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

Wednesday 2:00 PM
March 2, 2022
Room: 208B
Location: Anaheim Convention Center

Session Chair: Carly Romnes, University of Illinois at Urbana-Champaign

2:00 PM  Cancelled
Fabrication of Aluminum Alloy 6063 Tubing from Secondary Scrap with Shear Assisted Processing and Extrusion: Brandon Taysom1; Md. Reza-E-Rabby1; Xiaolong Ma1; Massimo DiCiano2; Tim Skszek2; Scott Whalen1; 1Pacific Northwest National Laboratory; 2Magna International
    Recycling allows for the reuse of aluminum with dramatic reductions of the energy, cost, and environmental impact as compared to the creation of primary aluminum from ore. Aluminum is normally recycled by remelting, adding primary aluminum, and casting, which can all be eliminated using Shear Assisted Processing and Extrusion (ShAPE). Using ShAPE, cold compacted briquettes of 100% AA 6063 scrap were extruded into tubing with an outer diameter of 12 mm. Tubes underwent T5 and T6 heat treatments, and had average strengths meeting T5 and T6 specifications. Briquette preparation methodology affected the properties of the final product, with higher pre-extrusion annealing temperatures resulting in higher strengths on average. Large variability in the data indicates that tighter process control will be necessary to reliably achieve peak strength. The application of ShAPE to secondary scrap enables a 44% reduction in CO2 of the billet material compared to remelt recycled aluminum.

2:25 PM  
NOW ON-DEMAND ONLY - Effect of Extrusion Parameters and Heat Treatment on Strength Performance of Low Sc 5181 Alloy: Alexander Gradoboev1; Dmitry Ryabov1; Roman Vakhromov1; Victor Mann2; Aleksandr Krokhin2; Dr. Martijn Vos; 1Lmti Llc (Uc Rusal); 2UC RUSAL
    The researchers are looking for combination of both cost-benefit and optimal content of Scandium to achieve effective strengthening for the replacement of 5083 alloy, which is widely used in marine construction. 5181 alloy contains 0.03%Sc and designed for marine and transportation industry. In order to achieve advanced strength some substitution of Sc was added. Complex alloying with transition metals require fine-tune of thermomechanical processing parameters. Marine construction also use various extrusions and Sc together with other additives may result in different negative effects on it like press-effect. The aim of the present study is to determine the optimal extrusion parameters and heat treatment of 5181 alloy extrusion, which ensures the achievement of a 20% improved strength compared to the profile made of 5083 alloy. The influence of the extrusion speed, heating temperature of billets and modes of heat treatment on the mechanical properties of extruded semi-finished products was studied.

2:50 PM  Cancelled
Influence of the Mg/Si Ratio on Speed Extrusion of 6XXX Alloys: Alexander Gradoboev1; Irina Matveeva1; Dmitry Ryabov1; Roman Vakhromov1; Victor Mann2; Aleksandr Krokhin2; 1Lmti Llc (Uc Rusal); 2UC RUSAL
    Development of the building & construction and automotive industries sets the task to increase the productivity of equipment and reduce the cost of aluminium extrusion. The absolute majority among all aluminium wrought alloys for extrusion belongs to Al-Mg-Si alloys (6XXX series). The small additions of Magnesium and Silicon allow precipitation of metastable phases with Mg/Si ratio close to 1 during aging resulting in five times higher strength in comparison with pure aluminium. The paper shows the evaluation of the effect of Magnesium-Silicon ratio on the extrusion speed of the developed high-speed 6XXX alloys named as MAXIFLOW family. Specially developed composition and homogenization parameters of these alloys ensure the increase of extrusion speed up to 10-30% compared to the standard alloys. The study of the influence of the content of alloying and impurity elements and modes of homogenization on phase composition of 6ХХХ billets is presented as well as anodizing response.

3:15 PM Break

3:30 PM  
Weldability Study of AlMg5ScZr Alloys versus Common 5083 Alloy: Dionysios Spathis1; John Tsiros1; Andreas Mavroudis1; Vassilis Stergiou2; 1ELVAL SA; 2Hellenic Aerospace Industry SA
     The current study shows the influence of Sc and Zr element additions in the heat affected zone of 5083 alloy fusion welds. Tungsten inert gas (TIG) welding tests of 3 mm thick AlMg5ScZr alloy sheets in temper H2X were carried out at Hellenic Aerospace Industry facilities. For comparison purposes 3 mm thick sheets of a typical alloy 5083 (AlMg4,8Mn0,5) in temper H321 were also welded under the same welding conditions. Welded samples were analyzed regarding mechanical and micro hardness properties. Heat affected zone microstructure of the weld was studied under light optical microscope. Heat affected zone recrystallization zone length is reduced significantly in the case of Sc containing alloys. On the other hand, the 5083 alloy shows extended recrystallization in the heat affected zone. Such microstructural improvements in heat affected zone of alloy AlMg5ScZr increase effectively the overall weld strength as illustrated by the mechanical properties testing of weld.

3:55 PM  
Modeling of Springback Behavior in AA6016-T4 Sheet via an Elastoplastic Self-consistent Model Incorporating Backstress: Dane Sargeant1; Zahidul Sarkar2; Rishabh Sharma1; Marko Knezevic2; David Fullwood1; Michael Miles1; 1Brigham Young University; 2University of New Hampshire
    Automotive stampings undergo complex strain paths during drawing, stretching and bending operations which develop large plastic strain gradients within the material. Aluminum sheet alloys are increasingly used for vehicle structure light-weighting, but limited formability and high levels of springback present challenges to the manufacturing and assembly processes. The current work explores the springback levels in AA6016-T4 sheet after pure bending operations. Finite element modeling is performed using both isotropic and elasto-plastic self-consistent (EPSC) crystal plasticity approaches. The EPSC model incorporates backstresses informed by GND content, as measured via high-resolution EBSD. Its predictions are shown to be more accurate than those of the isotropic model. The benefits and limitations of the current EPSC model are discussed.