised to overcome these disadvantages. Features of the high speed twin roll casters are as below. Mild steel rolls were used in order to increase the casting speed and to be made at a lower equipment cost. Roll coating is produced in casting of Al-Mg alloy. Therefore lubricant, that resists heat transfer, was not used in the present study. Heat transfer between melt and the roll was improved by hydrostatic pressure of the melt. Low superheat casting was carried out in order to improve microstructure of the strip. In the present study, effectiveness of a high-speed twin roll caster for recycling aluminum alloy was investigated. The effects of the high-speed twin roll caster on alleviating the deterioration of mechanical properties by impurities were investigated. Properties of the cast strip were investigated by metalography, a tension test, and a deep drawing test.

Effect of Forging Force on Fatigue Behavior of Spot Welded Joints of Aluminum Alloy 5182

Using experimental and finite element analysis methods, the effects of electrode forging force are investigated on fatigue behavior and residual stress of spot welded joints of aluminum alloy 5182. Results show that applying forging force significantly reduces the residual stresses in the heat affected zone and the fatigue cracks no longer initiate from there; instead, all cracks begin from the nugget edge. In addition, the mitigation of residual stress by forging force decreases the driving force for crack propagation and leads to longer fatigue life. It can be concluded that applying forging force appropriately has a positive effect on the fatigue strength of resistance spot welded joints.