Multi-axial Fatigue of 2024-T4 Aluminum Alloy

Only the fatigue initiation is considered by the safe-life design approach,while fatigue crack propagation is paid more attention by the damage tolerance approach.The reasonable fatigue design method and durability assessment standard should give these two phases equivalent concerns.To develop a unified model of fatigue initiation and crack propagation,a great deal of baseline fatigue properties of a material should be obtained by fatigue experiments.However,there is lack of thorough and comprehensive experiment study on the fatigue properties of 2024-T4 aluminum alloy,which is widely used as load-bearing components in aircraft industry.In this paper,strain-controlled uniaxial,torsion,and combined axial-torsion fatigue experiments are conducted on 2024-T4 aluminum alloy in ambient air.Fully reversed uniaxial and pure torsion experiments employ solid cylindrical specimens.Fatigue experiments under the fully reversed shear loading with a static axial stress,proportional axial-torsion loading,and 90°out-of-phase axial-torsion nonproportional loading are conducted by using thin-walled tubular specimens.The experimental results show that the mean stress has a significant influence on the fatigue strength of the material.A tensile mean stress decreases the fatigue life dramatically,while a compressive mean stress increases the fatigue life.The strain-life fatigue results obtained from the fully reversed uniaxial fatigue experiments can be represented by one smooth curve of a three-parameter equation.However,two fitting curves are needed for characterizing the results of the fully reversed pure torsion fatigue tests because of the existence of an obvious kink.The baseline fatigue properties of 2024-T4 aluminum alloy obtained from the fatigue experiments have applications for the fatigue design and safe assessment of engineering components.

EFFECT OF LOW-FREQUENCY ELECTROMAGNETIC FIELD ON THE AS-CASTING MICROSTRUCTURES AND MECHANICAL PROPERTIES OF HDC 2024 ALUMINUM ALLOY

The influences of the low frequency electromagnetic field on the horizontal direct chill casting process were investigated experimentally. Ingots of 2024 aluminum alloy with a cross size of 40 mm× 200 mm were produced by the conventional horizontal chill casting process and low frequency electromagnetic horizontal chill casting processre- spectively. The as-cast structures and the mechanical property of the ingots were examined. The results showed that the low frequency electromagnetic field could sub- stantially refine the microstructures and pronouncedly reduce the macrosegregation in the horizontal direct chill casting process. Moreover, the surface quality of the ingot was prominently improved by the low frequency electromagnetic field. The fracture strength and elongation percentage of the ingot was increased with the low frequency electromagnetic field.

Tensile properties and microstructure of 2024 aluminum alloy subjected to the high magnetic field and external stress

In order to explore the dependence of plasticity of metallic material on a high magnetic held,the effects of the different magnetic induction intensities（H = 0 T,0.5 T,1 T,3 T,and 5 T） and pulses number（N = 0,10,20,30,40,and 50） on tensile strength（σ;） and elongation（δ） of 2024 aluminum alloy are investigated in the synchronous presences of a high magnetic held and external stress.The results show that the magnetic held exerts apparent and positive effects on the tensile properties of the alloy.Especially under the optimized condition of H;=1 T and N;=30,the σ;and 8 are 410 MPa and 17% that are enhanced by 9.3% and 30.8% respectively in comparison to those of the untreated sample.The synchronous increases of tensile properties are attributed to the magneto-plasticity effect on a quantum scale.That is,the magnetic held will accelerate the state conversion of radical pair generated between the dislocation and obstacles from singlet to the triplet state.The bonding energy between them is meanwhile lowered and the moving flexibility of dislocations will be enhanced.At H;= 1 T and N;= 30,the dislocation density is enhanced by 1.28 times.The relevant minimum grain size is 266.1 nm,which is reduced by 35.2%.The grain rehning is attributed to the dislocation accumulation and subsequent dynamic recrystallization.The（211） and（220） peak intensities are weakened.It is deduced that together with the recrystallization,the hne grains will transfer towards the slip plane and contribute to the slipping deformation.

Deformation Behavior and Microstructure Evolution of AA2024-H18 Aluminum Alloy by Hot Forming with Synchronous Cooling Operations

Hot forming with synchronous cooling(HFSC)is a novel technique for heat-treatable,high-strength aluminum alloys,which allows the alloys to acquire good formability,negligible springback,rapid processing and better mechanical properties.However,the deformation behavior and microstructure evolution of the alloys during HFSC are complex and need to be studied due to the temperature and strain rate effects.Uniaxial tensile tests in a temperature range of 250—450℃and a strain rate range of 0.01—1 s-1 for AA2024-H18 aluminum alloy sheet are conducted with a Gleeble-3500 Thermal-Mechanical Simulation Tester.And based on metallography observation and analysis,AA2024-H18 aluminum alloy sheet in HSFC process exhibits hardening and dynamic recovery behaviors within the temperature range of 250—450 ℃.Strain rate shows different effects on ductility at different temperatures.Compared with traditional warm/hot forming methods,AA2024-H18 aluminum alloy achieves a better work-hardening result through HFSC operations,which promises an improved formability at elevated temperature and thus good mechanical properties of final part.After HSFC operations,the microstructure of the specimens is composed of elongated static recrystallization grain.

Grain refining in weld metal using short-pulsed laser ablation during CW laser welding of 2024-T3 aluminum alloy

The 2024 aluminum alloy is used extensively in the aircraft and aerospace industries because of its excellent mechanical properties.However,the weldability of 2024 aluminum alloy is generally low because it contains a high number of solutes,such as copper(Cu),magnesium(Mg),and manganese(Mn),causing solidification cracking.If high speed welding of 2024 aluminum alloy without the use of filler is achieved,the applicability of 2024 aluminum alloys will expand.Grain refining is one of the methods used to prevent solidification cracking in weld metal,although it has never been achieved for high-speed laser welding of 2024 aluminum alloy without filler.Here,we propose a short-pulsed,laser-induced,grain-refining method during continuous wave laser welding without filler.Bead-on-plate welding was performed on a 2024-T3 aluminum alloy at a welding speed of 1 m min−1 with a single mode fiber laser at a wavelength of 1070 nm and power of 1 kW.Areas in and around the molten pool were irradiated with nanosecond laser pulses at a wavelength of 1064 nm,pulse width of 10 ns,and pulse energy of 430 mJ.The grain-refinement effect was confirmed when laser pulses were irradiated on the molten pool.The grain-refinement region was formed in a semicircular shape along the solid–liquid interface.Results of the vertical section indicate that the grain-refinement region reached a depth of 1 mm along the solid–liquid interface.The Vickers hardness test results demonstrated that the hardness increased as a result of grain refinement and that the progress of solidification cracking was suppressed in the grain refinement region.

Fatigue Induced Alteration of the Superficial Strength Properties of 2024 Aluminum Alloy

aluminum alloy 2024 T3 specimens have been subjected to constant amplitude fatigue loading at R=0.1. During fatigue, an appreciable increase of the surface hardness of the material at the meso-scale can be observed and captured by means of nanoindentations. Surface hardness increases with increasing fatigue stress amplitude and advancing number of applied fatigue cycles. Observed increase of specimen surface hardening degree during fatigue causes an evolution of superficial mechanical strength properties of the alloy. Stress-strain curves associated with the evoluting superficial mechanical properties are derived, employing a developed finite element method （FEM）-supported evaluation procedure of nanoindentation experimental results.

Deformation characteristics and inertial effect of complex aluminum alloy sheet part under impact hydroforming:experiments and numerical analysis

Impact hydroforming(IHF),as a novel sheet metal forming technology with the advantages of high strain rate forming and flexible liquid loading,is highly suitable for efficiently manufacturing aluminum complex-shaped sheet parts.In this paper,deformation characteristics of complex sheet parts under IHF are systematically investigated.The mechanical properties of 2024 aluminum alloy under a wide range of strain rates(10-3 s-1–3.3×103 s-1)were studied.It indicated that the elongation of 2024 aluminum alloy was improved by 116.01%under strain rates of 3.306-×-103 s-1,referring to 10-3 s-1.Further,a complex-shaped part with symmetrical and asymmetrical structures was selected.The deformation characteristics of sheet and role of inertial effect under IHF were investigated with well-developed solid–liquid coupling finite element(SLC-FE)model with high accuracy.Differentiating deformation tendency is found for symmetrical structure with notably prior deformation at central zone,showing a“bulging”profile at initial forming stage.Whereas,synchronous deformation is presented for asymmetrical structure with a“flat”profile.Additionally,distinctive inertial effect was observed at different positions change for both symmetrical and asymmetrical structures,in which lower values were resulted at their central regions.Meanwhile,the inertial effect evolved with the impacting speed.Specially,larger difference of inertial effect was observed with increasing impacting speed.