Wire arc additive manufacturing of AA5183 with TiC nanoparticles

Aluminium alloys processed by wire arc additive manufacturing (WAAM) exhibit a relatively coarse microstructure with a columnar morphology. A powerful measure to refine the microstructure and to enhance mechanical properties is to promote grain refinement during solidification. Addition of ceramic nanoparticles has shown great potential as grain refiner and strengthening phase in aluminium alloys. Thus, an Al-Mg alloy mixed with TiC nanoparticles was manufactured by the novel metal screw extrusion method to a wire and subsequently deposited by WAAM. Measures to restrict oxidation of magnesium during metal screw extrusion were examined. Purging of CO2 gas into the extrusion chamber resulted in a remarkable reduction in formation of MgO and Mg(OH)2. TiC decomposed to Al3Ti during WAAM deposition, leading to a significant grain refinement of 93% compared to a commercial benchmark. The presence of remaining TiC nanoparticles accounted for an increased hardness of the WAAM material through thermal expansion mismatch strengthening and Orowan strengthening. Exposure of TiC to moisture in air during metal screw extrusion increased the internal hydrogen content significantly, and a highly porous structure was seen after WAAM deposition.

Ex-situ and In-situ Microstructure Investigations of AM Part and Powders

This paper presents an advanced microstructural analysis of the AlSiMg, Ti64 and N700 powders used for additive manufacturing. The internal microstructure of the regular and irregular powder grains were characterized down to atomic resolution by using scanning electron microscopy and high resolution scanning transmission electron microscopy.The accretionary forms on top of the irregular AlSiMg powder grains exhibit a slightly coarse microstructure with a network of eutectic Si consisting of nano-crystallites, suggestinga slower cooling than the grain itself that contain a predominately amorphous Si network. A nm thin amorphous C layer on the surface of some Ti64 plasma atomized powder grains promoted the attachment of satellites and growth of envelopes. In case of gas atomized N700 powder grains, we identified thin oxide and carbon amorphous layers as well as metal segregations at the interface between the grain body and the accretionary forms.

Influence of titanium oxide-based colourants on the morphological and tribomechanical properties of injection-moulded polyoxymethylene spur gears

Regardless of colouration for functional or aesthetic purposes, technical polymer parts, like gears, require consistent properties. However, there is a lack of research into the effect of colourants on the tribomechanical properties of gears. Therefore, the effects of two pigments, titanium dioxide (white) and chrome antimony titanium oxide (yellow), and three delivery methods, masterbatch, liquid colour and direct compounding, on part morphology, dimensions, tribological and mechanical performance of injection-moulded polyoxymethylene (POM) spur gears are investigated in this paper. The white pigment accelerates the crystallisation of POM, causing fine and highly-crystalline morphological structures and smaller dimensions. However, the yellow pigment decelerates crystallisation, resulting in a coarser morphology with highly crystalline core material and bigger parts. Furthermore, the delivery method affects only the tribomechanical properties. Using a masterbatch decreases loads at break and increases deflection at break, since the carrier material acts as an impact modifier and a weak spot. The liquid colour decreases wear due to lubricating properties, whereas the pure pigments increases abrasion, especially in combination with a coarse microstructure. However, the effects of carrier systems and changes in morphology are always superimposed. Considering the performance and tolerance of technical components, colourants have to be carefully selected to ensure beneficial properties.

Effect of the Spinning Deformation Processing on Microstructure and Mechanical Properties of A356 Wheels

The influences of spinning deformation and heat treatment on microstructure and tensile properties of A356 alloy at different cooling rates were investigated in this study by optical and scanning electron microscopes. The results indicated that spinning deformation enhanced the tensile properties of the alloy due to the reduction of Si size and porosity percentage, especially in the samples with coarse microstructure. Heat treatment increased the strength while decreased the ductility of the alloy because of the precipitation of brittle Mg2Si in Al matrix. It is suggested that the spinning deformation processing is an effective technique to produce A356 alloy wheels with high mechanical properties.

Individual Phase Mechanical Properties at Different Temperatures of Sn–Ag–Cu Lead-Free Solders Incorporating Special Pileup Effects Using Nanoindentation

Sn–Ag–Cu (SAC) alloys are considered as good replacements of Sn–Pb alloys which are banned due to the toxic nature of Pb. But, SAC alloys have a coarse microstructure that consists of β-Sn rich and eutectic phases. Nanoindentation is a useful technique to evaluate the mechanical properties at very small length scale. In this work, continuous stiffness measurement (CSM) nanoindentation setup (CSM Instruments SA, Peseux, Switzerland) is used to determine the individual phase mechanical properties like Young's modulus and hardness at high temperatures. It is demonstrated that these properties are a function of temperature for both β-Sn rich and eutectic phases. Loadings starting from 500 μN up to 5000 μN are used with 500 μN steps and average values are presented for Young's modulus and hardness. The loading rates applied are twice that of the loadings. High temperatures result in a higher creep deformation and therefore, to avoid it, different dwell times are used at peak loads. The special pileup effect, which is more significant at elevated temperatures, is determined and incorporated into the results. A better agreement is found with the previous studies.

Investigation on the Physical and Chemical Grain Refinement of the Mg-10Sm Alloy

In this paper the physical and chemical grain refining of the Mg-10Sm alloy was investigated. Physical grain refinement was achieved by strongly shearing the melt above the liquidus temperature using a twin-screw string device and then cast at the near liquidus temperature. Chemical grain refiner was added into Zr master alloy in the melt. Casting the Mg-10Sm alloy at 730°C produced an extremely coarse microstructure consisting of huge dendritic grains. The physical grain refinement greatly refined the dendritic grains to smaller rosette grains, being reduced from several millimeters to about 200μm. Chemical grain refinement produced fine and equiaxed grain structure with size of approximated 111μm. Combination of the physical and chemical grain refinement creates more significant refining effect than either of the two methods.

Fatigue-Life and Leak-Before-Break Assessments of Cr-Mo Steel Pressure Vessels With High-Pressure Gaseous Hydrogen

Pressure cycle tests were performed on two types of Cr-Mo steel pressure vessels with inner diameters of 306 mm and 210 mm and notches machined on their inside under hydrogen-gas pressures, varied between 0.6 and 45 MPa at room temperature. One of the Cr-Mo steels had a fine microstructure with tensile strength of 828 MPa, while the other had a coarse microstructure with tensile strength of 947 MPa. Fatigue-crack growth (FCG) and fracture-toughness tests of the Cr-Mo steels were also carried out in gaseous hydrogen. The Cr-Mo steels showed accelerated FCG rates in gaseous hydrogen compared to ambient air with an upper bound corresponding to an approximately 30-times higher FCG rate. Furthermore, in gaseous hydrogen, the fracture toughness of the Cr-Mo steel with coarse microstructure was significantly smaller than that of the steel with fine microstructure. Four pressure vessels were tested; then, all of the pressure vessels failed by leak-before-break (LBB). Based on the fracture-mechanics approach, the LBB failure of one pressure vessel could not be estimated by using the fracture toughness in gaseous hydrogen. The fatigue lives could be estimated by using the upper bound of the accelerated FCG rates in gaseous hydrogen.

High Temperature Tensile Behaviour of the A354 Aluminum Alloy

The high temperature tensile behaviour of the A354 casting aluminum alloy was investigated also evaluating the influence of secondary dendrite arm spacing (SDAS). Cast specimens were produced through a gradient solidification equipment, obtaining two different classes of SDAS, namely 20-25 µm (fine microstructure) and 40-50 µm (coarse microstructure). After hot isostatic pressing and T6 heat treatment, the samples underwent mechanical characterization both at room and high temperature (200 °C). Results of tensile tests and hardness measurements were related to the microstructural features and fractographic characterization, in order to investigate the effect of microstructure and high temperature exposure on the mechanical behaviour of the alloy.