Materials Science Forum Vols. 618-619

Abstract: By applying the elastic pre-tension method, 5A05 aluminium alloy sheets with 4mm thickness were welded. It is shown that the peak value of residual stresses and their distribution vicinity, the longitudinal buckling distortions and plane deformations of specimens after welding under pre-tension were obviously reduced. It is considered that pre-tension counteracts the compression stress in regions close to the weld generated by thermal expansion, consequently reduces the compression plastic deformations and the tensile stresses in these regions when cooling down, and accordingly diminishes the compressive stresses far from the weld.

Abstract: The demand for safer, lighter and more fuel efficient vehicles has led to the market entry of light weight construction, with the use of advanced high strength steels, engineering plastic and light weight metals. Maximum weight savings potential will be limited if these are used in isolation. Chemistry based structural adhesives and foams enable the intelligent use of all three weight saving methodologies to overcome the problems of safety, quality and high processing cost.

Abstract: The mechanisms of hot tearing are generally understood; inadequate feeding initiates the tear and further thermal deformation propagates the tear. However, a reliable experimental methodology/apparatus to quantitatively measure and characterize hot tearing is not available for the casting industry. In this study, a hot tearing apparatus with a load cell and LVDT developed at CANMET-MTL was used to measure the load and contraction in the mushy zone of an Al-Cu alloy. The onset of hot tearing can be determined from the load curve, its first derivative and cooling curve. The linear solidification contraction of the bar is measured. Alloy 206, which is an alloy that is quite prone to hot tearing was evaluated by the apparatus; results are given and discussed.

Abstract: Friction stir processing (FSP) combines frictional heating and severe plastic deformation to produce microstructural modification, either locally targeted at the near-surface regions or through the bulk, of metallic components fabricated by conventional processing routes. In this paper, we highlight the capabilities of this process by applying it to a high-pressure die cast Al-Si-Mg-(Cu) alloy and examining the resulting microstructure and mechanical properties.

Abstract: Magnesium has become an interesting candidate in the field of bioabsorbable implant materials; it is an essential element in the human body, biocompatible and degradable due to its low corrosion resistance in a pH range below 11.5. However, in the human body (pH  7.4) a magnesium implant might degrade too quickly and lose its mechanical strength before the tissue has fully healed. However, the corrosion resistance can be improved for example by the choice of a suitable Mg alloy containing corrosion-inhibiting elements such as yttrium or by the deployment of surface heat treatments at high temperatures causing protective oxide layers to form. We studied the bio-degradation behaviour of a Mg–Y–RE alloy in different heat treatment states by electrochemical impedance spectroscopy and immersion testing in simulated body fluid. The heat treatments caused a change in microstructure and also the formation of a thermal oxide layer on the sample surface, which consisted mainly of Y2O3 and which slowed the degradation and increased the polarisation resistance significantly compared to the polished state. However, in some specimens localised corrosion attacks occurred which drastically weakened the protective effect of the oxide. Because the implant might be deformed during implantation resulting in the oxide cracking, we intentionally strained the samples and investigated the degradation performance. These cracks led to a decrease in polarisation resistance compared to the non-strained oxidised state, but in comparison to the polished state they still perform better. Macroscopically, the degradation process occurred in a homogeneous way without localised corrosion attacks. Microscopically, corrosion attacks started at the cracks and undermined the oxide layer with time.

Abstract: The aim of this article is to describe the design strategy deployed in developing new bioabsorbable Mg–Y–Zn alloys. The development approach is based on a microalloying concept, which aims to restrict grain growth considerably during alloy casting and forming. We discuss the efficiency of the design approach, and evaluate the characteristics of the new alloys using metal-physical experiments, thermodynamic calculations, and TEM analysis. Our results show that after extrusion the alloys have very fine grains (<10m), exhibit high ductility (uniform elongation: 17–20%) at considerable strength (ultimate tensile strength: 250–270 MPa), and reveal the presence of finely distributed intermetallic particles, which are stable upon annealing. Due to an attractive combination of mechanical, electrochemical and biological properties, the new alloys are very promising not only for applications in medicine but also in other fields.

Abstract: In this study, an attempt was made to enhance the degradation resistance of magnesium alloys for potential biodegradable implant applications through surface treatment. AZ91 magnesium alloy was taken as the test sample and was alkali-treated for two different periods of time and then the in vitro degradation behaviour of the alloy was studied using electrochemical impedance spectroscopy and polarization techniques in simulated body fluid. The study suggests that alkali-treatment reduces the degradation rate in AZ91 magnesium alloy.

Abstract: Removal of heat from the cutting zone is critical when machining titanium. The application of high pressure coolant during turning of titanium results in longer tool life and better surface finish. In this paper, the effect of the application of cutting fluid at high pressure during the milling of titanium alloys is presented.

Abstract: Electron beam cold hearth melting process is an efficient method to produce the premium quality titanium alloys, especially to eliminate inclusions. A simulation work was carried out to study the process, concerning the flow field and particle trajectory at three different melt rates. The simulation results show that, when there is an overheat zone near the outlet zone, the molten metal flows to the sidewall of the cold hearth, and from the outlet zone to the inlet zone at the top surface which avoids the inclusion particle flows out the cold hearth. At the bottom of the liquid pool, the fluid flows to the outlet directly along the center plan, which forms a short circuit, decreases the residence time of the inclusion particles; there is a critical density range of inclusion particles, which have more probability to flow out of the cold hearth. The inclusion particles, whose density lower than it, will flow to the sidewall. The inclusion particles, whose density higher than it, will sink into the bottom mushy zone. Both cases let the inclusion have higher probability to eliminate the inclusions.

Abstract: The recent shift in the design focus for aeroplanes from strength to damage tolerance has led to a subsequent shift in the focus of Ti alloy research. China first started to research Ti alloys with damage tolerance from the year 2000. The first product stemming from this research is a Ti alloy with high strength, high toughness and damage tolerance (TC21). TC21 exhibits high strength (UTS  1100MPa), high fracture toughness (K1c  70MPa.m1/2) and a low crack propagation rate (da/dN being similar to Ti-6-4 with  annealing). Another Ti alloy, named TC4-DT, has also been produced. It has moderate strength, along with high toughness and damage tolerance (UTS  900MPa, K1c  70MPa.m1/2, da/dN being similar to Ti-6-4 with  annealing). Both TC21 and TC4-DT are now undergoing rapid development, with the former alloy also being applied to a full scale aeronautical application. Both TC21 and TC4-DT have promising futures in the industry. They will be the main Ti alloys with damage tolerance utilised in the Chinese market.