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1
Wieszała, R., J. Piątkowski, Z. Stanik, M. Roszak, and W. Pakieła. "Surface topology of friction pairs of A390.0 alloys." Journal of Achievements in Materials and Manufacturing Engineering 2, no. 82 (June 1, 2017): 58–62. http://dx.doi.org/10.5604/01.3001.0010.2355.
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Purpose: In the paper, geometric structure of the surface of A390.0 alloy, manufactured using various methods are presented, in combination with EN-GJL-350 cast alloy, which corresponds to parameters used in combustion engines. Design/methodology/approach: Alloy after a modification with CuP10 master alloy and overheating to 920°C for 30 min was analysed, and the results were compared with those of the material without overheating. Roughness studies allowed for defining the influence of technological history on the wear parameters of the alloy. Findings: Analysis of result shows that all investigated properties were improved. Significant differences between the analysed materials were proved during the analysis of friction coefficient and surface topography of wear track. Research limitations/implications: The application of modified by CuP10 aluminium alloy allows to improve parameters such as friction coefficient and wear rate. This property’s causes that this new modified material can be used in many applications where the aim is to reduce friction coefficient as well as wear rate. Practical implications: Improvement the tribological properties as well as reducing the coefficient of friction makes these materials may be used in many applications in the automotive industry such as engine cylinder, engine blocks, etc.. Originality/value: Influence of aluminium modification on chosen tribological properties and friction coefficient have been investigated.
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Kowalski, Mirosław, and Antoni Jankowski. "Advantages of using composite alloys for internal combustion engine pistons." Archives of Transport 55, no. 3 (September 30, 2020): 85–94. http://dx.doi.org/10.5604/01.3001.0014.4236.
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Combustion engine pistons are subject to variable mechanical and thermal loads, and to variable deformations. The article presents the possibilities of using novel composite alloys for the construction of pistons for combustion engines. The novel alloys make it possible to meet high demands, especially for highly load designs, which practically cannot be met by conventional alloys used so far. These high requirements relate to the weight of the pistons, high temperature strength, alloy crystalline structure, abrasive wear resistance, dimensional stability. The requirements for pistons have an impact on the durability of the engine's operation, the level of noise emissions; exhaust gas blow-by into the crankcase, the level of emitted toxic exhaust components, mainly hydrocarbons. The research covered metallography (chemical composition, microstructure), material strength, abrasive wear, and thermal expansion. Investigations of the alloy crystallization process during casting were carried out using the Differential Thermal Analysis (DTA) method. The castings were used for metallographic tests. The strength of the samples was tested at room temperature (20° C) and elevated temperature (up to 350° C) on a testing machine equipped with a special climatic chamber. In particular, the article presents Thermal Derivative Analysis curves and representative microstructures of conventional AlSi12 alloy and the novel composite alloy; dependence of the tensile strength versus temperature for the samples of the novel alloy with various nickel content 2% and 4 %; comparison of the tensile strength for conventional alloy and the novel alloy at ambient and 250° C temperature; comparison of abrasive wear of samples, made of novel aluminium alloy and different cast iron; course of the linear expansion coefficient versus temperature for the conventional AlSi12 alloy with incorrect heat treatment; course of the linear expansion coefficient versus temperature for one of tested silumin alloy which expansion coefficient during sample cooling is smaller than during sample heating; course of the linear expansion coefficient versus temperature for the novel composite silumin alloy, after correct heat treatment. The great benefits of using this novel alloy and the introduction of novel alloying elements (in-Situ) have been confirmed in engine research.
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Natesan, Elanghovan, Knut Andreas Meyer, Stefan Eriksson, Johan Ahlström, and Christer Persson. "Effects of Dwell Time on the Deformation and Fatigue Behaviour of A356-T7 Cast Aluminium Alloys Used in High Specific Power IC Engine Cylinder Heads." Materials 13, no. 12 (June 15, 2020): 2727. http://dx.doi.org/10.3390/ma13122727.
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The electrification of automotive powertrains in recent years has been driving the development of internal combustion engines towards reduced volumes with higher power outputs. These changes place extreme demands on engine materials. Engineers employ the computer-aided engineering approach to design reliable and cost-effective engines. However, this approach relies on accurate knowledge of the material deformation and fatigue characteristics during service-like loading. The present study seeks to investigate the effect of dwell times on the deformation and fatigue behaviour of the A356-T7 + 0.5 wt.% Cu alloy used to cast cylinder heads. In particular, we study the effect of dwell time duration at various temperatures. A combined fatigue-dwell testing procedure, with the dwell at the maximum compressive strain, replicates the service conditions. It is found that the material exhibits a stress relaxation behaviour with a decreasing relaxation rate. At lower temperatures, the load level influences the relaxation more than at elevated temperatures. However, the dwell does not significantly affect the hardening behaviour or the life of the tested alloy. Finally, we model the time-dependent material behaviour numerically. The Chaboche model, combined with a Cowper–Symonds power-law, is found to capture the visco-plastic deformation behaviour accurately.
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Khan, Aamer Nusair. "Microstructural Characterization of Silicon Added Titanium Aluminide." Key Engineering Materials 442 (June 2010): 74–80. http://dx.doi.org/10.4028/www.scientific.net/kem.442.74.
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Titanium aluminides intermetallic compounds have received great attention during the past decade, since they have the potential, in aircraft and automotive engines, to replace the high density Ni-base superalloys However, these intermetallics possess poor oxidation properties at high temperatures. Previous studies showed that protective alumina scale formation on γ-TiAl can be obtained by small additions (around 2 at.%) of Ag. In the present study, a number of cast Ti–Al–Si alloys were investigated in relation to transient oxide formation in air at 1300°C. After various oxidation times the oxide composition, microstructure and morphology were studied by combining a number of analysis techniques. The TiAl–Si alloys appear to form Al Ti and Si oxides. However, the formation of silicon oxide at the interface of base metal and scale slows down the oxidation rate significantly.
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Ozigis, I. I., J. I. O. Oche, and N. M. Lawal. "Locomotive engines and the future of railway automotive power in Africa: A review." Nigerian Journal of Technology 40, no. 4 (October 25, 2021): 660–73. http://dx.doi.org/10.4314/njt.v40i4.13.
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This work presents the review of locomotives and the future of railway automotive power in Africa. Locomotives down time on account of inadequate spare parts still remains a challenge in African. It is thus, imperative to review the locomotives in African, to establish the current capabilities as well as provide recommendations to bridge the gaps and its extrapolated trends in future. Firstly, the comparison factors were track length, electrified rails, number of locomotives and yearly passengers on each of Egypt, Ghana, Kenya, Nigeria, South Africa and Zambia rails. Secondly, the focus was on engine parameters from literatures and maintenance logbooks of locomotives. From available data, it was found that South Africa and Egypt have more advanced rail system than the rest four selected countries. It was also found that additive manufacturing, 3D printing, ductile cast iron and die-forging can be used to produce the engine body for diesel engine using steel and aluminum alloys while aluminum silicon and tin doped with copper are good for reciprocation mechanisms. And finally, increased reliability of locomotives can be guided by an engine selection matrix, while use of renewable and energy hybridization are needed to meet the expansion of railroads in Africa.
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Salleh, M. S., M. Z. Omar, J. Syarif, M. N. Mohammed, and K. S. Alhawari. "Effect of Pouring Temperature and Cooling Slope Length on Microstructure and Mechanical Properties of Rheocast A319 Aluminium Alloy." Applied Mechanics and Materials 699 (November 2014): 251–56. http://dx.doi.org/10.4028/www.scientific.net/amm.699.251.
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Aluminium alloys are among the most prominent and well known materials used in automotive industries. Nowadays, many vehicles used aluminium engine blocks instead of cast iron to improve fuel efficiency. Among cast aluminium alloys, A319 grade alloys are normally used in automotive industries due to a combination of good fluidity and mechanical strength. In this study, A319 cooling slope rheocasting billets were produced in order to obtain near spherical morphology of primary aluminium phase. The change in the α-Al morphology upon the cooling slope casting was remarkable and the dendritic microstructure was almost replaced by α-Al globules and rosettes. The rheocasting billets were prepared for tensile testing at room temperature. It is found that, the yield strength and elongation of cooling slope rheocasting billets is higher than those from as-cast A319 alloy.
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Hurtalová, Lenka, Eva Tillová, Mária Chalupová, and Jaroslaw Piątkowski. "Optical and Scanning Electron Microscope Studies of Recycled (Secondary) Al-Si Cast Alloys." Solid State Phenomena 203-204 (June 2013): 266–71. http://dx.doi.org/10.4028/www.scientific.net/ssp.203-204.266.
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Production of primary Al- alloys belong to heavy source fouling of life environs. Care of environment in industry of aluminium connects with the decreasing consumptions resource as energy, materials, water and soil, with increase recycling and extension life of products. Recycled (secondary) aluminium alloys are made out of Al-scrap and workable Al-garbage by recycling. Applications of these alloys in recent years increase especially in automotive industry (dynamic exposed cast, engine parts, cylinder heads, pistons and so on). Controlling the microstructure of secondary aluminium cast alloy is very important, because these alloy containing more of additions elements, that forming various intermetallic phases in the structure. Improved mechanical properties of secondary alloys are strongly dependent upon the morphologies, type and distribution of the second phases, which are in turn a function of alloy composition and cooling rate. The presence of additional elements as Mg, Mn, Fe or Cu allows many complex intermetallic phases to form, which make characterization non-trivial. A combination of different analytical techniques (light microscopy, scanning electron microscopy (SEM) upon deep etching and energy dispersive X-ray analysis (EDX)) were therefore been used for the various phases identification.
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Anantha Padmanaban, D., and Gulshan Kurien. "Silumins: The Automotive Alloys." AM&P Technical Articles 170, no. 3 (March 1, 2012): 28–30. http://dx.doi.org/10.31399/asm.amp.2012-03.p028.
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Abstract Aluminum-silicon (Al-Si) alloys have good castability in combination with high corrosion resistance, thermal conductivity, and specific strength, making them a strong candidate for many automotive applications. This article describes the processes used in the production of die-cast AlSi9Mg engine brackets for Volvo trucks, the effects of solution treatment temperature on Si particle size, and the benefits of Mg additions on yield strength and heat treatability.
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Honnaiah, C., M. S. Ashok Kumar, M. S. Srinath, and S. L. Ajit Prasad. "Microstructural Characterization of Microwave Processed Al-SiCP Metal Matrix Composites Subjected to Extrusion." Applied Mechanics and Materials 895 (November 2019): 115–21. http://dx.doi.org/10.4028/www.scientific.net/amm.895.115.
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Aluminium Metal Matrix composites (AMC) are known to be very promising light weight materials with enhanced mechanical properties which are used in various industries [1]. Aluminium metal–matrix composites reinforced with SiC and Al2O3 are used in automotive and aerospace applications due to reduction in weight and increase the engine efficiency and thereby reducing fuel consumption [2]. Replacing cast iron engine components with light-weight Al alloys requires overcoming of the poor adhesion and seizure resistance of Aluminium achieved by dispersing SiC, Al2O3 or graphite particles in aluminium, Considerable reduction in wear and friction can be achieved by the use of these reinforcement particulate [3].
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Horváth, Richárd, Gyula Mátyási, and Ágota Drégelyi-Kiss. "The Examination of the Cutting Capacity of Different Aluminium Alloys with Statistical Methods, Using Different Edge Material Non-Conventional (Wiper) Edge Geometry Diamond Tools." Materials Science Forum 812 (February 2015): 71–76. http://dx.doi.org/10.4028/www.scientific.net/msf.812.71.
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The aluminium alloys are used by the automotive, aerospace industries increasingly because of their numerous advantageous mechanical and chemical properties. Surface roughness measurements are essential in characterization of the features of a machined surface. The most widespread aluminium alloy used in cutting is the die-cast type, alloyed with silicon. Industries prefer using two types of such alloys, the so-called eutectic and hypereutectic alloys reinforced with silicon. In this article the cutting capacities of two die-cast aluminium alloys are examined. The cutting experiments were carried out with design of experiment – DOE (the so-called central composite design – CCD). In the course of the examination three factors were altered (cutting speed – vc, m/min; feed – f, mm; depth of cut – a, mm), and the main surface roughness parameters used in the industries were taken as output parameters. The parameters of the manufactured surface roughness and their deviation in case of different workpiece-materials, tool-materials and edge-materials were analysed with statistical methods. Besides minimizing surface roughness, another important criterion of the manufacturing system (machine – tools – chuck – workpiece) is its surface roughness maintaining capacity, which was analyzed with coefficient of variation (CV).
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LABISZ, Krzysztof. "REFLECTIVITY OF ANODISED AL-SI ALLOY SURFACE OF BELT PULLEYS USED IN COMBUSTION ENGINES." Scientific Journal of Silesian University of Technology. Series Transport 112 (September 1, 2021): 125–33. http://dx.doi.org/10.20858/sjsutst.2021.112.7.10.
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The recent trend of using aluminium alloys instead of steel has reached the transportation industry, where increasingly, more parts are made of aluminium. An example is the belt pulley, applied for combustion engines for energy transmission. This part should be strong, durable, and lightweight. Aluminium-silicon alloys are a good choice, moreover, even when the surface is anodised, also because of their moderate inertia control and excellent wear characteristic during mechanical operations. Since aluminium is lightweight yet mechanically durable and anodised, it is an ideal belt pulley to use, especially in high-temperature operations. However, the main question is what type of Al-Si alloy, casting method and anodisation method should be used in terms of energy adsorption, having long-term properties for a lifetime, has to be applied. For this reason, this paper presents the influence of the chemical composition, casting method and anodising parameters on the structure and thickness of the anodic layer produced on aluminium alloys, as well as on the albedo value as an ability to reflect or absorb light. The aluminium alloys, AlSi12Cu1 and AlSi9Cu3, were used as research materials, obtained using different casting methods. The goal of this work was to determine the optimal combination of the anodisation conditions and materials for maximising the reflectivity factor of the surface, as a very important factor, determining the energy amount absorbed by an anodised surface. For further improvement of these surface properties as well as for enhancement of the properties and strengthen the material produced with different aluminium alloys production methods, different alloying additives were added. In addition, the mechanical properties of the surface layer were measured, where a remarkable hardness increase was obtained, and the best combination in form of AlSi12Cu1 high pressure cast was found with the highest albedo factor among all tested surface variants.
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González, Rodrigo, Alejandro González, José Talamantes-Silva, Salvador Valtierra, Rafael D. Mercado-Solís, Nelson F. Garza-Montes-de-Oca, and Rafael Colás. "Fatigue of an aluminium cast alloy used in the manufacture of automotive engine blocks." International Journal of Fatigue 54 (September 2013): 118–26. http://dx.doi.org/10.1016/j.ijfatigue.2013.03.018.
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Tillová, Eva, and Mária Chalupová. "Unconventional Metallographic Methods for the Structural Characterization of Laser Hardened Al-Zn-Si Cast Alloy." Materials Science Forum 782 (April 2014): 369–72. http://dx.doi.org/10.4028/www.scientific.net/msf.782.369.
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The laser surface hardening is method which provides increased mechanical properties of secondary (recycled) Al-Si cast alloys for automotive industry. Improvement of mechanical properties and structure of secondary aluminium alloys can often significantly increase the lifetime of casting and reduce costs for fuel and reduction of environmental loading. For study was used a laser beam Nd: YAG lasers, BLS 720, on the test samples of secondary cast alloy AlZn10Si8Mg. AlZn10Si8Mg cast alloy are used for engine and vehicle constructions, hydraulic unit and mould making without the need of heat treatment because this alloy is self-hardened. The effect of laser beam was evaluated with the laser power 50 W and 80 W on the surface of samples. The final microstructure of Al-alloys depend on the laser process parameters. The changes of microstructure after laser surface hardening was observed by using classical techniques of etching (standard black-white contrast - etching by 0.5 % HF, 10 % H3PO4and colour contrast - etching by Weck-Al) and deep etching with HCl. Due to the action of laser beam on the surface of the secondary alloy AlZn10Si8Mg there have been changes in the microstructure of the material. Melting area is alpha-phase with much fine columnar dendrites morphology without the presence of Si-particles and intermetallic phases. In the transition area were observed grain refinement of eutectic Si (finer and rounder Si particles) as the modify action of the laser. By increasing the laser power the microhardness of surface layers decreases. In the surface layer (80 W) were observed cracks due to uneven heat transfer of the material.
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Adamane, Anilchandra R., Elena Fiorese, Giulio Timelli, Franco Bonollo, and Lars Arnberg. "Reference Dies for the Evaluation of Tensile Properties of Gravity Cast Al-Si Alloys: An Overview." Materials Science Forum 794-796 (June 2014): 71–76. http://dx.doi.org/10.4028/www.scientific.net/msf.794-796.71.
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Aluminium-Silicon (Al-Si) alloys are the most extensively used Al foundry alloys and are widely used in gravity die-casting (GDC) of automotive components. Reference dies are used to characterize the tensile properties of the castings. Among the various die configurations, the ASTM B-108 (also called the Stahl Mold), and the AA Step Mold are most popular in the foundries. Several modifications to the standard dies have been suggested in the scientific literature to obtain better mechanical properties in minimizing casting defects. This work reviews the scientific literature on the effect of different reference dies on the porosity and tensile properties of the Al alloy castings.
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Sanath, M. N., C. L. Nihal, Prabhuling, P. M. Shivaprasad, H. V. Puneeth, and M. K. Srinath. "Review on Corrosion studies of Heat Treated Al-Si Alloy." IOP Conference Series: Materials Science and Engineering 1258, no. 1 (October 1, 2022): 012028. http://dx.doi.org/10.1088/1757-899x/1258/1/012028.
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Heat-treated Al-Si alloys are widely used in the automotive, military, marine, electrical, food and chemical industries. This alloy exhibits high-strength properties used in corrosion-resistant homes. However, this alloy has low mechanical properties and a large granular structure when cast. The properties of aluminium alloys depend primarily on the microstructure. It is very important to achieve a smooth structure. The formation of fine and equivalent grains depends primarily on the amount of hardening, the addition of basic alloys (grain cleaners), the mixing and processing of alloys. Aluminium alloys are an important component of light metals used in industry. Al-Si alloys are essential for automotive, aerospace, marine and engineering applications. Al-Si alloys have excellent physical and mechanical properties. These alloys offer low weight, excellent corrosion resistance, easy machining, heat treatment, excellent casting ability and excellent machining performance. The mechanical properties of these alloys depend primarily on the size, shape and distribution of Si and Al particles. Al-Si alloy produces coarse α-Al dendrites and shark eutectic silicon. Fine structures are known to provide good mechanical properties and reduce casting defects. During the casting process, a fine-grained structure can be obtained by adding a lower alloy to the melt.
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Donlon, W. T., and J. W. Zindel. "The Determination of the Orientation Relationship Between Primary and Eutectic Aluminum in A.Cast 319 Aluminum Alloy." Microscopy and Microanalysis 7, S2 (August 2001): 1250–51. http://dx.doi.org/10.1017/s1431927600032323.
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Cast 319 aluminum is an important automotive alloy used for engine blocks and cylinder heads. in order to “optimize” the as-cast microstructure and physical properties, a detailed understanding of its solidification behavior is required. One aspect of the solidification behavior which is not well understood is the mechanism by which aluminum and silicon in the eutectic regions nucleate. Figure 1 is an optical micrograph which identifies the aluminum dendrites, the Al-Si eutectic region, iron intermetallics, and Al2Cu particles. Dahle, Hjelen & Arnberg have utilized electron backscattered diffraction (EBSD) patterns, obtained with an SEM, on several Al-Si alloys to examine the orientation relationship between the aluminum in the eutectic to that of the surrounding aluminum dendrites. in this investigation transmission electron microscopy (TEM) is used to provide a more detailed examination of this eutectic structure while selected area diffraction (SAD) provide similar data to EBSD on the orientation relation between regions of primary and eutectic aluminum.
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Abramchuk, Fedor I., and Andrey N. Avramenko. "Prospects of Using Steel Pistons in Transport Diesel Engines." Periodica Polytechnica Transportation Engineering 48, no. 2 (November 14, 2019): 196–202. http://dx.doi.org/10.3311/pptr.12466.
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The results of comparative design research in the thermal stress and strain state of the piston in transport diesel engine 2 F 10.5/12 are given for its rated power operation. The standard piston is made of an aluminium alloy, and the modernized one, of steel. Piston thermal profiling and indicator test results were used for identifying the mathematical models and refining the boundary conditions for mechanics and heat conduction problems. To ensure reliable heat rejection from the piston, the paper considered the case of oil jet cooling. This was taken into account when describing the boundary conditions of the heat conduction problem. The thin-wall steel piston with oil jet cooling was shown to function reliably under the study conditions. The temperature in the first compression ring groove does not exceed 200 °С, and the radial deformation of the piston crown is less than half of that of an aluminium alloy standard piston.
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Maculotti, G., S. Bonù, L. Bonù, R. Cagliero, G. Genta, G. Marchiandi, and M. Galetto. "Analysis of residual plastic deformation of blanked sheets out of automotive aluminium alloys through hardness map." IOP Conference Series: Materials Science and Engineering 1193, no. 1 (October 1, 2021): 012102. http://dx.doi.org/10.1088/1757-899x/1193/1/012102.
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Abstract Reducing overall vehicle weight is essential to reduce fuel consumption and pollutant emission and to improve noise, vibration, and harshness (NVH) performances. The substitution with lighter alloys can involve the grand majority of vehicle components, depending on the market sector. In several applications, e.g., chassis, pulleys, and viscodampers, metal sheets are formed in several steps, each of whom work-hardens the material reducing the available residual plasticity. Typically, the process is designed via FEM, whose results are affected by the initial conditions, often neglected, and is performed on pre-processed materials from suppliers. In this regard, correctly simulating the first step of the process is critical. However, the related initial conditions, in terms of residual stress and strain induced by former preliminary operations, are often neglected. This work proposes a quick and economical experimental procedure based on a hardness map to estimate initial conditions and to validate FEM results. The procedure allows evaluating the material’s residual plasticity, which is necessary to process engineers to design following manufacturing steps. The approach is demonstrated on an industrially relevant case study, i.e., the blanking of an AA 5754, in use for water pump pulleys.
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Gebril, Mohamed Abdelgawad, Mohd Zaidi Omar, Intan Fadhlina Mohamed, Norinsan Kamil Othman, Dawod Mohamed Elabar, Farag Ibrahim Haider, Saziana Samat, and Osama M. Irfan. "Effect of Semisolid and Heat Treatment Process on Microstructural Refinement of Al–7Si Alloy." Materials 16, no. 3 (January 27, 2023): 1086. http://dx.doi.org/10.3390/ma16031086.
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Improving the engineering properties of Al–7Si cast alloys (300 series) provides an attractive alternative to automotive and aircraft engine industries. The solubility limit of silicon (Si) in Al contributes to the precipitation of flake-shaped Si particles with sharp edges, which function as a stress riser and promote crack propagation during the eutectic phase while also weakening the protective layer’s durability. In this study, the impact of microstructure refinement of Al–7Si alloys by using cooling slope, thixoforming and the T6 heat treatment process on hardness and corrosion resistance behavior was investigated. Results showed that the microstructures of the as-cast alloy had a very coarse dendritic shape, whereas the dendritic transferred to the globular α-Al phase, and the Si particles were replaced into a lamellar- or acicular-like shape after the cooling slope and thixoforming process, respectively. The as-cast, cooling slope and thixoformed samples were subjected to the T6 heat treatment process, which enhanced the hardness to 79, 99 and 104 HV, respectively, due to Si particle refinement. The potentiodynamic test revealed that the corrosion rate dropped to 0.00790 and 0.00736 mmpy−1 in the heat-treated cooling slope and thixoforming samples. This finding can be attributed to the substantially refined Si particles and reduced eutectic phase area due to the smaller cathodic to anodic area ratio.
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Côté, Pascal, Bryksi Vlastimil, and Barbora Bryksí Stunová. "Case Study: Engine Bracket Made by Rheocasting Using the SEED Process." Solid State Phenomena 285 (January 2019): 441–45. http://dx.doi.org/10.4028/www.scientific.net/ssp.285.441.
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In the context of increasing needs for lightweighting vehicles, semisolid casting of aluminium components is a proven route that can be efficiently applied for automotive parts. Although semisolid forming has not yet reached the market penetration that suits its actual potential, it is currently and efficiently used in many applications around the world on a daily basis. An example of such will be shown. This paper presents a case study on the application of the SEED rheocasting technology for the casting of an engine bracket. The part is made of the widely used AlSi7Mg0.3 alloy and is heat treated in T6 condition to benefit from the enhanced mechanical properties made possible by semi-solid forming. Throughout the development phase, different aspects associated with semisolid casting, such as slurry condition, gate design, mold filling behaviour, lubrication, blistering and others, were addressed successfully. In the final, the combination of the SEED technology with a thorough development process and the specific casting rules for semi-solid forming led to actual commercial production and contributed to weightsaving on the actual part as compared to a former design made from high pressure die casting.
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Kurz, Gerrit, Jan Bohlen, Dietmar Letzig, and Karl Ulrich Kainer. "Influence of Process Parameters on Twin Roll Cast Strip of the Alloy AZ31." Materials Science Forum 765 (July 2013): 205–9. http://dx.doi.org/10.4028/www.scientific.net/msf.765.205.
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Reducing vehicle weight and emissions by lightweight design is a major goal of the automotive industry. Magnesium as the lightest structural metal offers a significant weight saving potential compared to steel and aluminium. Cast magnesium components are widely used, e.g. as engine blocks or gear box housings. The application of magnesium sheets is currently hampered by the low formability of magnesium which means that a large number of rolling passes is required to roll a DC cast slab to final gauge sheet. This large number of rolling steps is the main reason for the high cost of magnesium sheets. Twin-roll casting (TRC) is an alternative, economic production process for the generation of fine-grained feedstock materials that subsequently can be warm rolled to thin sheets. It therefore receives attention in actual research and development projects for the application of magnesium alloys as prospective light metal solutions. This production process for thin strips combines solidification and rolling into one single production step and therefore saves a number of rolling and annealing passes in comparison to the conventional rolling process. The main goal of the activities at the Magnesium Innovation Centre MagIC of the Helmholtz-Centre Geesthacht (HZG) is the development of wrought magnesium alloys and their introduction into industrial, structural applications. The current focus of the research work is on alloy design and their processing for magnesium sheets produced by twin roll casting. In order to understand the influence of process parameters on the microstructure and texture the first twin roll casting experiments were performed with the alloy AZ31 (Mg-3Al-1Zn-Mn) as benchmark. As an example, the influence of melt temperature on the microstructure of the strip is presented and discussed with respect to arising material properties. Optimisation of process parameters of twin roll casting and the subsequent rolling of the sheets, offers the possibility to produce high quality sheet material.
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Gerbe, Sascha, Stephan Knorre, Ulrich Krupp, and Wilhelm Michels. "The significance of microstructure heterogeneities on the fatigue thresholds of aluminum castings." MATEC Web of Conferences 165 (2018): 14005. http://dx.doi.org/10.1051/matecconf/201816514005.
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Industrial in-series aluminum castings contain a wide range of microstructural heterogeneities like differences in secondary dendrite arm spacing (SDAS), eutectic silicon and intermetallic precipitates of varying morphologies and diverse-shaped and-sized porosity. Regarding to technical and economic limitations, the complete elimination of them is hard to achieve, which requires conservative design, i.e., increased wall thicknesses to accommodate the failure tolerance. To improve the performance of cast aluminum products concerning safety and fatigue properties, the present work deals with the significance of such structures with respect to the threshold for crack propagation ΔKI,th under pure bending and the fatigue behaviour in the high-and very-high-cycle-fatigue regime (HCF and VHCF). Therefore, two automotive cast alloys taken from engine blocks (AlSi8Cu3) and cylinder heads (AlSi7Cu0.5Mg) and a gravity die cast set (AlSi7Mg0.3), either T6 conditioned or additionally hot isostatic pressed (HIP), were used. For in-series castings, two positions of maximal difference in cooling rate and respective microstructure were extracted. With this set of specimens, the significance of SDAS in interaction with (i) eutectic silicon regions, (ii) intermetallic precipitates in varying occurrence, (iii) the crystallographic orientation, and (iv) the porosity in correlation with the fatigue threshold is shown and compared with first results of fatigue damaging mechanisms in quasi pore-free material.
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Hurtalová, Lenka, Eva Tillová, and Mária Chalupová. "Identification and Analysis of Intermetallic Phases in Age-Hardened Recycled AISi9Cu3 Cast Alloy." Archive of Mechanical Engineering 59, no. 4 (November 1, 2012): 385–96. http://dx.doi.org/10.2478/v10180-012-0020-3.
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PurposeThe influence of age-hardening solution treatment at temperature 515_C with holding time 4 hours, water quenching at 40_C and artificial aging by different temperature 130_C, 150_C, 170_C and 210_C with different holding time 2, 4, 8, 16 and 32 hours on changes in morphology of Fe-rich Al15(FeMn)3Si2 and Cu-rich (Al2Cu, Al-Al2Cu-Si) intermetallic phases in recycled AlSi9Cu3 cast alloy. Material/Methods: Recycled (secondary) AlSi9Cu3 cast alloy is used especially in automotive industry (dynamic exposed cast, engine parts, cylinder heads, pistons and so on). Microstructure was observed using a combination of different analytical techniques (scanning electron microscopy upon standard and deep etching and energy dispersive X-ray analysis - EDX) which have been used for the identification of the various phases. Quantitative study of changes in morphology of phases was carried out using Image Analyzer software NIS-Elements. The mechanical properties (Brinell hardness and tensile strength) were measured in line with STN EN ISO. Results/Conclusion: Age-hardening led to changes in microstructure include the spheroidization of eutectic silicon, gradual disintegration, shortening and thinning of Fe-rich intermetallic phases and Al-Al2Cu-Si phases were fragmented, dissolved and redistributed within _-matrix. These changes led to increase in the hardness and tensile strength in the alloy.
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Kulkarni, Siddharth, David John Edwards, Erika Anneli Parn, Craig Chapman, Clinton Ohis Aigbavboa, and Richard Cornish. "Evaluation of vehicle lightweighting to reduce greenhouse gas emissions with focus on magnesium substitution." Journal of Engineering, Design and Technology 16, no. 6 (December 4, 2018): 869–88. http://dx.doi.org/10.1108/jedt-03-2018-0042.
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Purpose Vehicle weight reduction represents a viable means of meeting tougher regulatory requirements designed to reduce fuel consumption and control greenhouse gas emissions. This paper aims to present an empirical and comparative analysis of lightweight magnesium materials used to replace conventional steel in passenger vehicles with internal combustion engines. The very low density of magnesium makes it a viable material for lightweighting given that it is lighter than aluminium by one-third and steel by three-fourth. Design/methodology/approach A structural evaluation case study of the “open access” Wikispeed car was undertaken. This included an assessment of material design characteristics such as bending stiffness, torsional stiffness and crashworthiness to evaluate whether magnesium provides a better alternative to the current usage of aluminium in the automotive industry. Findings The Wikispeed car had an issue with the rocker beam width/thickness (b/t) ratio, indicating failure in yield instead of buckling. By changing the specified material, Aluminium Alloy 6061-T651 to Magnesium EN-MB10020, it was revealed that vehicle mass could be reduced by an estimated 110 kg, in turn improving the fuel economy by 10 per cent. This, however, would require mechanical performance compromise unless the current design is modified. Originality/value This is the first time that a comparative analysis of material substitution has been made on the Wikispeed car. The results of such work will assist in the lowering of harmful greenhouse gas emissions and simultaneously augment fuel economy.
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De Cicco, Michael, Lih Sheng Turng, Xiao Chun Li, and John H. Perepezko. "Semi-Solid Casting of Metal Matrix Nanocomposites." Solid State Phenomena 116-117 (October 2006): 478–83. http://dx.doi.org/10.4028/www.scientific.net/ssp.116-117.478.
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Semi-solid casting (SSC) techniques have proven useful in the mass production of high integrity castings for the automotive and other industries. Recent research has shown metal matrix nanocomposite (MMNC) materials to have greatly improved properties in comparison to their base metals. However, current methods of MMNC production are costly and time consuming. Thus development of a process that combines the integrity and cost effectiveness of semi-solid casting with the property improvement of MMNCs would have the potential to greatly improve cast part quality available to engineers in a wide variety of industries. This paper presents a method of combining SSC with MMNC in a way that benefits from MMNCs’ tendency to naturally form the globular microstructure necessary for SSC. This method uses ultrasonically dispersed nanoparticles as nucleating agents to achieve globular primary grains such that fluidity is maintained even at high solid fractions. Once particle dispersion is achieved, the material needs no further processing to become a semi-solid slurry of globular primary grains as it cools. This quiescent method of slurry production, while still imposing some constraints on cooling rates, has a large process window making this process capable of industrial rates of throughput. It was found that the key factor to achieving globular microstructure is a sufficiently slow cooling rate at the onset of solidification such that particle-induced nucleation can occur. Once nucleation occurs, continued cooling is virtually unconstrained, with globular microstructure evident in quenched samples as well as samples cooled at rates as slow as 1 °C/min. This method was demonstrated in several material systems using zinc (Zn), aluminum (Al), and magnesium (Mg) alloys and nanoparticles of aluminum oxide (Al2O3), silicon carbide (SiC), and titanium oxide (TiO2). Additionally, several nucleation models are examined for applicability to nanoscale composites.
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P K, Dinesh Kumar, and Darius Gnanaraj Solomon. "Aluminium-Silicon based metal matrix composites for brake rotor applications: a review." Engineering Research Express, April 17, 2023. http://dx.doi.org/10.1088/2631-8695/accdb6.
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Abstract In an automotive vehicle, the brake discs, also known as rotors, contribute significant weight to the engine chassis. Hence, lightweight aluminum brake discs are in the developmental stage as a popular alternative to traditional cast iron or steel brake discs. Weight reduction is desirable to improve vehicle performance and fuel efficiency. Monolithic aluminum is not a practical choice as an alternative to existing commercial brake discs because of its poor operational temperature and wear performance. Literature suggests that Aluminum Metal Matrix composite (AMC) can be an ideal choice for brake discs. AMC brake discs are more resistant to warping and cracking than cast iron discs. They also have better heat dissipation properties, which help reduce brake fade and prolong the life of the brake pads. This study examines the different types of aluminum alloys, reinforcements, and manufacturing processes for manufacturing ideal AMC brake discs. The significance of silicon as the principal alloying element to improve thermal characteristics and incorporate various reinforcements to increase the AMC's wear resistance and frictional stability for brake disc applications is outlined. This article focuses on the thermal and tribological behavior of the AMC brake discs' performance over traditional rotors. The review discusses the different equipment required to assess the tribological characteristics of brake discs to meet industrial requirements. In addition to experimental validation, this paper addresses the necessity of proper rotor design selection and numerical analysis to evaluate the thermo-mechanical behavior of the brake disc at various braking events. The article points out that aluminum metal matrix composites have great potential to replace conventional grey cast iron brake discs. Finally, this review discusses possible future research avenues for developing an AMC rotor disc.
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Narayanan, Govindarajan. "Probabilistic fatigue model for cast alloys of aero engine applications." International Journal of Structural Integrity ahead-of-print, ahead-of-print (July 21, 2020). http://dx.doi.org/10.1108/ijsi-05-2020-0048.
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PurposeThe purpose of this study is to address the complexity involved in computing the fatigue life of casted structure with porosity effects in aero engine applications. The uncertainty of porosity defects is addressed by introducing probabilistic models.Design/methodology/approachOne major issue of casted aluminium alloys in the application of aerospace industries is their internal defects such as porosities, which are directly affecting the fatigue life. Since there is huge cost and time effort involved in understanding the effect of fatigue life in terms of the presence of the internal defects, a probabilistic fatigue model approach is applied in order to define the realistic fatigue limit of the casted structures for the known porosity fractions. This paper describes the probabilistic technique to casted structures with measured porosity fractions and its relation to their fatigue life. The predicted fatigue life for various porosity fractions and dendrite arm spacing values is very well matching with the experimentally predicted fatigue data of the casted AS7G06 aluminium alloys with measured internal defects. The probabilistic analysis approach not only predicts the fatigue life limit of the structure but also provides the limit of fatigue life for the known porosity values of any casted aluminium bearing support structure used in aero engines.FindingsThe probabilistic fatigue model for addressing porosity in casting structure is verified with experimental results.Research limitations/implicationsThis is grey area in aerospace and automotive industry.Originality/valueThis work is original and not published anywhere else.
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Vončina, Maja, Gregor Hvala, Jožef Medved, Borut Žužek, and Mitja Petrič. "Determination of material quality by methods of thermal analysis." Materials and Geoenvironment, November 7, 2022. http://dx.doi.org/10.2478/rmzmag-2021-0006.
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Abstract Cast aluminium alloys are commonly used in the automotive industry for casting applications. There are both primary and secondary/recycled aluminium alloys in the market, which differ in price and quality. In this study, the effect of alloy quality on solidification, microstructure and mechanical properties was investigated. The comparison of properties was carried out in the as-cast condition and in the heat-treated condition. The influence of alloy quality on solidification was analysed by simple thermal analysis and differential scanning calorimetry, and thermodynamic simulations. The basic mechanical properties analysed were tensile strength, yield strength, elongation, and hardness. The microstructural differences were analysed using a light microscope. The Mn:Fe ratio, which is strongly influenced by the alloy quality, was found to have a pronounced effect on the mechanical properties, while magnesium together with silicon hardens the aluminium matrix during heat treatment, which significantly increases the mechanical properties. This research proved that thermal analysis methods can give us a necessary and important indication of the quality of the alloys used.
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Gopal, V., D. Marx Raghu Raja, Jaikumar Mayakrishnan, and V. Hariram. "Mechanical Behaviour of Al7075 Hybrid Composites Developed through Squeeze Casting." International Journal of Vehicle Structures and Systems 13, no. 3 (August 4, 2021). http://dx.doi.org/10.4273/ijvss.13.3.14.
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The automotive and aerospace sector are behind the development of squeeze casting process, as the squeeze cast components exhibit improved mechanical properties. Squeeze casting is a hybrid metal processing technique that combines the advantage of both casting and forging in one operation. The aluminium alloy 7075 is a futuristic material that is widely used to produce automotive and aerospace components. Cylindrical component of AL 7075 was produced by varying the squeeze pressure at certain level. The specimen was made from the component as per ASTM standard and they were tested for mechanical properties such as tensile hardness and impact strength respectively. It was found that mechanical properties were enhanced with increase in squeeze pressure. The aluminium 7075 hybrid composites developed through squeeze casting is fabricated and experimented upon and found to have adequate potential for wide variety of application. In aerospace industries it can be used in gear components, blade sleeves, guide vanes, wing components etc. Applications in surface transport are brake rotors, automotive engine cylinder, engine exhaust valve, body chassis and connecting rods. This material can be used in light weight applications such as power lines and wind mill fans.
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"Effect of Copper Addition on Tensile Behaviour of Al-Cu Alloy Used in High Temperature Applications." International Journal of Surface Engineering and Interdisciplinary Materials Science 10, no. 1 (January 2022): 0. http://dx.doi.org/10.4018/ijseims.302238.
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Aluminium (Al) alloys are now-a-days used starting from aerospace, automotive body panel, to kitchen ware especially due to their high strength to weight ratio. Aluminium having copper as major alloying element exhibit good mechanical properties at room as well as at high temperature working conditions. But presence of silicon in these alloys adversely affect the strength at high temperature. The current paper analyses change in microstructure and it’s effect on mechanical properties of Aluminium-Copper(Al-Cu) alloy with varying wt% of copper. The Al-Cu alloy developed for study contain silicon as trace element only. Tests carried out to evaluate the impact of such variations on tensile and metallurgical behaviour at room temperature. Analysis of microstructure change with varying wt% of Copper is studied which goes well with the tensile data recorded. Effect of heat treatment (T6) on tensile properties was studied. The tensile results both as cast and heat treated suggest Al-Cu alloy containing 8wt% of Copper as the optimum composition.
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Nasution, A. K., D. Gustiani, A. Handoko, Mukhtar, Zulkarnain, A. Arafat, M. H. Idris, and M. H. Ramlee. "A Preliminary Study of Fabrication Technology for Dynamic Compression Plates Using Centrifugal Casting Process." International Journal of Automotive and Mechanical Engineering 18, no. 2 (June 18, 2021). http://dx.doi.org/10.15282/ijame.18.2.2021.15.0671.
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The high cost of health services in low-income countries has caused them to produce implants and medical devices at low cost. This research highlights a preliminary study of the design concept, mould design, and fabrication of horizontal type centrifugal casting machines for the manufacture of dynamic compression plates materials. Normally, dynamic compression plate is produced from materials such as 316L stainless steel, cobalt, and titanium alloys. In this work, aluminium-silicon alloy was used in this preliminary study. Aluminium-silicon alloy was melted at a temperature of 730 °C and poured into a mould with a rotational speed of 1500 rpm. Tensile, hardness and microstructure investigation were carried out to discern the mechanical properties of the cast product from the horizontal type centrifugal casting machine. Results showed the measured value of tensile strength is not significantly different in the two zones of cast pipe, the butt zone of fall of molten metal (specimen A) was 147 MPa, and the butt-end zone (specimen B) was 142 MPa. The hardness value for the as-cast pipe obtained from the outside, middle, and inside, was 104.0, 92.9, and 80.3 HV, respectively. Evaluation of microporosity in fractures (from tensile test) results from horizontal type centrifugal castings showed a small distribution. Meanwhile, the calculation of the contour hole processing time for DCP with eight holes is 38 minutes per implant.
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Baby, Ajith Kurian, M. Priyaranjan, K. Deepak Lawrence, and PK Rajendrakumar. "Tribological behaviour of hypereutectic Al-Si automotive cylinder liner material under dry sliding wear condition in severe wear regime." Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, October 9, 2020, 135065012096461. http://dx.doi.org/10.1177/1350650120964616.
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Hypereutectic Al-Si alloys are used as material for the engine block and cylinder liners in automobiles. Wear behaviour of hypereutectic Al-Si alloy system changes significantly with applied normal load in both mild wear and severe wear regime. Significant improvement in wear resistance can be obtained by exposing silicon particles through the chemical etching process. For Al-25% Si alloys, most studies are reported in mild and ultra-mild wear regime. In the present work, the wear of exposed silicon particles with varying load and speed in severe wear regime was investigated under the unidirectional sliding condition and bi-directional sliding condition using a pin-on-disk tribometer (POD) and a linear reciprocating tribometer (LRT), respectively. Rapidly solidified and T6 heat-treated Al-25Si alloy was polished and etched using 5% NaOH solution to expose the silicon particles. Experiments were carried out with normal loads varying from 40 N to 120 N in dry sliding conditions. Sliding speeds of 0.8 m/s and 1.5 m/s were applied for each load in case of a pin on disk tribometer whereas, in an LRT, the sliding velocities were 0.2 m/s and 0.45 m/s respectively for each set of the load. The surface topography was measured by means of a 3-D optical profilometer, and surface morphology was analyzed using SEM images. It was observed that at higher loads, larger Si particles were fractured and pushed into the matrix. Fractured silicon particles, along with smaller particles, were embedded into the matrix, thereby increasing the silicon concentration in the wear region. The comparison of the experimental results of unidirectional and bi-directional sliding that reveal the change in surface morphology of silicon particles, the friction characteristics at the interface, variation of surface 3-D roughness parameters, the wear rate and wear mechanisms of Al-25% Si alloys are analyzed and reported in the study.
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Prasad, Rabindra, Harikishor Kumar, Parshant Kumar, and Abha Gupta. "Nugget zone characterization of friction stir welded hypereutectic Al-Si alloy." Engineering Research Express, February 8, 2023. http://dx.doi.org/10.1088/2631-8695/acba67.
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Abstract Despite excellent properties of aluminium silicon (Al-Si) alloys in several aircraft and automotive applications, its usage is limited because near net shape casting of Al-Si alloys may cause several defects like surface pinholes and grooves. Fabrication of components and then welding them via fusion-based welding processes imposes issues like porosity and slag inclusions which may severely degrades its properties. Thus in present study, friction stir welding (FSW) was employed for welding of hypereutectic Al-Si cast alloy. The nugget zone (NZ) of welded alloy and its as-cast counterparts were characterized for their performance in terms of mechanical and tribological behaviour. The results depicted fragmentation of α-Al dendrites, refinement and redistribution of acicular Si particles as a result of stirring with high strain rate, and improvement in mechanical properties such as ultimate tensile strength, yield strength, ductility, hardness and wear resistance as compared to as-cast alloy. It is also shown that disparate wear mechanisms occured in friction stir welded (FSWed) and as-cast alloys. A sizeable amount of adhesion with plastic deformation and delamination pits were observed for as-cast alloy, while the dominant mechanism in FSWed alloy was peeling with little adhesion.
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Rajiv, T. G., T. V. Sreerama Reddy, and R. Chandrashekar. "Comparative Evaluation of the Damping Capacity of As-cast and t6 Temper a 356-sic AMMCS." Journal of Mines, Metals and Fuels, November 25, 2022, 354–63. http://dx.doi.org/10.18311/jmmf/2022/31959.
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The paper discusses the response to free vibration and also to forced vibration of the A356-SiC AMMCs in the as-cast and T6 temper conditions for the comparative assessment of the damping capacities. The base A356 aluminium alloy and seven A356-SiC composites with SiC percentage ranging from 2% to 12% were stir cast and cantilever specimens of 180 mm length were tested for their frequency and amplitude responses. From the results obtained, it was concluded that the A356-SiC composites with 8% SiC and 3% SiC in the T6 condition could be favourably considered as candidate materials for diesel engine parts in the automotive industry.
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Nagaraju, Sharath Ballupete, Madhu Kodigarahalli Somashekara, Pradeep Dyavappanakoppalu Govindaswamy, Madhu Puttegowda, Premkumar Bagade Girijashankar, and Karthik Sathyanarayana. "Mechanical Characterization of B4C-Gr Al2618 Based Composites Synthesized by Stir Casting Method." Applied Science and Engineering Progress, December 27, 2022. http://dx.doi.org/10.14416/j.asep.2022.12.005.
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Aerospace and automotive industries rely heavily on aluminium alloys because of their advantageous physical and mechanical properties. This paper presents studies on the performance of stir cast B4C (Boron carbide) and Gr (graphite) reinforced aluminium metal matrix composite (AMMC). Particulate reinforcement of B4C and Gr is in the ratio 2:1 (wt.%). Characterization of AMMC's mechanical properties reveals that the composite has enhanced mechanical properties compared to Al2618. Through Scanning electron microscope(SEM), it is identified that microstructure of AMMC and distribution of B4C and Gr particles in Al2618 are found to be uniform. Based on the results of the experiments, it was determined that the best AMMC mixture for improving the material's mechanical properties is a combination of B4C and Gr, with the proportions at 8:4. As a result, the automobile sector stands to benefit greatly from the use of this AMMC in the production of engine components.