Aluminum Alloys, Characterization and Processing: Poster Session
Sponsored by: TMS Light Metals Division, TMS: Aluminum Committee
Program Organizers: Julie Levesque, Quebec Metallurgy Center; Stephan Broek, Kensington Technology Inc
Monday 5:30 PM
March 20, 2023
Room: Exhibit Hall G
Location: SDCC
E-1: Aluminum Alloy Design and Mechanical Properties for Next-generation Mobility Structural Materials: Minsang Kim1; Hyun Joo Choi2; Young Do Kim3; Se Hoon Kim1; 1KATECH; 2Kookmin University; 3Hanyang University
Aluminum alloys applied to next-generation mobility are required to be eco-friendly in zero-carbon era along with their reliability. At present, tens of aluminum alloys for automobiles are being applied. Therefore, during recycling, there is a problem that it is used as low-grade scrap due to the difference in alloy composition, so the next-generation aluminum alloys for mobility such as xEV, UAM is required to be improved. In this study, Al-Zn-Mg-(Cu) wrought alloy designed for structural materials of next-generation mobility that can be used universally in body-in-white. Al-Zn-Mg-(Cu) wrought alloy can realize all of the characteristics of Al-Mg, Al-Mg-Si, Al-Zn-Mg-(Cu) based aluminum alloys applied to vehicle structural materials and has a single composition designed for easy recycling. In this study, the effects of major additive elements on microstructures and mechanical properties were analyzed through the design of Al-Zn-Mg-(Cu) based aluminum alloys for application to next-generation mobility.
E-2: Comparison Finite Element Simulations with Tensile Tests of Different Aluminum Alloys: Melih Caylak1; Gorkem Ozcelik1; Ilyas Sari1; 1ASAS Aluminum
With the development of technology, finite element (FE) simulation studies have started to gain importance. Companies have been started to use finite element softwares to simulate their designs and aimed providing cost reduction during to design process. Therefore, performance of this softwares were gained importance for studies.In this study, to evaluate the performance of different FE simulations with comparison of tensile test simulations and experiments. AA6005 and AA6082 aluminum alloys have been considered as test materials. Several tensile tests have been carried out according to EN ISO 6892-1 test standard. LS-Dyna and Marc finite element softwares were used to perform FE simulations. von Mises yield criterion was employed as yield function. The FE results were compared with experimental tests and it was seen that numerical solutions provide accurate results with tests.
E-3: Correlation between the Precipitation Phase and Mechanical Properties of Al-Mg-Si(-Cu) Based Aluminum Alloy Sheets According to the Change in Mg Content: Gyeongseok Joo1; YongWook Song2; MinSang Kim3; Hyunjoo Choi2; SeHoon Kim3; JaeHyuk Shin3; SoonMok Choi4; 1Korea Automotive Technology Institute- Korea University of Technology & Education; 2Kookmin University; 3Korea Automotive Technology Institute; 4Korea University of Technology & Education
6xxx series aluminum alloys were mainly used for automobile exterior panels due to its advantages such as appropriate strength, excellent formability, corrosion resistance and dent resistance. Recently, demand is increasing due to the issue of weight reduction for the purpose of improving fuel efficiency, and accordingly, better aging hardening characteristics and research are required. In this study, changes in the amount of Mg-Si-based precipitates, which are the main reinforcing phases of 6xxx-based aluminum alloys, and the changes in mechanical properties were investigated according to the change in the Mg content. Quantitative changes in precipitates according to differences in Mg content were predicted by the phase analysis software (JMatPro13.0). By different pre-aging conditions for each composition, the behavior of hardness and strength change according to temperature and holding time and BH characteristics were investigated to investigate changes in mechanical properties.
E-4: Depth Dependent Microstructure and Mechanical Properties of Hot Rolled AA 7075 - T651: Damilola Alewi1; Paul Rottmann1; 1University Of Kentucky
The evolution of the microstructure and mechanical properties of a 32 mm thick hot rolled AA7075 plate specimen in T651 temper condition was investigated with the aim of understanding the qualitative and quantitative contribution of precipitate phases and grain structure. The microstructure is studied quantitatively in detail by a combination of scanning electron microscopy (SEM) and Electron backscatter diffraction (EBSD). Mechanical properties measured with the aid of ex-situ micromechanical and hardness test showed an interesting anisotropic trend in the tensile and yield strength with respect to depth from the surface to the midplane of the specimen. Backscatter SEM analysis of the microstructure showed the preferential nucleation and distribution of η/η’ quench induced precipitates on the grain boundaries, sub grain boundaries and dispersoids because of their high interfacial energy. This study will make it possible to better understand the contribution of these precipitate phases in the mechanical properties’variability.
Effect of Eu and Er on Mechanical Properties of 201 and 206 Alloys: Hayati Sahin1; Derya Dispinar1; 1Foseco
Erbium (Er) and Europium (Eu) was added to 201 and 206 alloys at different ratios. Cast parts were heat treated at T7 condition and the tensile properties were compared with and without heat treatment. In 206 alloy, as the Eu and Er content of the alloy was increased, UTS and YS was decreased while as conditions revealed higher elongation at fracture than the heat treated samples. On the other hand, in 201 alloy, UTS and YS was decreased slightly with increased Er and Eu content while elongation at fracture was decreased significantly. SEM studies showed that this effect was associated with intermetallic phase in the form of fish-bone morphology that decreased the toughness of the alloy.
E-5: Effect of Thermal Treatment (T5) on Microstructure and Tensile Properties of Vacuum High Pressure Die Cast Al-Si-Mg Alloy: Hongfa Hu1; Ali Dhaif1; Kazi Ahmed1; 1University of Windsor
In this work, a modified Al-Si-Mg (A356) alloy was prepared by vacuum-assisted high pressure die casting processes (V-HPDC). To release residual stresses, various thermal treatment schemes over a wide range of temperatures between 120˚ to 350˚ C were experimented to the as-cast V-HPDC alloy, in an effort of understanding the effect of thermal treatment on tensile properties of V-HPDC modified Al-Si-Mg (A356) alloy. The morphology of eutectic silicon has a sound effect on the tensile properties of the tested alloy. The content of magnesium-based intermetallic phase, their morphology and distribution throughout the matrix affect on the tensile properties as well. The reduction in the strengths of the alloy treated at 350˚C for two hours should be at least attributed partly to the absence of the magnesium-based intermetallic phase. However the presence of sufficient amount of magnesium intermetallic phase plays an important role in strengthening the alloy thermally treated at 200˚C.
E-6: Effects of Mn Addition on Electrical Conductivities, Tensile Properties and Microstructure of Wrought Al Alloys: An Overview: Wutian Shen1; Ali Dhaif1; Anita Hu1; Sufeng Liu1; Hongfa Hu1; 1University of Windsor
Development of lightweight Al alloy with high electrical conductivities, tensile properties and low cost has become an urgent task for market expansion of battery-powered electric vehicles in the past few years. Manganese (Mn) is one of the alloying elements often used in wrought Al alloys (3xxx series), which can ensure uniform deformation and enhance strengths, compared to pure aluminum. This is because Mn has a low maximum solubility of 1.25 wt% in Al under equilibrium solidification and forms Al6Mn dispersoid as a strengthening phase. In this paper, the effects of Mn on the electrical and tensile properties of Al alloys are reviewed. The electric conduction principles and microstructure characteristics of Mn-containing Al alloys are presented. The strengthening mechanisms are discussed. The effects of cooling rates on the tensile properties of Mn-containing Al alloys are highlighted.
Cancelled
E-7: Effects of Zn and Cu Contents and Heat Treatment Conditions on the Precipitation Behavior of 7xxx Series Al Alloy: Suwon Park1; Dae Cheol Yang2; Min Sang Kim3; Heon Kang1; Seok Su Sohn2; Se Hoon Kim3; Hyunjoo Choi1; 1Kookmin University; 2Korea University; 3Korea Automotive Technology Institute
Aluminum alloys have numerous applications owing to their light weight and the abundance of their raw materials. The 7xxx series alloys, based on the Al–Zn–Mg(–Cu) system, are designed as heat-treatable aluminum alloys with high specific strength. However, they undergo hydrogen embrittlement, which restricts their application as advanced structural material in hydrogen-rich environments in the aerospace and transportation fields. In this study, 7xxx series Al alloys were designed with different contents of Zn and Cu by various solid solution heat treatments and artificial aging to produce an alloy less susceptible to hydrogen. The effects of chemical composition and heat treatment conditions on the precipitation behavior of the alloys were investigated using different microscopic methods. The relationship between the microstructure and mechanical/hydrogen embrittlement behaviors will be discussed
E-35: Evaluating Fractional Crystallization Methods for Closed-Loop Recycling of End-of-Life Automotive Aluminum Sheet: Alissa Tsai1; Daniel Cooper1; 1University of Michigan
Vehicle electrification and lightweighting are leading to the growing use of wrought aluminum in vehicle design, which are subject to strict composition limits. Consequently, an impending issue in end-of-life vehicle (ELV) recycling is the high value recovery of automotive aluminum sheet. A major challenge for automotive recyclers is the efficient separation and refining of ELV scrap to improve scrap purity. One such refining technology is fractional crystallization, which our preliminary analysis suggests is cheaper and more energy efficient than existing refining technologies (e.g., Hoopes, membrane purification, low temperature electrolysis). Current methods for achieving fractional crystallization are reviewed and compared for feasibility in removing contaminant elements from ELV scrap. A linear programming model, using results from Scheil solidification simulations, is used to quantify the recycling benefits of incorporating fractional crystallization into automotive reverse supply chains. We conclude by discussing the barriers and opportunities to scaling these technologies for commercial application.
E-8: Experimental Investigation and Thermodynamic Consideration of Oxide Inclusions Formation in Al-Mg Alloys: Young-Ok Yoon1; Nam-Seok Kim1; Seung-Yoon Yang1; Seong-Ho Ha1; Bong-Hwan Kim1; Hyun-Kyu Lim1; Shae K. Kim1; 1Korea Institute of Industrial Technology
Experimental investigation and thermodynamic consideration of oxide inclusions formation in Al-Mg alloys were done in this study. The surfaces of alloy samples right after the long time heating showed significant changes depending on the heating rates. Cross-sections of the oxidized samples air-cooled after the heating showed the existence of significantly formed pores and coarse oxide clusters near the surfaces. As a result of compositional analysis by a microscope on the oxide clusters, much higher contents of oxygen than other constituent elements were present in the oxide areas, indicating that the oxide clusters possibly contained a significant amount of gas. The compositional points corresponding to the oxide clusters were located in phase regions including MgO and spinel of isothermal Al-Mg-O ternary phase diagram.
High Temperature Deformation Analysis of A1-12Ce Alloy: Ashutosh Sonule1; Srinu Gangolu2; 1National Institute of Technology, Calicut; 2IIT Kanpur
The Aluminium and Cerium alloy is fabricated by casting in binary composition of 10-12 wt% Ce and followed by homogenization. Compression testing is appropriate for bulk size Al-12Ce alloy and is utilized in the current investigation. Homologous temperature range (near to 0.5Tm) and dynamic strain rates are selected for testing. Arrhenius equation proposed by Sellars and Tegart is used for constitutive analysis during hot deformation. The activation energy and stress exponent is determined to be 632 kJ/mol and 3.85 respectively. The maximum instability region occurred in the regions of all temperatures between 430°C to 490°C and between the strain rates of 0.001 to 0.01 /sec. The optimum hot working condition of Al-12Ce are all true strain occurs in the temperature range of 430°C to 490°C and strain rate range of 0.1 to 1 /sec with optimum processing window (i.e. maximum power dissipation efficiency) occurs at 470 °C and 0.1 /sec
E-9: Investigation the Effects of Natural Aging Parameters on Mechanical Properties of 6082 Alloys: Zeynep Tutku Ozen1; Abdullah Kagan Kinaci1; Gorkem Ozcelik1; Ilyas Artunc Sari1; Anil Umut Ozdemir1; Alptug Tanses1; Emre Cankaya1; Mustafa Serkan Ozcan1; 1Asas Aluminyum As
Mechanical properties of the aluminum alloys can be optimised by controlling the aging parameters. Natural aging of the aluminum alloys is achieved by holding the samples at room conditions for required time. Natural aging itself is a complex route since it depends not only on composition but also on processing. In some applications that requires high compression characteristics, like upgrade crash worthiness needs of automotive structural parts, over aging conditions must be controlled. In this study, effects of different natural aging conditions on 6082 alloys mechanical properties have been investigated. Characterization studies of the samples have been carried out with tensile and compression tests.
E-33: Laser Powder-Bed Fusion AA 7075 Aluminium Alloy Synthesis and Characterization: Irena Paulin1; Crtomir Donik1; Nejc Velikajne1; Matjaž Godec1; 1Institute of Metals and Technology
Conventionally processed, high-strength aluminium alloys from the AA2xxx, AA6xxx and AA7xxx series are widely used for aerospace applications. With the emergence of SLM technology, they are confronted with a number of difficulties due to the phenomenon of solidification-cracking susceptibility. This solidification cracking is related to the alloy’s characteristics, such as a large solidification range, the solidification shrinkage, and poor fluidity of the molten phase. It occurs during the melt-pool solidification when the thin liquid film cannot accommodate the solidification shrinkage. An additional challenging issue is the evaporation of the volatile alloying elements (Zn, Mg, Mn, Li) during the SLM process. This causes a modification of the composition, which could lead to an increase in the cracking susceptibility as well as changing the microstructure and the properties. In our study, we manage to LPBF produced the AA7075 aluminium alloy with low porosity and promising mechanical properties.
Local Formability Improvement of Commercial Aluminum Sheets Using Friction Stir Processing: Wahaz Nasim1; Hrishikesh Das1; Mert Efe1; Piyush Upadhyay1; 1Pacific Northwest National Laboratory
Friction Stir Processing (FSP) was implemented on 7085-T76, 7075-T6, 7055-T6 and 6111-T6 sheet metal to improve local formability where desired. FSP uses a fast-rotating tool head to impart high plastic deformation at high temperatures into the sheet metal. Rotation rate of the tool head and welding speeds were controlled to find the optimized processing parameters of each alloy. FSP sheet alloys were tested under bending to find radius to thickness ratio (r/t) at failure. FSP of 7xxx series and 6111 alloys showed formability improvement upwards of 40% and 69% respectively compared to the base alloy condition, suggesting that T4-temper level formability can be obtained locally in T6 temper sheets. A significant dependance of r/t at failure was found with the surface finish and the stress type (compression vs. tension) on the processed zone. This study also incorporated robot integration of the process to showcase integration of FSP into manufacturing lines.
Mapping the Laser Additive Manufacturing Process of Aluminium Alloys Through In-situ Synchrotron Radiography: Rubén Lambert-Garcia1; Samy Hocine1; Sebastian Marussi1; Andy Farndell2; Elena Ruckh1; Maureen Fitzpatrick3; Anna Getley1; Martha Majkut3; Alexander Rack3; Nick Jones2; Peter Lee1; Chu Lun Alex Leung1; 1UCL Mechanical Engineering; 2Renishaw plc; 3European Synchrotron Radiation Facility
Laser powder bed fusion (LPBF) is an additive manufacturing technology capable of processing aluminium alloy powder feedstock into geometrically complex structures. Aluminium casting alloys such as AlSi10Mg are gaining popularity in additive manufacturing applications such as high-performance heat exchangers, taking advantage of the design flexibility afforded by LPBF. However, the processing window for aluminium alloys is narrow and the formation of defects (such as porosity, lack of fusion between layers, and droplet spatter) is common. Here we apply in situ and operando synchrotron X-ray imaging to see inside the melt pool during laser processing and observe the formation of such defects to better understand the conditions under which they occur. We mapped these imaging results into distinct melting regimes as a function of processing parameters which could be used to guide optimum industrial settings to produce high-quality parts.
E-10: Mechanical Properties of Aluminum Matrix Composites Containing Sub-micron High-entropy Alloy (HEA) Particles: Jung Chahee1; Son Hansol1; Jung Jaewon2; Choi Hyunjoo1; 1Kookmin University; 2Korea Institute of Materials Science
Aluminum matrix composites (AMCs) have been extensively studied in future mobility industries because of excellent mechanical properties. Although carbon-based materials and ceramics are used as reinforcement for AMCs, they have a poor wettability with Al. To solve this, high entropy alloys (HEAs) have recently attracted a great attention as reinforcement for AMCs. They have high wettability with Al and high strength while maintaining the crystal structure. In this study, AMCs reinforced by sub-micron Al0.5CoCrCuFeNi HEA particles were produced by powder metallurgical routes. First, HEA powder was produced by attrition milling. And then, they were subjected to thermal plasma process to make them sub-micron. 2 vol% of HEAs was then attrition milled with Al powder. The composite powder was hot-rolled and was subjected to heat treatment for 12 h at 500 °C. Reinforcing effect of Al0.5CoCrCuFeNi HEA particles on mechanical properties of AMCs will be discussed in the microstructural perspective.
E-11: Meshfree Simulation and Analysis of Contact Conditions and Microstructure Evolution in Shear Assisted Processing and Extrusion (ShAPE) of Aluminum Alloy 7075: Lei Li1; Tianhao Wang1; Scott Whalen1; Suveen Mathaudhu2; Glenn Grant1; Ayoub Soulami1; 1Pacific Northwest National Laboratory; 2Colorado School of Mines
Shear assisted processing and extrusion (ShAPE) is a solid-phase processing technique that adds an additional shear force as compared with a conventional extrusion approach. This work proposes a thermomechanical meshfree model for ShAPE processing of AA7075 using the smoothed particle hydrodynamics (SPH) method. The model is first validated thoroughly by experimental data in terms of material flow, die face temperature, and extrusion force with various processing parameters. The validated model is then used to analyze the steady-state contact conditions and heat generation rates during ShAPE processing. Simulation results reveal that extrusions conducted at lower temperatures and higher strain rates yield more refined grains and possibly higher material strength, which is consistent with the experimental observations. The strain rate and temperature histories are also extracted and used for predicting Zener-Hollomon parameter and average material grain size. Numerical results on the microscale are also found to agree with experimental observations.
Microhardness Analysis of Directionally Solidified Al-Si Alloys: Edgar Ibañez1; Paula Alonso2; Alicia Ares1; 1Universidad Nacional de Misiones (UNaM). Facultad de Ciencias Exactas, Químicas y Naturales (FCEQyN). Instituto de Materiales de Misiones (IMAM). Programa de Materiales y Fisicoquímica (ProMyF).; 2Comisión Nacional de Energía Atómica (CNEA). División Aleaciones Especiales. Departamento Transformaciones y Propiedades. Gerencia de Materiales. Gerencia de Área Energía Nuclear. Instituto Sabato.
The columnar to equiaxed transition (CET) was studied in Al-Si alloys (Al-5wt.%Si, Al-10wt%Si and Al-12wt%Si,) which were solidified directionally upward from a chill face. The size of the equiaxed grains increase with distance from the transition, an observation that was independent of alloy composition. Microhardness values were measured for each of the macrostructure zones (columnar, CET and equiaxed). When comparing the microhardness between lamellae and interlamellae, it was observed that lamellae are significantly higher in microhardness with respect to interlamellae for each of the zones of the macrostructure. Analyzing the specific values of the microstructures (lamellae and interlamellae), it was observed that comparing the microhardness values for the macrostructure in the CET zone presents significantly different values with respect to the columnar and equiaxed zone for the lamellae microhardness values. In all uses, the results obtained in the present investigation were compared with previous results published in the literature.
E-37: Microstructural Evolution, Mechanical Properties and Faster Aging Kinetics in Friction Extruded AA6061 and AA7075 Alloys: Rajib Kalsar1; Benjamin Schuessler1; Julian Atehortua1; Xiaolong Ma1; Tianhao Wang1; Lei Li1; Jens Darsell1; Nicole Overman1; Ayoub Soulami1; Darrell Herling1; Vineet Joshi1; 1Pacific Northwest National Laboratory
Friction Extrusion (FE) is a newly developed solid phase processing technique and emerging as a potential processing method for microstructural modifications with desired properties. In this study, the FE process has been utilized to extrude both AA6061 and AA7075 alloy to achieve better strength and ductility with refined microstructure. Texture and microstructure evolution during extrusion are investigated in detailed via scanning electron microscopy (SEM), electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) analysis. Refined microstructure, uniform distribution of second phase particles and shear type texture development was observed in FE extruded rod. The uniform distribution and refinement of the particles resulted in faster aging kinetics. Smoothed particle hydrodynamics (SPH) simulation method was utilized to understand the material flow, temperature evolution, strain and strain rate during extrusion process.
Resistance Heating Analysis of a 7xxx Aluminum Sheet for Hot Forming System: Jaehyuck Shin1; Gyeongseok Joo1; Beomsuck Han1; Sanggyu Bae1; Kyeonggeun Jung1; 1Korea Automotive Technology Institute
Recently, various researches have been conducted to expand the application of 7xxx aluminum sheets as reinforcing material for transport components, including aviation parts. However, in the case of a 7xxx-based aluminum sheet, due to the high strength and high sensitivity to thermal treatment, a complicated forming process is required. In this study, the effect of various process variables on heating was analyzed to apply a 7xxx aluminum sheet to resistance heat forming process. According to the variables, such as sheet size and thickness, current, voltage, and time, the temperature gradient of Al 7xxx sheets have been simulated to optimize a heating condition. In addition, analysis results were compared through actual heating experiments.