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Aluminum Alloys, Processing and Characterization: Poster Session
Sponsored by: TMS Light Metals Division, TMS: Aluminum Committee
Program Organizers: Andre Phillion, McMaster University; Dmitry Eskin, Brunel University

Monday 5:30 PM
February 28, 2022
Room: Exhibit Hall C
Location: Anaheim Convention Center

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E-2: Corrosion Evaluations of Aluminium for Pre-painted Products with Alternative Alloys and Comparable Test Methods: Yusuf Ozcetin¹; Ezgi İpek¹; Koray Dündar¹; Cemre Kocahakimoğlu²; Sümbüle Sağdıç¹; Ali Ulus¹; ¹ASAS Aluminum I. Company; ²AkzoNobel Kemipol I. Company
    Aluminum alloys have been used as pre-painted composite panel materials in the building sector for years, thanks to their mechanical properties and lightness. Since these materials are constantly in contact with the open atmosphere, corrosion resistance must be at a certain level. In industry; in order to evaluate the corrosion resistance of painted composite panels, long-term salt spray corrosion tests are carried out. These tests can take up to 1000 hours. In this study; painted productions were made from two alloys developed as an alternative to conventionally used aluminum composite panel alloys. Corrosion tests were carried out with the Tafel Extrapolation method, which is one of the short-term electrochemical corrosion test methods. The results obtained from these tests were compared with the salt spray test results. In corrosion resistance measurements; a correlation was observed between the conventional salt spray method and the electrochemical Tafel Extrapolation method.

E-3: Development and Analysis of Near Shape Powder Processed Aluminum Alloy Materials: Steven Johnson¹; William Caron¹; ¹Central Connecticut State University
    Aluminum alloy materials fabricated using near shape consolidation of powders are highly desirable structural materials due to their low density, high strength to weight ratio, and efficient fabrication processing. In this work, near shape consolidation of Al7075 and pure Al powder materials was performed using room temperature mechanical compaction of powders and sintering in N2 (g) and inert atmospheres. Sintering was performed at temperatures below and above the solidus or melting temperature facilitating both solid and liquid phase sintering. Specific attention is paid to the effect oxygen content has on the sinter densification of these powders. Resultant materials were characterized for density, microstructure, phase development, hardness, and hardening response. Results indicate that densification is directly related to the volume of liquid formed during sintering. Additionally, while present primarily as a powder particle surface oxide, small oxygen content generally does not impede liquid phase sintering of pure Al and Al7075 alloys.

E-5: Effect of Step Aging Conditions on Mechanical Properties of AlMgSi Alloy Profiles for Automotive Industry: Osman Halil Çelik¹; Mehmet Bugra Guner¹; Zeynep Tutku Özen¹; İlyas Artunç Sarı¹; ¹Asas Aluminium
    Automotive companies will start to sell their electric vehicles by 2021. It is aimed to produce chassis and other parts from aluminum, which has 2.7 g/cm3 density which iron has 7.8 g/cm3 because of the high weight of electric vehicles’ battery. Therefore, especially easy extrude and medium strength 6xxx series aluminum alloys are used for vehicles in different segments for sustainable production. 6060, 6063, 6005A, 6082 alloys are the most preferred alloys. In this study, 6005A alloy developed according to the automotive standard chemical composition was studied. Firstly, billet production by direct chill casting, homogenization, test profile production by extrusion technique and heat treatment studies of the profiles were conducted. During heat treatment studies, the effect of step aging process on mechanical properties was investigated. Optical microscope, SEM, EDS and tensile tests were performed as characterization studies.

E-6: Effects of Different Homogenization Conditions on High Strength Al-Mg-Si Alloys with Cu Addition: Mehmet Bugra Guner¹; Görkem Özçelik¹; Tolga Demirkıran¹; Osman Halil Çelik¹; Zeynep Tutku Özen¹; Barış Akın¹; Esra Kaymak Aksu¹; ¹Asas Aluminium
     Al-Mg-Si alloys with Cu addition have been extensively used where huge amounts of mechanical loads apply on extruded profiles. In order to obtain better extrusion capability and post extrusion characteristics, homogenization is a crucial process to be optimized.In presented study, homogenization yield of newly developed high strength Al-Mg-Si alloy with Cu addition has been investigated. Experimental studies that have been applied according to design of experiment have been done to get extreme and normal conditions of homogenization process. From considerably high temperatures to considerably low temperatures different time arrivals have been utilized to get sample set. To determine homogenization yield, conventional characterization methodologies blend with novel approaches to understand the mechanism of homogenisation. SEM investigations with elemental analysis and a novel approach for gainig better understanding on precipitate morphologies. To bring microstructure outputs in mechanical performance basis, analyses have been supported with microhardness and conductivity measurements.

E-7: Evaluation of As-built Properties of Aluminum Alloys Manufactured Using Various Directed Energy Deposition Techniques: Carly Romnes¹; Omar Mireles²; James Stubbins¹; ¹University of Illinois at Urbana-Champaign; ²NASA Marshall Space Flight Center
    The high strength-to-weight ratios of aluminum alloys is of major interest in the aerospace industry. There are many Directed Energy Deposition (DED) techniques that have been used to fabricate aluminum alloy components. In this study, several aluminum alloys were fabricated using a variety of DED techniques, such as arc-wire DED and additive friction stir deposition (AFS-D). Our presentation will discuss the microstructure, surface finish, and mechanical properties of the as-built aluminum alloys. The alloys investigated in this study include: AA2219, AA4047, AA2319, and AA6061. EBSD and EDS were used to characterize the microstructure. Additionally, hardness testing and surface roughness were measured. This research will highlight the differences between DED techniques and aluminum alloys printed using these techniques.

E-8: Experimental and Modelling Investigation of Oxide Layer Fragmentation and Metal Micro-extrusion Behavior during Cold Rolling of Aluminum Alloy : Mahsa Navidirad¹; John Plumeri¹; Wojciech Misiolek¹; Masashi Watanabe¹; Wojciech Stepniowski¹; ¹Lehigh University
    Physical experimentation and modelling approaches of bond rolling of aluminum strips were investigated in this study. For better monitoring of oxide fragmentation and metal micro-extrusion behavior, the surfaces of the strips were deliberately covered by aluminum oxide layer with three different thicknesses through anodizing process. A progressive reduction per pass ranging from 2% to 70% was implemented on sandwiches made out of two clamped coated aluminum strips. The evolution of cracks on the oxide coatings as well as the height of metal micro-extrusion through the cracks as function of deformation and oxide thickness were characterized using electron microscopy. A numerical model of the rolling process was constructed utilizing DEFORM-3D software, wherein strain, strain rate, and stress fields were calculated for each condition. The calculated strain distribution reinforced with experimental data was used to develop criteria for oxide layer fracture, metal flow behavior and bonding between cold rolled aluminum alloy strips.

E-10: Joining of Aluminum Alloy 6061 Using Additive Friction Stir Deposition: Jacob Strain¹; Malcolm Williams¹; Christopher Williamson¹; Ryan Kinser¹; Paul Allison¹; James Jordon¹; ¹The University of Alabama
     In this study, 3 mm thick Aluminum Alloy 6061 (AA6061) plates were joined using the Additive Friction Stir Deposition (AFSD) process with AA6061 as the deposited filler material. Three different butt-weld grooves were used for this study, and each groove type was joined with four different spacings. Square, U, and V weld grooves were joined at 0, 2, 4 and 6 millimeter spacings to produce fully dense defect free welds. Monotonic and cyclic data performed on the specimens access the robustness of AFSD as a joining method to fill gaps between base material of varying spaces. Localized properties of the joints were probed by Vickers microhardness measurements to detail the formation of the heat effected zone (HAZ) in the solid-state joints. Microstructure characterization with optical and electron microscopy techniques captured material flow and dynamic recrystallization occurring in the deposited material with refined equiaxed grain morphology observed in the deposition nugget.

E-11: New 6xxx Al-Mg-Si Alloy with High Formability for Structural Automotive Parts and Suitable for E-mobility Applications: Gregor Michael¹; Zahra Tarzimoghadam¹; Angela Thum¹; Josef Berneder¹; ¹AMAG Rolling GmbH
     Using heat treatable aluminum alloys for structural applications, suitable for e-mobility applications, demands not only appropriate strength values but also a high formability of the material in the delivery condition T4, while exhibiting a sufficient age-hardening response at the industrial paint bake process. To fulfill these OEM requirements, as part of this work a 6xxx (Al-Mg-Si) was developed, which shows high formability as of an outer skin alloy and achieves the required age-hardening response. Additionally, this alloy contains a higher iron content to allow for a higher scrap input to reduce the CO2 footprint to a minimum.Key factor is the correct Si:Mg ratio and the cluster size stabilization after solution heat treatment in a fine-tuned pre-aging process. Mechanical properties and formability were tested and compared to a reference alloy used for outer skin applications. Results showed an improved forming behavior making the material suitable for e-mobility applications.

E-12: Optimization of Twin Roll Casting Method of 5XXX Series Alloys for Automotive Applications Possible to be Produced with 6XXX Series Alloy: Gorkem Demir¹; ¹Asas Aluminyum Sanayi Ve Ticaret A.S
    Al-Mg-Si aluminum alloys (AA6xxx series), which can be hardened by age, are widely used in automotive applications due to their high formability and strength properties. The 6xxx series is shaped while in the T4 temper form. They reach their final strength with the paint process, which is an automotive production procedure. Except for the 6xxx series, Al-Mg alloys (5XXX), which come to the fore in the automotive industry, are the preferred alternative series due to their superior properties. Specific to the laboratory studies, microstructure analysis and thermo-mechanical properties were analyzed throughout the process in comparison by SEM-EDS applications. In this context, automotive final product was produced by using 5xxx (Twin Roll Casting) alloy process studies as an alternative to 6xxx (Hot Rolled) alloy.

NOW ON-DEMAND ONLY - E-14: Solid Stir Extrusion: An Innovative Solid-state Extrusion Process: Anurag Krishnakedar Gumaste¹; Sanya Gupta¹; Supreeth Gaddam¹; Ravi Sankar Haridas¹; Rajiv Mishra¹; Kumar Kandasamy²; Brandon McWilliams³; Kyu Cho³; ¹University of North Texas Denton; ²Enabled Engineering; ³CCDC Army Research Laboratory
    Solid Stir Extrusion (SSE), a novel and innovative process based on friction stir technology has been introduced with Al 6061 as a model material. The process is designed to obtain final solid-state extrudate of desired shape. As an alternate solid-state manufacturing technique, SSE process enjoys advantages such as lower power consumption, continuity over larger time frame, applicability over a wide range of materials, and possibility of rescaling to preferential design requirements. The process outcomes have been correlated with detailed microstructural and mechanical characterization. Extrudate exhibited refined equiaxed grain morphology with enhanced ductility as compared to the base material. Post process aging further enhanced the mechanical performance of the extrudate. Additionally, an attempt was made to correlate independent process variables and process-based outcomes in SSE through a conceptual model which has been validated through extensive experimental runs. The metal recycling capability of this process was demonstrated using compacted aluminum chips.

E-15: TEM Dislocation Interaction with the Microstructure of an Al-Si-Mg Alloy Elaborated by Laser Beam Melting: Nicolas Bello¹; Malo Jullien¹; Cassiopée Galy²; Céline Larignon²; Joël Douin¹; ¹CEMES-CNRS; ²IRT Saint Exupéry
     To understand the microscale precipitation hardening in an AS7G06 alloy elaborated by laser beam melting, a comparison between T6 heat treatment and a direct artificial ageing (DAA) have been made. TEM in situ straining experiments conducted on a JEOL allow the direct observation of the dislocation movement within a microstructure. The precipitate resistance can then be calculated based on the Hazzeldine formula to obtain a value of its resistance.Fine TEM characterizations confirmed the presence of the Si-network on the DAA microstructure and a foundry-like one for the T6 heat treatment. TEM in situ straining experiments allow the identification of the hardening precipitates. Though the dislocation interactions, their resistance has been calculated. With these values we were able to quantify hardening participation and adapt the Hirsh & Kelly formula to fit with the measured properties.

E-16: The Study on the Relationship with Rolling Condition and Properties in Al Alloys: Sun Ki Kim¹; Taeyang Kwak²; changhee Cho³; Jinkyu Lee¹; Youngjig Kim⁴; ¹NICELMS Co., Ltd; ²Ruantech Co., Ltd; ³Korea Institute of Industrial Technology; ⁴Sungkyunkwan Univ.
    Pure Al and Al alloys are used as the main alloy for the sputtering process in the field of electronic materials, and the amount used is increasing worldwide. Recently, in the sputtering process using the Al alloy, various target manufacturing processes have been developed and applied in order to increase the deposition efficiency of the sputtering process. In this study, we investigated the effects of rolling process variables on the microstructure, texture, and specific resistance through the control of the rolling processes, which is one of the manufacturing processes of the Al target, also examined the relationship between the distribution of dislocation and mechanical properties. For this study, we evaluated the texture, microstructure, and mechanical properties using Al rolling plate manufactured under various rolling process conditions, and examined the relevance of each experimental results through EBSD analysis.

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