Search results for: machining of aluminum alloy

Authors: Omar M. Elmabrouk

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The cutting tool, in the high-speed machining process, is consistently dealing with high localized stress at the tool tip, tip temperature exceeds 800°C and the chip slides along the rake face. These conditions are affecting the tool wear, the cutting tool performances, the quality of the produced parts and the tool life. Therefore, a thin film coating on the cutting tool should be considered to improve the tool surface properties while maintaining its bulks properties. One of the general coating processes in applying thin film for hard coating purpose is PVD magnetron sputtering. In this paper, the prediction of the effects of PVD magnetron sputtering coating process parameters, sputter power in the range of (4.81-7.19 kW), bias voltage in the range of (50.00-300.00 Volts) and substrate temperature in the range of (281.08-600.00 °C), were studied using artificial neural network (ANN). The results were compared with previously published results using RSM model. It was found that the ANN is more accurate in prediction of tool hardness, and hence, it will not only improve the tool life of the tool but also significantly enhances the efficiency of the machining processes.

Keywords: artificial neural network, hardness, prediction, titanium aluminium nitrate coating

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Authors: Kaouka Alaeddine, K. Benarous

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This study aims to obtain a surface of pure titanium and titanium alloy Ti-64Al with high performance by the diffusion process. Two agents metal alloy have been used in this treatment, niobium (Nb) and molybdenum (Mo), spread on elemental titanium and Ti-64Al alloy. Nb and Mo are used as powder form to increase the contact surface and to improve the distribution. Both Mo and Nb are distributed on samples of Ti and Ti-64Al at 1100 °C and 1200 °C for 3 h. They were performed to effect different experiments objectives. This work was achieved to improve some properties and microstructure of Ti and Ti-64Al surface, using optical microscopy and SEM and study some mechanical properties. The effects of temperature and the powder contents on the microstructure of Ti and Ti-64Al alloy, different phases and hardness value of Ti and Ti-64Al alloy were determined. Experimental results indicate that increasing the powder contents and/or the temperature, the α + β phases change to the equiaxed β lamellar structure. In particular, experiments in 1200 °C were created by diffusion α + β phases both equiaxed β phase laminar and α + β phase, thus meeting the objectives were established in the work. In addition, simulation results are used for comparison with the experimental results by DICTRA software.

Keywords: diffusion, powder metallurgy, titanium alloy, molybdenum, niobium

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Authors: P. Abachi, S. Karami, K. Purazrang

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The amorphous reinforcements (metallic glasses) can be considered as promising options for reinforcing light-weight aluminum and its alloys. By using the proper type of reinforcement, one can overcome to drawbacks such as interfacial de-cohesion and undesirable reactions which can be created at ceramic particle and metallic matrix interface. In this work, the Zr-based amorphous phase was produced via mechanical milling of elemental powders. Based on Miedema semi-empirical Model and diagrams for formation enthalpies and/or Gibbs free energies of Zr-Cu amorphous phase in comparison with the crystalline phase, the glass formability range was predicted. The composite was produced using the powder mixture of the aluminum and metallic glass and spark plasma sintering (SPS) at the temperature slightly above the glass transition Tg of the metallic glass particles. The selected temperature and rapid sintering route were suitable for consolidation of an aluminum matrix without crystallization of amorphous phase. To characterize amorphous phase formation, X-ray diffraction (XRD) phase analyses were performed on powder mixture after specified intervals of milling. The microstructure of the composite was studied by optical and scanning electron microscope (SEM). Uniaxial compression tests were carried out on composite specimens with the dimension of 4 mm long and a cross-section of 2 ˟ 2mm2. The micrographs indicated an appropriate reinforcement distribution in the metallic matrix. The comparison of stress–strain curves of the consolidated composite and the non-reinforced Al matrix alloy in compression showed that the enhancement of yield strength and mechanical strength are combined with an appreciable plastic strain at fracture. It can be concluded that metallic glasses (amorphous phases) are alternative reinforcement material for lightweight metal matrix composites capable of producing high strength and adequate ductility. However, this is in the expense of minor density increase.

Keywords: aluminum matrix composite, amorphous phase, mechanical alloying, spark plasma sintering

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Authors: Emre Kara, Metehan Demir, Şura Karakuzu, Kadir Koç, Ahmet F. Geylan, Halil Aykul

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While the polymeric foam cored sandwiches have been realized for many years, recently there is a growing and outstanding interest on the use of sandwiches consisting of aluminum foam core because of their some of the distinct mechanical properties such as high bending stiffness, high load carrying and energy absorption capacities. These properties make them very useful in the transportation industry (automotive, aerospace, shipbuilding industry), where the "lightweight design" philosophy and the safety of vehicles are very important aspects. Therefore, in this study, the sandwich panels with aluminum alloy foam core and various types and thicknesses of glass fiber reinforced polymer (GFRP) skins produced via Vacuum Assisted Resin Transfer Molding (VARTM) technique were obtained by using a commercial toughened epoxy based adhesive with two components. The aim of this contribution was the analysis of the bending response of sandwiches with various glass fiber reinforced polymer skins. The three point bending tests were performed on sandwich panels at different values of support span distance using a universal static testing machine in order to clarify the effects of the type and thickness of the GFRP skins in terms of peak load, energy efficiency and absorbed energy values. The GFRP skins were easily bonded to the aluminum alloy foam core under press machine with a very low pressure. The main results of the bending tests are: force-displacement curves, peak force values, absorbed energy, collapse mechanisms and the influence of the support span length and GFRP skins. The obtained results of the experimental investigation presented that the sandwich with the skin made of thicker S-Glass fabric failed at the highest load and absorbed the highest amount of energy compared to the other sandwich specimens. The increment of the support span distance made the decrease of the peak force and absorbed energy values for each type of panels. The common collapse mechanism of the panels was obtained as core shear failure which was not affected by the skin materials and the support span distance.

Keywords: aluminum foam, collapse mechanisms, light-weight structures, transport application

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Authors: Asmae Tafraouti, Yasmina Layouni, Pascal Kleimann

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The growing market for Microsystems (MST) and Micro-Electromechanical Systems (MEMS) is driving the research for alternative manufacturing techniques to microelectronics-based technologies, which are generally expensive and time-consuming. Hot-embossing and micro-injection modeling of thermoplastics appear to be industrially viable processes. However, both require the use of master models, usually made in hard materials such as steel. These master models cannot be fabricated using standard microelectronics processes. Thus, other micromachining processes are used, such as laser machining or micro-electrical discharge machining (µEDM). In this work, µEDM has been used. The principle of µEDM is based on the use of a thin cylindrical micro-tool that erodes the workpiece surface. The two electrodes are immersed in a dielectric with a distance of a few micrometers (gap). When an electrical voltage is applied between the two electrodes, electrical discharges are generated, which cause material machining. In order to produce master models with high resolution and smooth surfaces, it is necessary to well control the discharge mechanism. However, several problems are encountered, such as a random electrical discharge process, the fluctuation of the discharge energy, the electrodes' polarity inversion, and the wear of the micro-tool. The effect of different parameters, such as the applied voltage, the working capacitor, the micro-tool diameter, and the initial gap, has been studied. This analysis helps to improve the machining performances, such as the workpiece surface condition and the lateral crater's gap.

Keywords: craters, electrical discharges, micro-electrical discharge machining, microsystems

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Authors: Muna Khethier Abbass, Khairia Salman Hussan, Huda Mohummed AbdudAlaziz

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This work aims to study the effect of shot peening on the mechanical properties of welded joints which performed by two different welding processes: Tungsten inert gas (TIG) welding and friction stir welding (FSW) processes of aluminum alloy 6061 T6. Arc welding process (TIG) was carried out on the sheet with dimensions of (100x50x6 mm) to obtain many welded joints with using electrode type ER4043 (AlSi5) as a filler metal and argon as shielding gas. While the friction stir welding process was carried out using CNC milling machine with a tool of rotational speed (1000 rpm) and welding speed of (20 mm/min) to obtain the same butt welded joints. The welded pieces were tested by X-ray radiography to detect the internal defects and faulty welded pieces were excluded. Tensile test specimens were prepared from welded joints and base alloy in the dimensions according to ASTM17500 and then subjected to shot peening process using steel ball of diameter 0.9 mm and for 15 min. All specimens were subjected to Vickers hardness test and micro structure examination to study the effect of welding process (TIG and FSW) on the micro structure of the weld zones. Results showed that a general decay of mechanical properties of TIG and FSW welded joints comparing with base alloy while the FSW welded joint gives better mechanical properties than that of TIG welded joint. This is due to the micro structure changes during the welding process. It has been found that the surface hardening by shot peening improved the mechanical properties of both welded joints, this is due to the compressive residual stress generation in the weld zones which was measured using X-Ray diffraction (XRD) inspection.

Keywords: friction stir welding, TIG welding, mechanical properties, shot peening

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Authors: Asmae Tafraouti, Yasmina Layouni, Pascal Kleimann

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The growing market for Microsystems (MST) and Micro-Electromechanical Systems (MEMS) is driving the research for alternative manufacturing techniques to microelectronics-based technologies, which are generally expensive and time-consuming. Hot-embossing and micro-injection modeling of thermoplastics appear to be industrially viable processes. However, both require the use of master models, usually made in hard materials such as steel. These master models cannot be fabricated using standard microelectronics processes. Thus, other micromachining processes are used, as laser machining or micro-electrical discharge machining (µEDM). In this work, µEDM has been used. The principle of µEDM is based on the use of a thin cylindrical micro-tool that erodes the workpiece surface. The two electrodes are immersed in a dielectric with a distance of a few micrometers (gap). When an electrical voltage is applied between the two electrodes, electrical discharges are generated, which cause material machining. In order to produce master models with high resolution and smooth surfaces, it is necessary to well control the discharge mechanism. However, several problems are encountered, such as a random electrical discharge process, the fluctuation of the discharge energy, the electrodes' polarity inversion, and the wear of the micro-tool. The effect of different parameters, such as the applied voltage, the working capacitor, the micro-tool diameter, the initial gap, has been studied. This analysis helps to improve the machining performances, such: the workpiece surface condition and the lateral crater's gap.

Keywords: craters, electrical discharges, micro-electrical discharge machining (µEDM), microsystems

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Authors: Noor Arda Adrina Daud, Mohd Hanafi Ali

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The compensating filter is placed between the patient and X-ray tube to compensate various density and thickness of human body. The main purpose of this project is to study the effect of compensating filter on image quality in lateral projection of thoracolumbar radiography. The study was performed by an X-ray unit where different thicknesses of aluminum were used as compensating filter. Specifically the relationship between thickness of aluminum, density and noise were evaluated. Results show different thickness of aluminum compensating filter improved the image quality of lateral projection thoracolumbar radiography. The compensating filter of 8.2 mm was considered as the optimal filter to compensate the thoracolumbar junction (T12-L1), 1 mm to compensate lumbar region and 5.9 mm to compensate thorax region. The aluminum wedge compensating filter was designed resulting in an acceptable image quality.

Keywords: compensating filter, aluminum, image quality, lateral, thoracolumbar

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Authors: B. Z. Manuel, H. D. Esmeralda, H. S. Felipe, D. R. Héctor, D. de la Torre Sebastián, R. L. Diego

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Aluminum Matrix Composites reinforced with nanocrystalline Ni3Al carbon-coated intermetallic particles, were synthesized by powder metallurgy. Powder mixture of aluminum with 0.5-volume fraction of reinforcement particles was compacted by spark plasma sintering (SPS) technique and the compared with conventional sintering process. The better results for SPS technique were obtained in 520ºC-5kN-3min.The hardness (70.5±8 HV) and the elastic modulus (95 GPa) were evaluated in function of sintering conditions for SPS technique; it was found that the incorporation of these kind of reinforcement particles in aluminum matrix improve its mechanical properties. The densities were about 94% and 97% of the theoretical density. The carbon coating avoided the interfacial reaction between matrix-particle at high temperature (520°C) without show composition change either intermetallic dissolution.

Keywords: aluminum matrix composites, intermetallics, spark plasma sintering, nanocrystalline

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Authors: Rohin Sharma, Sumantu Chaulagain

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This paper presents calculations of total energy of InGaN alloy carried out in a disordered quasirandom structure for a triclinic super cell. This structure replicates the disorder and composition effect in the alloy. First principle calculations within the density functional theory with the local density approximation approach is employed to accurately determine total energy of the system. Lattice constants and band gaps associated with the ground states are then estimated for different concentration ratios of the alloy. We provide precise results of quasirandom structures of the alloy and their lattice constants with the total energy and band gap energy of the system for the range of seven different composition ratios and their respective lattice parameters.

Keywords: DFT, ground state, LDA, quasicrystal, triclinic super cell

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Authors: Aynur Aker, Hasan Kaya

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Al-12.6wt.%Si-2wt.%Cu ternary alloy of near eutectic composition was directionally solidified upward at a constant temperature gradient in a wide range of growth rates (V=8.25-165.41 µm/s). The microstructures (λ), microhardness (HV), tensile stress (σ) and electrical resistivity (ρ) were measured from directionally solidified samples. The dependence of microstructures, microhardness and electrical resistivity on growth rate (V) was also determined by statistical analysis. According to these results, it has been found that for increasing values of V, the values of HV, σ and ρ increase. Variations of electrical resistivity for casting Al-Si-Cu alloy were also measured at the temperature in range 300-500 K. The enthalpy (ΔH) and the specific heat (Cp) for the Al-Si-Cu alloy were determined by differential scanning calorimeter (DSC) from heating trace during the transformation from solid to liquid. The results obtained in this work were compared with the similar experimental results in the literature.

Keywords: Al-Si-Cu alloy, microstructures, micro-hardness, tensile stress electrical resistivity, enthalpy

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Authors: Faisal Islam, J. Ramkumar

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The applications of composite materials in aerospace, sporting and automotive industries need high quality machined surfaces and dimensional accuracy. Some studies have been done to understand the fiber failure mechanisms encountered during milling machining of CFRP composites but none are capable of explaining the exact nature of the orientation-based fiber failure mechanisms encountered in the milling machining process. The objective of this work is to gain a better understanding of the orientation-based fiber failure mechanisms occurring on the slot edges during CFRP milling machining processes. The occurrence of damage is predicted by a schematic explanation based on the mechanisms of material removal which in turn depends upon fiber cutting angles. A geometric model based on fiber cutting angle and fiber orientation angle is proposed that defines the critical and safe zone during machining and predicts the occurrence of delamination. Milling machining experiments were performed on composite samples of varying fiber orientations to verify the proposed theory. Mean fiber pulled out length was measured from the microscopic images of the damaged area to quantify the amount of damage produced. By observing the damage occurring for different fiber orientation angles and fiber cutting angles for up-milling and down-milling edges and correlating it with the material removal mechanisms as described earlier, it can be concluded that the damage/delamination mainly depends on the portion of the fiber cutting angles that lies within the critical cutting angle zone.

Keywords: unidirectional composites, milling, machining damage, delamination, carbon fiber reinforced plastics (CFRPs)

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Authors: Steadyman Chikumba, Vasudeva Vereedhi Rao

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This paper reports on the synthesis of FeCrCoNiZn and its characterisation using SEM and nanoindentation. The high entropy alloy FeCrCoNiZn was fabricated using spark plasma sintering at a temperature of 1100ᵒC from powders mixed for 9 hours. The powders mixture was equimolar, and the resultant microstructure had a single crystalline structure when studied under SEM. Several nano Vickers hardness measurements were taken on a polished surface etched by Nital solution. The hardness ranged from 711 Vickers to a maximum of 1773.2. The alloy FeCrCoNiZn showed a nano hardness of 1070 Vickers and a modulus of elasticity of 460.4 MPa. The process managed to fabricate a very hard material that can find applications where wear resistance is desired.

Keywords: high entropy alloy, FeCrVNiZn, nanohardness, SEM

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Authors: Dejan Tanikić, Miodrag Manić, Jelena Đoković, Saša Kalinović

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This paper deals with the determination of the optimum machining parameters, according to the measured and modelled data of the cutting temperature and surface roughness, during the turning of the AISI 4140 steel. The high cutting temperatures are unwanted occurences in the metal cutting process. They impact negatively on the quality of the machined part. The machining experiments were performed using different cutting regimes (cutting speed, feed rate and depth of cut), with different values of the workpiece hardness, which causes different values of the measured cutting temperature as well as the measured surface roughness. The temperature and surface roughness data were modelled after that using Response Surface Methodology (RSM). The obtained RSM models are used in the process of optimization of the cutting regimes using the Genetic Algorithms (GA) tool, which enables the metal cutting process in the optimum conditions.

Keywords: genetic algorithms, machining parameters, response surface methodology, turning process

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Authors: M. Derraz, M. Farhaoui

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Problem statement: In the water treatment processes, the coagulation and flocculation processes produce sludge according to the level of the water turbidity. The aluminum sulfate is the most common coagulant used in water treatment plants of Morocco as well as many countries. It is difficult to manage Sludge produced by the treatment plant. However, it can be used in the process to improve the quality of the treated water and reduce the aluminum sulfate dose. Approach: In this study, the effectiveness of sludge was evaluated at different turbidity levels (low, medium, and high turbidity) and coagulant dosage to find optimal operational conditions. The influence of settling time was also studied. A set of jar test experiments was conducted to find the sludge and aluminum sulfate dosages in order to improve the produced water quality for different turbidity levels. Results: Results demonstrated that using sludge produced by the treatment plant can improve the quality of the produced water and reduce the aluminum sulfate using. The aluminum sulfate dosage can be reduced from 40 to 50% according to the turbidity level (10, 20, and 40 NTU). Conclusions/Recommendations: Results show that sludge can be used in order to reduce the aluminum sulfate dosage and improve the quality of treated water. The highest turbidity removal efficiency is observed within 6 mg/l of aluminum sulfate and 35 mg/l of sludge in low turbidity, 20 mg/l of aluminum sulfate and 50 mg/l of sludge in medium turbidity and 20 mg/l of aluminum sulfate and 60 mg/l of sludge in high turbidity. The turbidity removal efficiency is 97.56%, 98.96%, and 99.47% respectively for low, medium and high turbidity levels.

Keywords: coagulation process, coagulant dose, sludge reuse, turbidity removal

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Authors: Wen Po Cheng, Chi Hua Fu, Ping Hung Chen, Ruey Fang Yu

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Recovering resources from water purification sludge (WPS) have been gradually stipulated in environmental protection laws and regulations in many nations. Hence, reusing the WPS is becoming an important topic, and recovering alum from WPS is one of the many practical alternatives. Most previous research efforts have been conducted on studying the amphoteric characteristic of aluminum hydroxide for investigating the optimum pH range to dissolve the Al(III) species from WPS, but it has been lack of reaction kinetics or mechanisms related discussion. Therefore, in this investigation, water purification sludge (WPS) solution was broken by ultrasound to make particle size of reactants smaller, specific surface area larger. According to the reaction kinetics, these phenomena let the dissolved aluminum salt quantity increased and the reaction rate go faster.

Keywords: aluminum, acidification, sludge, recovery

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Authors: Rakesh Prajapati, Purvik Patel, Hardik Patel

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Productivity and quality are two important aspects that have become great concerns in today’s competitive global market. Every production/manufacturing unit mainly focuses on these areas in relation to the process, as well as the product developed. The electrical discharge machining (EDM) process, even now it is an experience process, wherein the selected parameters are still often far from the maximum, and at the same time selecting optimization parameters is costly and time consuming. Material Removal Rate (MRR) during the process has been considered as a productivity estimate with the aim to maximize it, with an intention of minimizing surface roughness taken as most important output parameter. These two opposites in nature requirements have been simultaneously satisfied by selecting an optimal process environment (optimal parameter setting). Objective function is obtained by Regression Analysis and Analysis of Variance. Then objective function is optimized using Genetic Algorithm technique. The model is shown to be effective; MRR and Surface Roughness improved using optimized machining parameters.

Keywords: MMR, TWR, OC, DOE, ANOVA, minitab

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Authors: Jana Petrů, Tomáš Zlámal, Robert Čep, Lenka Čepová

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This article is focused on the thermal spray coating machining issue. Those are irreplaceable in many areas of nowadays industrial branches such as aerospace industry, mostly thanks to their excellent qualities in production and also in renovation of machinery parts. The principals of thermal spraying and elementary diversification are described in introduction. Plasma coating method of composite materials -cermets- is described more thoroughly. The second part describes thermal spray coating machining and grinding in detail. This part contains suggestion of appropriate grinding tool and assessment of cutting conditions used for grinding a given part. Conclusion describes a problem which occurred while grinding a cermet thermal spray coating with a specially designed grindstone and a way to solve this problem.

Keywords: coating, aerospace, plasma, grinding

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Authors: C. Sánchez de Rojas Candela, A. Riquelme, P. Rodrigo, M. D. Escalera-Rodríguez, B. Torres, J. Rams

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Selective laser melting is one of the most commonly used AM techniques. In it, a thin layer of metallic powder is deposited, and a laser is used to melt selected zones. The accumulation of layers, each one molten in the preselected zones, gives rise to the formation of a 3D sample with a nearly arbitrary design. To ensure that the properties of the final parts match those of the powder, all the process is carried out in an inert atmosphere, preferentially Ar, although this gas could be substituted. Ti6Al4V alloy is widely used in multiple industrial applications such as aerospace, maritime transport and biomedical, due to its properties. However, due to the demanding requirements of these applications, greater hardness and wear resistance are necessary, together with a better machining capacity, which currently limits its commercialization. To improve these properties, in this study, Selective Laser Melting (SLM) is used to manufacture Ti/TiN metal matrix composites with in-situ and ex-situ titanium nitride reinforcement where the scanning speed is modified (from 28.5 up to 65 mm/s) to study the influence of the processing parameters in SLM. A one-step method of nitriding the Ti6Al4V alloy is carried out to create in-situ TiN reinforcement in a reactive atmosphere and it is compared with ex-situ composites manufactured by previous mixture of both the titanium alloy powder and the ceramic reinforcement particles. The microstructure and mechanical properties of the different Ti/TiN composite materials have been analyzed. As a result, the existence of a similar matrix has been confirmed in in-situ and ex-situ fabrications and the growth mechanisms of the nitrides have been studied. An increase in the mechanical properties with respect to the initial alloy has been observed in both cases and related to changes in their microstructure. Specifically, a greater improvement (around 30.65%) has been identified in those manufactured by the in-situ method at low speeds although other properties such as porosity must be improved for their future industrial applicability.

Keywords: in-situ reinforcement, nitriding reaction, selective laser melting, titanium nitride

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Authors: Mohsen Marani Barzani, Ahmed A. D. Sarhan, Saeed Farahany, Ramesh Singh

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Surface roughness and chip morphology are important output in manufacturing product. In this paper, an experimental investigation was conducted to determine the effects of various cutting speeds and feed rates on surface roughness and chip morphology in turning the Al-Si cast alloy and Sr-containing. Experimental trials carried out using coated carbide inserts. Experiments accomplished under oblique dry cutting when various cutting speeds 70, 130 and 250 m/min and feed rates of 0.05, 0.1 and 0.15 mm/rev were used, whereas depth of cut kept constant at 0.05 mm. The results showed that Sr-containing Al-Si alloy have poor surface roughness in comparison to Al-Si alloy (base alloy). The surface roughness values reduce with cutting speed increment from 70 to 250 m/min. the size of chip changed with changing silicon shape in Al matrix. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev.

Keywords: strontium, surface roughness, chip, morphology, turning

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Authors: Lenka Hurtalová, Eva Tillová, Mária Chalupová, Juraj Belan, Milan Uhríčik

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The secondary alloy A226 is used for many automotive casting produced by mould casting and high pressure die-casting. This alloy has excellent castability, good mechanical properties and cost-effectiveness. Production of primary aluminium alloys belong to heavy source fouling of life environs. The European Union calls for the emission reduction and reduction in energy consumption, therefore, increase production of recycled (secondary) aluminium cast alloys. The contribution is deal with influence of recycling on the quality of the casting made from A226 in automotive industry. The properties of the casting made from secondary aluminium alloys were compared with the required properties of primary aluminium alloys. The effect of recycling on microstructure was observed using combination different analytical techniques (light microscopy upon black-white etching, scanning electron microscopy-SEM upon deep etching and energy dispersive X-ray analysis-EDX). These techniques were used for the identification of the various structure parameters, which was used to compare secondary alloy microstructure with primary alloy microstructure.

Keywords: A226 secondary aluminium alloy, deep etching, mechanical properties, recycling foundry aluminium alloy

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Authors: Sori Won, Bosung Seo, Kwangsuk Park, Seok Hong Min, Tae Kwon Ha

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With the increased needs for lightweight materials in automobile industry, the usage of aluminum alloys becomes prevailed as components and car bodies due to their comparative specific strength. These parts composed of different aluminum alloys should be connected each other, where welding technologies are commonly applied. Among various welding methods, friction welding method as a solid state welding gets to be popular in joining aluminum alloys as it does not produce a defect such as blowhole that is often formed during typical welding processes. Once two metals are joined, corrosion would become an issue due to different electrochemical potentials. In this study, we investigated variations of corrosion properties when Duralumin and AA6063 were joined by friction welding. From the polarization test, it was found that the potential of the welded was placed between those of two original metals, which could be explained by a concept of mixed potential. Pitting is a common form as a result of the corrosion of aluminum alloys when they are exposed to 3.5 wt% NaCl solution. However, when two different aluminum alloys (Duralumin and AA6063) were joined, pitting corrosion occurred severely and uniformly in Duralumin while there were a few pits around precipitates in AA6063, indicating that AA6063 was cathodically protected.

Keywords: corrosion properties, friction welding, dissimilar Al alloys, polarization test

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Authors: M. Zadshakoyan, H. Marassem Bonab, P. M. Keshtiban

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The SPD process widely used to optimize microstructure, strength and mechanical properties of the metals. Processes such as ARB and APB could have a considerable impact on improving the properties of metals. The aluminum material after steel, known as the most used metal, Because of its low strength, there are restrictions on the use of this metal, it is required to spread further studies to increase strength and improve the mechanical properties of this light weight metal. In this study, Annealed aluminum material, with yield strength of 85 MPa and tensile strength of 124 MPa, sliced into 2 sheets with dimensions of 30 and 25 mm and the thickness of 1.5 mm. then the sheets press bonded under 6 cycles, which increased the ultimate strength to 281 MPa. In addition, by adding 0.1%Wt of SiC particles to interface of the sheets, the sheets press bonded by 6 cycles to achieve a homogeneous composite. The same operation using Al2O3 particles and a mixture of SiC+Al2O3 particles was repeated and the amount of strength and elongation of produced composites compared with each other and with pure 6 cycle press bonded Aluminum. The results indicated that the ultimate strength of Al/SiC composite was 2.6 times greater than Annealed aluminum. And Al/Al2O3 and Al/Al2O3+SiC samples were low strength than Al/SiC sample. The pure 6 time press bonded Aluminum had lowest strength by 2.2 times greater than annealed aluminum. Strength of aluminum was increased by making the metal matrix composite. Also, it was found that the hardness of pure Aluminum increased 1.7 times after 6 cycles of APB process, hardness of the composite samples improved further, so that, the hardness of Al/SiC increased up to 2.51 times greater than annealed aluminum.

Keywords: APB, nano composite, nano particles, severe plastic deformation

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Authors: Khaled Mohamed Ibrahim

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A comprehensive study on two biomaterials of NiTi and Ti-6Al-4V (Ti64) was done. Those materials were cast using vacuum arc remelting technique. As-cast structure of Ni-Ti alloy consists of NiTi matrix and some fine precipitates of Ni4Ti3. Ti-6Al-4V alloy showed a structure composed of equiaxed β grains and varied α-phase morphologies. Maximum ultimate compressive strength and reduction in height of 2042 MPa of 18%, respectively, were reported for the cast Ti64 alloy. However, minimum ultimate compressive strength of 1804 MPa and low reduction in height of 3% were obtained for the cast NiTi alloy. Wear rate of both Ni-Ti and Ti-6Al-4V alloys significantly increased at saline solution (0.9% NaCl) condition as compared to dry testing condition. Saline solution harmed the wear resistance of about 2 to 4 times compared to the dry condition. Corrosion rate of NiTi alloy at saline solution (0.9% NaCl) was (0.00038 mm/yr) is almost three times the value of Ti64 alloy (0.000171 mm/yr). The corrosion rate of Ti64 in SBF (0.00024 mm/yr) was lower than Ni-Ti (0.0003 mm/yr).

Keywords: NiTi, Ti64, vacuum casting, biomaterials

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Authors: Armansyah, I. P. Almanar, M. Saiful Bahari Shaari, M. Shamil Jaffarullah

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Finite element approach have been used via three-dimensional models by using Altair Hyper Work, a commercially available software, to describe heat gradients along the welding zones (axially and coronaly) in Friction Stir Welding (FSW). Transient thermal finite element analyses are performed in AA 6061-T6 Aluminum Alloy to obtain temperature distribution in the welded aluminum plates during welding operation. Heat input from tool shoulder and tool pin are considered in the model. A moving heat source with a heat distribution simulating the heat generated by frictions between tool shoulder and work piece is used in the analysis. The developed model was then used to show the effect of various input parameters such as total rate of welding speed and rotational speed on temperature distribution in the work piece.

Keywords: Frictions Stir Welding (FSW), temperature distribution, Finite Element Method (FEM), altair hyperwork

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Authors: Balwinder Singh

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The present research is a paper on the characterization of aluminum alloy-6063 hybrid metal matrix composites using three different reinforcement materials (SiC, red mud, and fly ash) through stir casting method. The red mud was used in solid form, and particle size range varies between 103-150 µm. During this investigation, fly ash is received from Guru Nanak Dev Thermal Plant (GNDTP), Bathinda. The study has been done by using Taguchi’s L9 orthogonal array by taking fraction wt.% (SiC 5%, 7.5%, and 10% and Red Mud and Fly Ash 2%, 4%, and 6%) as input parameters with their respective levels. The study of the mechanical properties (tensile strength, impact strength, and microhardness) has been done by using Analysis of Variance (ANOVA) with the help of MINITAB 17 software. It is revealed that silicon carbide is the most significant parameter followed by red mud and fly ash affecting the mechanical properties, respectively. The fractured surface morphology of the composites using Field Emission Scanning Electron Microscope (FESEM) shows that there is a good mixing of reinforcement particles in the matrix. Energy-dispersive X-ray spectroscopy (EDS) was performed to know the presence of the phases of the reinforced material.

Keywords: reinforcement, silicon carbide, fly ash, red mud

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Authors: Wen Po Cheng, Chia Yun Chung, Ruey Fang Yu, Chao Feng Chen

Abstract:

The main objective of this research was to study the differences of aluminum hydrolytic products between two PACl preparation methods. These two methods were the acidification process of freshly formed amorphous Al(OH)₃ and the conventional alkalization process of aluminum chloride solution. According to Ferron test and ²⁷Al NMR analysis of those two PACl preparation procedures, the reaction rate constant (k) values and Al₁₃ percentage of acid addition process at high basicity value were both lower than those values of the alkaline addition process. The results showed that the molecular structure and size distribution of the aluminum species in both preparing methods were suspected to be significantly different at high basicity value.

Keywords: polyaluminum chloride, Al13, amorphous aluminum hydroxide, Ferron test

Procedia PDF Downloads 339

Authors: Mandeep Kumar, Hari Singh

Abstract:

The effective optimization of machining process parameters affects dramatically the cost and production time of machined components as well as the quality of the final products. This paper presents the optimization aspects of a Wire Electrical Discharge Machining operation using Inconel X-750 as work material. The objective considered in this study is minimization of the dimensional deviation. Six input process parameters of WEDM namely spark gap voltage, pulse-on time, pulse-off time, wire feed rate, peak current and wire tension, were chosen as variables to study the process performance. Taguchi's design of experiments methodology has been used for planning and designing the experiments. The analysis of variance was carried out for raw data as well as for signal to noise ratio. Four input parameters and one two-factor interaction have been found to be statistically significant for their effects on the response of interest. The confirmation experiments were also performed for validating the predicted results.

Keywords: ANOVA, DOE, inconel, machining, optimization

Procedia PDF Downloads 165

Authors: Himanshu Payal, Sachin Maheshwari, Pushpendra S. Bharti

Abstract:

Electrical discharge machining (EDM), a non-conventional machining process, finds wide applications for shaping difficult-to-cut alloys. Process modeling of EDM is required to exploit the process to the fullest. Process modeling of EDM is a challenging task owing to involvement of so many electrical and non-electrical parameters. This work is an attempt to model the EDM process using artificial neural network (ANN). Experiments were carried out on die-sinking EDM taking Inconel 825 as work material. ANN modeling has been performed using experimental data. The prediction ability of trained network has been verified experimentally. Results indicate that ANN can predict the values of performance measures of EDM satisfactorily.

Keywords: artificial neural network, EDM, metal removal rate, modeling, surface roughness

Procedia PDF Downloads 375

Authors: Emin Çadirli, Izzettin Yilmazer, Uğur Büyük, Hasan Kaya

Abstract:

Al-2Mn-5Fe eutectic alloy (wt.%) was prepared in a graphite crucible under vacuum atmosphere. The samples were directionally solidified upward at a constant temperature gradient in four different of growth rates by using a Bridgman method. The values of eutectic spacing were measured from longitudinal and transverse sections of the samples. The dependence of eutectic spacing on the growth rate was determined by using linear regression analysis. The microhardness and tensile strength of the studied alloy also were measured from directionally solidified samples. The dependency of the microhardness and tensile strength for directionally solidified Al-2Mn-5Fe eutectic alloy on the growth rate were investigated and the relationships between them were experimentally obtained by using regression analysis. The results obtained in present work were compared with the previous similar experimental results obtained for binary and ternary alloys.

Keywords: eutectic alloy, microhardness, microstructure, tensile strength

Procedia PDF Downloads 434