Materials Science Forum Vols. 638-642

Abstract: An unequal diameter twin roll caster which can cast clad strips was devised and assembled. The casting of the clad strip was tried, and fabrication of the clad strip was attained. This twin roll caster was planned for the process saving. The clad strip was assembled directly from AA3003 molten metal and AA4045 molten metal at speed of 20m/min. The Si-diffusion-area between the strips was very narrow, and the interface between the strips was clear. The strips were bonded firmly. The strips were not pealed by the cold rolling and the continuous bending.

Abstract: Detail parts of airframe should have higher precision and lightweight to satisfy the requirements of safety, payload, and controllability. Due to requirement of lightweight, aluminum alloy is widely used in airframe parts. Anodizing process is an important surface treatment process uses to prevent corrosion in aluminum parts. Salt spray is the critical test to verify the anodizing process of aluminum alloy and ensure the corrosion resistance can meet the requirement of specification. This study collects the failure time of salt spray and uses statistical method to construct the suitable probability distribution of those failure data. Furthermore, analyzes the failure time of salt spray and evaluate the reliability of anodizing process. Thereby the process control engineer can use the concept of reliability to monitor the anodizing process.

Abstract: Although titanium is considered to be a ubiquitous element since it has the tenth highest Clarke number of all elements, it is classified as a rare metal because the current refinement process is more environmentally damaging than the processes used to refine iron and aluminum. Furthermore, the beta stabilizing elements of titanium alloys (e.g., V, Mo, Nb, and Ta) are very expensive due to their low crustal abundances. Manganese is also considered to be a ubiquitous element, since it has the 12th highest Clarke number of all elements. Therefore, manganese is a promising alloying element for titanium, especially as a beta-stabilizer. In order to develop beta titanium alloys as ubiquitous metallic materials, it is very important to investigate the properties of Ti-Mn alloys. In this study, the phase constitution of and the effect of heat treatment on Ti-3.3 to 8.7 mass% Mn alloys were investigated by electrical resistivity and Vickers hardness (HV) measurements and by X-ray diffraction (XRD) analysis and optical microscopy. In 3.3, 5.1, and 6.0 mass% Mn alloys quenched from 1173 K, ’ martensite and  phase were identified by XRD, whereas in the 8.7 mass% alloy, only the  phase was detected. The resistivities at both temperatures increased with increasing Mn content up to 6.0 mass% Mn and the positive temperature dependence of resistivity became negative at 6.0 mass% Mn. LN increased gradually with increasing Mn content up to 8.7 mass% Mn, whereasRT decreased considerably at a Mn content of 8.7 mass% Mn. HV increased with increasing Mn content up to 5.1 mass%, after which it began to decrease. In Ti-3.3 mass%Mn and 5.1 mass%Mn alloys, the resistivity and the resistivity ratio decreased with increasing temperature of isochronal heat treatment because of decomposition of ’ martensite. In 6.0Mn and 8.7Mn alloys, the resistivity and the resistivity ratio decreased, while Vickers hardness increased with increasing temperature of isochronal heat treatment because of isothermal  precipitation. Furthermore, the temperature for the onset of precipitation increased with higher Mn content.

Abstract: The ultrasonic melt treatment is highly efficient in controlling the size and morphology of the alpha-aluminum phase in the Al-Si cast alloys. However, the influence of this treatment on the other phases, namely: the eutectic Si and the Fe-intermetallic phases, has not been thoroughly investigated. This study was undertaken to investigate the effect of ultrasonic melt treatment on the morphology and size of these phases. Four Al-Si cast alloys, 384, 380, 356 and 356 (with 0.8% Fe), were considered in this study. The treatment temperatures were varied from about 100oC above the liquidus temperatures down to the Al-Si eutectic temperature, for different treatment times (4 to 54 s). The results showed that the Si particles are only affected by the ultrasonic vibrations when the eutectic reaction takes place under the ultrasonic field, where more compacted and large Si particles are formed. This limited effect was observed only near to the ultrasonic horn. For other investigated conditions, including treatment in the liquid and semisolid states, the Si particles were obviously unaffected by the ultrasonic treatment. On the other hand, the iron intermetallic phases changed their morphology from large plate-like particles to a more compacted globular form, by the application of ultrasonic vibrations at temperatures up to 10oC above liquidus. Treatments at higher temperatures have limited effect on the morphology of the Fe-intermetallic phases. These observations are general and apply to all the studied alloys.

Abstract: A major motivation for the development of new vehicle structures is, apart from the reduction of fuel consumption, is to decrease emissions which affect the climate. Therefore we also have to look at the reduction of vehicle weight and consequently at various strategies for lightweight construction. In the future steel structure concepts still show lightweight potential. But even more attractive potential for lightweight body in white structures could be realised by new multi-material design concepts and highly integrated light metal applications. Today’s research activities are focussed on the area of multi-material design, with the objective of placing the material with the best properties for the given requirements in the right position. Based on various methods of lightweight construction, techniques and tools, it is possible to find an optimum between lightweight design and costs. These activities will be illustrated by several research examples. One example will be the lightweight concept of the front module developed by the Institute of Vehicle Concepts (DLR) in the European research project -‘Super Light Car’ (SLC). By using aluminium in the front structure and the high pressure die casting strut tower the concept has a weight benefit of 32% compared to a steel reference structure. The methodology for reaching targets and requirements like weight reduction, crash performance and cost targets will be explained. Another example is a concept which is developed in the DLR project ‘Novel Vehicle Structures’. This concept shows the combination of different materials and a new construction method to increase front impact crash performance.

Abstract: Equal Channel Angular Pressing (ECAP) is currently being widely investigated because of its potential to produce ultra-fine grained microstructures in metals and alloys. The objective of this work is to study the effect of ECAP on Al 6061 alloy. ECAP is processed using die channel angles of 90º, 120º and 140º. The stress and the deformation behavior of the ECAP processed material were investigated by hardness tests. The finite element analysis (FEA) is carried out for ECAP using PAM-CRASH software for different channel angles, which are prescribed in the experiment. The inputs such as material properties, loads, boundary conditions, contacts and controls were provided to the software and the results were visualized. The Von Mises Stress values obtained by FEA were found to be in good consistence with the experimental stress values.

Abstract: A comprehensive and systematic study using hardness, tensile test and Kahn tear test was undertaken to follow property development during the recently promoted interrupted ageing treatment. In contrast to the reported claims hardness remains lower than that of single stage heat treatment. Toughness does not improve substantially and deteriorates further as re-ageing time is prolonged. For most cases, the effect of interrupted ageing could not produce a simultaneous improvement in mechanical properties. TEM observations indicate the size and distribution co-existing S” and S phases upon re-ageing depend on interrupted condition.

Abstract: The AlSi8Cu3 and AlSi7MgCu0.5 cast aluminium alloys of different composition and heat treatment were investigated to verify their applicability as cylinder heads in the car engines [1]. Creep tests under the step-increased stresses at different temperatures, and low cycle fatigue (LCF) tests for a range of strain amplitudes and temperatures were carried out. The results exhibit a significant influence of the heat treatment on the mechanical properties of the AlSi8Cu3 and AlSi7MgCu0.5. An interesting fact is that the properties strongly depend on the type of quenching. Lower creep resistance (higher strain rates) and lower stress response during fatigue tests were observed for the air quenched materials in comparison to those in the water quenched. Cyclic hardening/softening were also observed during the LCF tests due to the heat treatment applied. The mechanical properties determined during the tests can be used to identify new constitutive equations and to verify existing numerical models.

Abstract: Precipitation behavior of a metastable β Ti alloy, Ti-6.8Mo-4.5Fe-1.5Al(masss%), during two-step aging has been investigated. Supersaturated β phase after solution treatment decomposes into β+ω phases during the first aging at 300°C for 2ks. β′ phase is observed during the second aging at 500°C for 50s. It is suggested that reverse transformation of the ω phase to β phase during the second aging at 500°C for 50s gives rise to solute-lean and –rich regions in the β phase, and that β′ phase is formed in the solute-rich region. β′ phase being coherent with β phase has larger lattice parameter than β phase. β′ phase acts as nucleation site for α phase, and accelerates the nucleation of α phase.

Abstract: Hydrogen (H) behaviour in materials was investigated in rapidly solidified (RS) foils of pure aluminium (Al), Al-0.4 Cr and Al-0.25 Zr alloys (at %) by means of thermal desorption spectroscopy (TDS). In addition, Al-0.25; 0.3 Zr alloys were examined with respect to microstructure and its instability during the thermal process using SEM and microhardness measurements. The effect of dopes and heating rate on H desorption was summarized. The lowest energy desorption is attributed with significant thermal desorption peak which temperature was found is correlated with sample composition.