Papers by Author: Carlos H. Cáceres

Abstract: Cross-sectional microhardness maps of cast-to-shape flat tensile specimens have been obtained for a binary Mg-3.44 mass% La alloy. Higher microhardness numbers were generally found near the casting surface, at the corners and along the segregation band. The higher hardness values were ascribed to the finer solidification microstructure near the surface and to localized positive macro segregation. The majority of lower hardness numbers was found at the core region. Lower hardness values were ascribed to the coarser grain size prevalent at the core and to dispersed microporosity. The non uniformity of the harder surface layer in both depth and hardness appeared related to local homogeneities in the grain size distribution caused by the scattered presence of large externally solidified grains.

Abstract: Specimens of rectangular and circular cross section of a Mg-9Al binary alloy have been tensile tested and the cross section of undeformed specimens examined using scanning electron microscopy. The rectangular cross sections showed three scales in the cellular intermetallics network: coarse at the core, fine at the surface and very fine at the corners, whereas the circular ones showed only two, coarse at the core and fine at the surface. The specimens of rectangular cross section exhibited higher yield strength in comparison to the circular ones. Possible reasons for the observed increased strength of the rectangular sections are discussed.

Abstract: Scanning electron microscopy has been used to characterize the intermetallic structure development across the tensile cross-section of binary Mg-Al alloys with solute content between ~0.5 and 12 mass%Al. The alloys which contain less than 1 mass%Al exhibited a single phase grain structure. For compositions greater than 1 mass% Al, an eutectic network with a discontinuous distribution of intermetallics across the cross-section became apparent. In alloys with greater than 8.77 mass%Al, the intermetallics form a continuous network over the entire cross-section. The scale of the intermetallics network is finer at the surface and corner regions of the cross section in comparison with the core regions.

Abstract: The Kocks-Mecking method of analysis is applied to solid solutions of up to 2.6 at.% Zn to separate the contributions to the alloys’ strain hardening rate from dislocations storage, solute in solution, and twinning, for temperatures between -50 °C (273 K) and 200 °C (473 K). Athermal storage of dislocations seems to account for the largest share of the strain hardening rate for both the pure metal and the solid solutions at or below room temperature. Solute in solution does not increase the strain hardening rate over that of pure Mg, although it delays the onset of dynamic recovery, especially for the higher alloys, presumably due to short range order. Twinning remains a very important deformation mechanism for the pure metal and the dilute alloys up to 200 °C.

Abstract: The presence of surface defects, such as streaking, is one of the most serious quality issues for 6000-series aluminium extrusions. The formation of a streaking defect near a web intersection of a hollow profile was investigated in detail. The streak was apparent on the extrusion in both the as-extruded and the as-anodised conditions. Microstructural examinations indicate that the streaked region contains different surface imperfections compared to the normal region and smaller grains and stronger texture than the normal region. The effects of die design and microstructural variables on the formation of streaks on aluminium extrusions are discussed.

Abstract: Binary Mg-Al alloys with varying content of aluminium from 0.5 to 12mass% have been studied. The proof stress increase in two steps whereas the ductility exhibits two correlated stepwise drops, as the aluminium content increases. The first increase in strength, and attendant drop in ductility, is observed between 4 and 5 mass% Al. The second stepwise change is observed between 10 and 12 mass% Al. These effects are connected with well defined changes in the microstructure: at 4 mass% a dispersion of β-phase intermetallic particles appears in the core region and a closed cell structure develops near the surface; at 12 mass% Al, the increased volume fraction of the β- phase intermetallics extends the interconnected network of intermetallics to include the core region as well. The micromechanics of the strengthening and decreased ductility are discussed.

Abstract: The economical and environmental effects of mass reduction through Al and Mg primary alloys substitutions for cast iron and steel in automotive components are discussed using M.F. Ashby’s penalty functions method. The viability of Mg alloy substitutions for existing Al alloy cast components is also considered. The cost analysis shows that direct, equal-volume, Al alloy substitutions for cast iron and steel are the most feasible in terms of the CAFE liability, followed by substitutions involving flat panels of prescribed stiffness. When the creation of CO2 associated to the production of Al and Mg is considered, the potential gasoline savings over the lifespan of the car compensate for the intrinsic environmental burden of Al in all applications, while electrolytic Mg substitutions for cast iron and steel are feasible for equal volume and panels only. Magnesium produced by the Pidgeon thermal process appears to be too primary energy intensive to be competitive in structural applications. Magnesium substitutions for existing Al alloy beams and panels are generally unviable. The current higher recycling efficiency of Al casting alloys confers Al a significant advantage over Mg alloys.