Synergistically Improved Mechanical Properties and Thermal Conductivity of Hypoeutectic AlSiNiFeMg Alloy Prepared by Ultrasonic-assisted Casting

We employed a melt ultrasonic treatment near the liquidus to prepare a high-thermal-conductivity Al-4Si-2Ni-0.8Fe-0.4Mg alloy.The influences of various ultrasonic powers on its microstructure,mechanical properties,and thermal conductivity were investigated.It is shown that near-liquidus ultrasonication significantly refines the alloy grains and eutectic structure,synergistically improving the alloy’s mechanical properties and thermal conductivity.Specifically,the grain size decreased by 84.5%from 941.4 to 186.2μm.Increasing the ultrasonic power improved the thermal conductivity of the alloy slightly and significantly enhanced its mechanical properties.At an ultrasonic power of 2100 W,the tensile strength,yield strength,elongation rate,and thermal conductivity were 216 MPa,142 MPa,6.3%,and 169 W/(m·k),respectively.

Influence of anodic oxide film structure on adhesive bonding performance of 5754 aluminum alloy

Three types of anodic films(unsealed,hot water sealed and agent sealed)were prepared to study the effects of anodic film structure on the adhesive bonding performance of AA5754 automotive sheets.The morphology of the anodic films was examined by using scanning electron microscope(SEM)and the composition was examined by glow discharge optical emission spectroscopy(GDOES).The adhesive bonding strength and the durability in corrosive environment were investigated by using single lap-hear test and salt spray test(SST),respectively.The results showed that the unsealed sample could provide high initial bonding strength,but the durability was poor in corrosive environment.The hot water sealed sample could provide high durability,but the bonding strength was low.In contrast,the agent sealed sample displayed porous structure at outer layer and partially plugged nano pores structure at inner layer,providing both excellent bonding strength and durability.

Microstructure characterization of Al-cladded Al-Zn-Mg-Cu sheet in different hot deformation conditions

Al-cladded Al-Zn-Mg-Cu sheets were compressed up to70%reduction on a Gleeble-3500thermo-mechanical simulatorwith temperatures ranging from380to450°C at strain rates between0.1and30s-1.The microstructures of the Al cladding and theAl-Zn-Mg-Cu matrix were characterized by electron back-scattered diffraction(EBSD)and X-ray diffraction(XRD).Themicrostructure is closely related to the level of recovery and recrystallization,which can be influenced by deformation temperature,deformation pass and deformation rate.The level of recovery and recrystallization are different in the Al cladding and theAl-Zn-Mg-Cu matrix.Higher deformation temperature results in higher degree of recrystallization and coarser grain size.Staticrecrystallization and recovery can happen during the interval of deformation passes.Higher strain rate leads to finer sub-grains atstrain rate below10s-1;however,dynamic recovery and recrystallization are limited at strain rate of30s-1due to shorter duration atelevated temperatures.

Hot deformation behaviors and dynamic recrystallization mechanism of Ti-35421 alloy inβsingle field

Hot deformation behaviors and microstructure evolution of Ti-3Al-5Mo-4Cr-2Zr-1Fe(Ti-35421)alloy in theβsingle field are investigated by isothermal compression tests on a Gleeble-3500 simulator at temperatures of 820-900°C and strain rates of 0.001-1 s^(-1).The research results show that discontinuous yield phenomenon and rheological softening are affected by the strain rates and deformation temperatures.The critical conditions for dynamic recrystallization and kinetic model of Ti-35421 alloy are determined,and the Arrhenius constitutive model is constructed.The rheological behaviors of Ti-35421 alloys aboveβphase transformation temperature are predicted by the constitutive model accurately.The EBSD analysis proves that the deformation softening is controlled by dynamic recovery and dynamic recrystallization.In addition,continuous dynamic recrystallization is determined during hot deformation,and the calculation model for recrystallization grain sizes is established.Good linear dependency between the experimental and simulated values of recrystallized grain sizes indicates that the present model can be used for the prediction of recrystallized grain size with high accuracy.

Micro porosity and its effect on fatigue performance of 7050 aluminum thick plates

Micro porosity in aluminum alloys may contribute to fatigue life degradation, which can largely limit the application of alloys. Therefore, the fatigue life of a commercial 7050-T7451 thick plate and an experimental plate with different porosities was compared in this study. The X-ray computed tomography(XCT) was utilized to characterize the size, number density and spatial distribution of porosity inside various samples, and the fracture surface of fatigued specimens was compared by using scanning electron microscope(SEM). The results showed that the fatigue cracks prefer to initiate from constituent particles in the commercial alloy. Whereas the micro porosity is the predominant site for crack nucleation and subsequent failure in the experimental one. The presence of micro porosity in experimental7050-T7451 thick plate may reduce the fatigue life by an order of magnitude or more compared with the defect-free alloy. The pores close to sample surface are the main fatigue crack initiation site, among which larger and deeper pore leads to a shorter fatigue life. The crack initiation is also affected by the pore geometry and direction. Besides, the overall porosity inside the bulk can affect the crack propagation during fatigue tests.

Quasi <i>In-Situ</i>Study on Microstructure Evolution of Al 2014 Alloy during Thermal Deformation and Following Solution Treatment

Microstructure evolution of 2014 aluminum alloy was studied by hot compression deformation at 410?C to 470?C and strain rates of 0.07 s?1 to 0.53 s?1, to provide manufacturing references for aluminum plate. The deformation temperature and especially strain rate ranges were chosen very close to the actual processing condition. The results show that the stress-strain curves display a stable flow at the given deformation conditions, corresponding a dominant microstructure evolution behavior of dynamic recovery (DRV) and few dynamic recrystallization (DRX). After solution treated at 502?C for 3 hours, quasi in-situ observation shows that static recrystallization (SRX) develop typical fine grains with several microns at grain boundaries, while static recovery (SRV) dominants the microstructure evolution during the soaking time, leading to a similar microstructure to that of the as-deformed. The average low angle grain boundaries (LAGBs) and high angle grain boundaries (HAGBs) display weak differences between as-deformed and solution treated specimens, which reveals a good thermal stability of microstructure for 2014 alloy. However, the deformation at the lower temperature has an obvious trend to induce SRX during solution soaking.

Constitutive behavior and microstructural evolution in hot deformed 2297 Al-Li alloy

The microstructural evolution mechanism and constitutive behavior of 2297 Al-Li alloy were studied via thermal compression test with the constant strain rates of 0.001–1 s-1 and the deformation temperatures ranging from 623 to 773 K.To verify the predictable ability of diverse constitutive models under different stress states,the hot compression experiments with stress triaxiality varying from-0.33 to 0.46 were conducted.The microstructures of the deformed specimens under diverse deformation conditions are probed to reveal the mechanism of hot deformation behavior.The experimental results indicate that the work-hardening and dynamic softening are competitive during the hot compression process,and the dynamic softening is more obvious under low deformation temperature and high strain rate.The microstructural analysis manifests that the dynamic recovery gets predominant at high deformation temperature to produce fine grains.Meanwhile,the dynamic recrystallization becomes more dominant as the strain rate decreases,which is sensitive to the stress triaxiality.In addition,both the modified Johnson-Cook model and straincompensated Arrhenius-type function are suitable for describing the flow behavior of 2297 alloy,while the latter reveals a more accurate prediction.However,the predictability of the two kinds of models is worsened with the transformation of stress triaxiality,and the validity of the Arrhenius-type model is restricted by high stress triaxiality.

Experimental and numerical investigation on surface quality for two-point incremental sheet forming with interpolator

The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.

Formation of intermetallic phases in unrefined and refined AA6082 Al alloys investigated by using SEM-based ultramicrotomy tomography

The spatial arrangement,distribution and morphology of Fe-bearing intermetallics in AA6082 alloys depends on the manufacturing process of the alloy and thus influences the macroscopic properties.Here,the microstructure of a near industrial scale casting AA6082 Al alloy fabricated by:(a)direct chill casting,(b)Al-5 Ti-1 B grain refiner addition and(c)intensive melt shearing has been investigated by threedimensional visualization using SEM-based serial ultra microtomy tomography.The formation sequence of phases in AA6082 alloys is generally categorized into four stages:formation ofα-Al grains,Fe-bearing intermetallics,Mg_(2)Si phase,and eutectic rosettes.Results of three-dimensional visualization of the microstructure indicated that TiBparticles not only could nucleate Fe-bearingβ-intermetallics,but also could provide substrate for the formation of Fe-bearingα-intermetallics and Mg_(2)Si.A further deep analysis reveals that the essential condition for the formation of secondary phases such as Fe-bearing intermetallics and Mg_(2)Si phase is the build-up of a supersaturated solute front at theα-Al solid-liquid interface irrespective of the specific nucleation site.In addition,the results indicate that grain refinement processing causes the severe interconnectivity of Fe-bearingα-intermetallics.However,the intensive melt shearing is a better manufacturing process because the intermetallics are more evenly distributed and refined than with the addition of the grain refiner,thereby improving the properties of the alloy.

Formation mechanism and modeling of surface waviness in incremental sheet forming

mproving and controlling surface quality has always been a challenge for incremental sheet forming (ISF), whereas the generation mechanism of waviness surface is still unknown, which impedes the widely application of ISF in the industrial field. In this paper, the formation mechanism and the prediction of waviness are both investigated through experiments, numerical simulation, and theoretical analysis. Based on a verified finite element model, the waviness topography is predicted numerically for the first time, and its generation is attributed to the residual bending deformation through deformation history analysis. For more efficient engineering application, a theoretical model for waviness height is proposed based on the generation mechanism, using a modified strain function considering deformation modes. This work is favorable for the perfection of formation mechanism and control of surface quality in ISF.