Papers by Author: J.B. Fogagnolo

Abstract: There is considerable industrial potential for aluminium alloys and aluminium metal matrix composites fabricated via net shape press-and-sintering powder metallurgy using low-cost, elemental premixed powder. In this work, the compressibility and sinterability of premixed Al– 4.5Cu–0.7Si–0.5Mg powder alloy reinforced with Al2O3 particles was analyzed. The powders reinforced with increasing ceramic particle content were cold-pressed under increasing pressure and sintered at 600 oC for 40 minutes, in nitrogen atmosphere. The powders showed the typical compressibility curves and the presence of hard ceramic particles decreased the powder deformation capacity and, consequently, the powder compressibility. The sintering produced swelling of the parts, due to the poor wettability of liquid phase on the aluminium particles and to the Kirkendall effect caused by the difference in diffusivity of aluminium in copper and copper in aluminium. The presence of Al2O3 particles increased the swelling during sintering probably due to the sooner formation of liquid phase.

Abstract: Nanostructured aluminium-based alloys are light yet much stronger than conventional materials, which offer technological opportunities for applications such as in aerospace industry. One of the alloys of great interest for such applications is based on Al-Cu system and one of the main challenges for development of such alloys are associated with powder processing. However, processing such powder alloys into bulk material requires relatively low temperature and high pressure, which presents significant processing difficulties. A two-step approach is being explored in our group to reach the goal of a fully dense bulk material. Firstly, cold pressing is used to partially consolidate the powder material and secondly, hot extrusion is used to consolidate the alloy to full density. Process modelling is being used to design the extrusion process, including the extrusion ratio and extrusion length, to limit the temperature increase during extrusion as a result of adiabatic heating, and to avoid excessive heating to limit the undesirable grain growth of the material. A parametric study of extrusion parameters is presented and processing parameters are recommended. The use of process modelling has proven to be a useful tool in understanding the results from the extrusion experiments and limiting the number of interactions during extrusion.

Abstract: A nanostructured aluminium alloy powder, prepared by rapid solidification via gas atomization, was consolidated into bulk material under various processing conditions via hot extrusion. The microstructure modifications and mechanical properties of the consolidated alloys as a function of the extrusion conditions were investigated. The increase in the extrusion-load with the increase of extrusion-rate and decrease of temperature are shown and discussed in association with the modification in the microstructures. The differences in mechanical properties measured by compressive tests are also discussed in association with the extrusion parameters. Furthermore, suggestions are given for rationalising the extrusion ratio and temperature conditions for the consolidation of nanostructured aluminium alloy powders via hot extrusion.