Dissertations / Theses on the topic 'Aluminum-magnesium alloys – Metallurgy'

Aluminum 5XXX alloys are of industrial importance and interest as they combine a wide range of desirable strength, forming and welding characteristics with a high resistance to corrosion. The presence of Mg in these alloys ensures favorable mechanical properties. However, the room temperature stretching performance of these alloys is limited. Moreover, Al-Mg alloys are known for being susceptible to the Portevin-LeChatelier effect when deformed at room temperature. Nevertheless, improvements in ductility can be achieved through warm forming, especially when the ductility approaches superplastic levels.
The aim of this study was to test for enhanced ductility in three coarse-grained Al-Mg alloys namely, super-pure Al-3%Mg and Al-5%Mg, and commercial AA 5056 alloy. The temperature-dependent flow stress and rate sensitivity behavior of these alloys was investigated by means of tensile testing using ASTM E8M-04 standard samples. Samples were deformed to 10% strain to allow enough deformation to occur such that serrations in the dynamic strain aging (DSA) temperature/strain rate range would be rendered visible on a stress-strain curve. Using this information, the regions of negative and higher-than-normal strain rate sensitivity ('m') were plotted and tensile tests to failure were performed in the vicinity of maximum 'm'. ASTM E2448-06 standard samples for superplasticity tensile testing were used in this case.
A maximum ductility of 170% was recorded with these samples and this was found to increase to nearly 300% when the gage length was shortened. It was observed that the DSA serrations were more prominent at lower strain rates, higher temperatures and higher Mg contents. The results of this study show clearly that if the rate sensitivity is high enough, then enhanced ductility in coarse-grained materials is possible at temperatures well below the maximum test temperature.

The kinetics of calcium and sodium removal at 730$ sp circ$C by chlorination from commercial purity (99.7% Al) and aluminum-1wt% magnesium alloys has been investigated. The contribution of chlorine containing gas bubbles, of intermediate reaction products generated by the chlorination process, as well as evaporation through the melt surface, to the removal of calcium and/or sodium has been documented quantitatively. Experimental parameters investigated were chlorine concentration in the gas bubbles and gas flow rate. The measurement of frequency of bubble formation at the tip of the gas bubbling nozzle enabled the surface areas of the bubbles to be estimated which in turn enabled melt phase mass transfer coefficients for the bubbles to be calculated.
It was demonstrated that the removal of calcium and sodium followed first order reaction kinetics with respect to calcium and sodium concentrations. The removal of the above mentioned elements was represented well by a kinetic model in which mass transfer of sodium and calcium in melt phase was rate limiting.
In the case of the magnesium containing alloys, the MgCl$ sb2$ salt phase that was generated during chlorination was found to have a profound effect on the removal of calcium and sodium. The contribution of the salt phase to the removal of these elements was calculated to reach as high as 60%. In commercial purity aluminum, however, while the major contribution to the removal of calcium was from the chlorine containing gas bubbles, the major contribution to the removal of sodium was calculated to be evaporation of sodium through the melt surface.

Magnesium additions to aluminum enhance strength and hardness, lowering density, and improve corrosion resistance. However, during melting and casting processes, significant amounts of magnesium are lost due to selective oxidation. Preventing these losses would reduce the production cost and improve the quality of the final product.
The effects of various levels of strontium addition on the oxidation behaviour of aluminum-magnesium alloy melts were investigated by monitoring sample weight gains with time using a thermogravimetric balance at 750°C. Sample cross-sections have been examined in detail using Hitachi S-4700 Field Emission Gun Scanning Electron Microscope, and phases formed on the oxide layer and in the alloy morphology were identified by EDS, WDS and low angle X-ray diffraction techniques. It was observed that in the absence of Sr, the Al-Mg samples gained substantial amounts of weight by formation of spinel (MgAl2O4) phase at the oxide-metal interface. Samples containing Sr had significantly lower weight gains. The drop in total weight gain by Sr additions was about 98% in low Mg-containing Al-Mg alloys. This change in oxidation behavior was linked to the presence of a Sr-enriched liquid phase underneath the first formed MgO layer, suppressing the formation of spinel crystals. In addition, spherical equilibrium shapes are found in the different as-cast and oxidized alloys of Al-Mg-Sr.

In the presence of air and oxygen, oxidation of a molten aluminum alloy will easily take place. The oxidation not only harms the operation by contributing to melt losses, but the processing of the oxides present in the melt and refractory is also costly in time and money. Refractory accretions formed due to the interactions between the oxide-layer and base refractory material, especially alumina-lined ones, are a significant problem for the industry. Aluminum alloys containing magnesium are known to oxidize much more easily and rapidly. In the foundry, oxidation of molten aluminum-magnesium alloy is more prominent than that of pure aluminum. Magnesium has a higher affinity for oxygen, causing it to oxidize more easily than aluminum. In previous studies of oxidation of aluminum alloys, it has been found that strontium additions to the alloy reduce the amount of oxidized layer in an undisturbed melt.
The effects of strontium additions on the oxidation behavior of commercial A356, A357 and 5182 aluminum alloys were investigated by monitoring sample weight gains with time with a thermo-gravimetric balance at 700, 750, and 800°C. Sample surfaces were examined using electron microscope and x-ray diffraction techniques. It was found that in the absence of Sr, the A356 and A357 samples gained substantial amounts of weight through the preferential oxidation of magnesium. Samples containing strontium had significantly lower weight gains. For the high magnesium-containing 5182 alloy, an increase of incubation period before the onset of significant oxidation is associated with the presence of strontium. This change in oxidation behavior was linked to the presence of strontium containing oxide species in the oxidizing surface.

Increasing use of aluminum alloys in the automotive industry increases the importance of the production of sheet aluminum. To provide cost effective sheet aluminum to the industry, twin-roll casting (TRC) is becoming more important compared to DC casting. Demand for usage of different aluminum alloys in sheet form introduces some difficulties that should be considered during their applications. The main problem encountered during the welding of aluminum alloys is hot cracking. The aim of this study is to understand the difference in hot cracking susceptibility of two twin roll cast (TRC) aluminum-magnesium alloys (5754 and 5049 alloys) during welding. Varestraint test method was used to evaluate the effect of welding parameters, strain levels, filler alloys and mid-plane segregation on hot cracking susceptibilities. Hot cracking susceptibility of both 5049(Al-2wt%Mg) and 5754(Al-3wt%Mg) alloys increased with increasing strain level. Also, it was observed that hot cracking susceptibility was higher for the alloy having higher magnesium content. Thermal analysis results verified that hot cracking susceptibility indeed can be related to the v solidification range. As is suggested in the solidification range approach, the results of the present study confirm that the extent of solidification and liquation cracking depend on the magnitude of solidification range and the strain imposed during welding. Hot cracking susceptibility of 5754(Al-3wt%Mg) alloy has shown slightly decreasing behavior with addition of 5356 filler alloy. On the other hand, addition of 5183 filler alloy has increased solidification cracking susceptibility of two base alloys. The fracture surfaces of liquation and solidification cracks were investigated by scanning electron microscope with EDS. Liquation crack surfaces of the 5754(Al-3wt%Mg) alloy were found to have high Mg and Si content. For the 5754(Al-3wt%Mg) alloy, a quench test was designed to observe the effect of mid-plane segregation zone. It was observed that there was a eutectic reaction resulting in formation of liquid phase below solidus temperature of 5754(Al-3wt%Mg) alloy. Moreover, internal cracks have formed at the mid-plane segregation zone after Varestraint test. Results show that 5049(Al-2wt%Mg) alloy should be chosen compared to 5754(Al-3wt%Mg) alloy for welding. Moreover, low line energy should be applied and filler alloys with high magnesium content should be used during welding to decrease hot cracking tendency of welds.

Thesis (Master of Sciences (Engineering))--Case Western Reserve University, 2010
Department of Materials Science and Engineering Title from PDF (viewed on 2010-05-25) Includes abstract Includes bibliographical references and appendices Available online via the OhioLINK ETD Center

The implementation of technologies such as aluminum powder metallurgy (P/M) can be used in the automobile industry to have potential economic and environmental advantages. This technology to produce vehicle components can offer the combination of weight savings due to the low density of aluminum and material and machining savings via near net shape processing attributes. In an effort to expand the scope of application for aluminum P/M, considerable research has emphasized the development of new alloys and composites. One such alloy is P/M 2324, an aluminum-copper-magnesium alloy developed to have increased mechanical properties over the standard aluminum P/M alloys of the AC2014 type. The objective of this work was to undertake a comprehensive study on the effects of hot deformation on the emerging alloy P/M 2324 as well as the alloy with a SiC addition. Here, a forgeability study of these alloys and its wrought counterpart AA2024 was completed. To

Aluminum (Al) powder metallurgy (PM) provides a cost effective and environmentally friendly means of creating lightweight, high performance, near net shape components, relative to conventional casting/die casting technology. Unfortunately, the current lack of commercially available Al alloy powder blends has hindered development in this field as a result of the limited scope of mechanical properties available; especially under elevated temperature conditions common to many automotive applications. As such, the objective of this research was to attempt to improve the versatility of current Al PM technology through the incorporation of Fe and Ni transition metal additions into an emerging Al- 4.4Cu-1.5Mg-0.2Sn alloy, as this technique is known to enhance the elevated temperature stability of wrought/cast Al alloys through the formation of stable, Fe/Ni aluminide dispersoids. Initial experimentation consisted of evaluating the feasibility of incorporating Fe and Ni both elementally and pre-alloyed, through a series of tests related to their PM processing behaviour (compressibility, sintering response) and sintered product performance (ambient tensile properties). Results confirmed that pre-alloying of the base Al powder was the most effective means of incorporating Fe and Ni as all such specimens achieved properties similar or slightly superior to the unmodified alloy. Of the pre-alloyed systems considered, that containing 1%Fe+1%Ni displayed the most desirable results in terms of mechanical performance and microstructural homogeneity of the Fe/Ni dispersoid phases present in the sintered product. Bars of the baseline system and that modified with pre-alloyed additions of 1Fe/1Ni were then sintered industrially to gain a preliminary sense of commercial viability and obtain additional specimens for elevated temperature exposure tests. Results confirmed that the sintering response, tensile properties and microstructures were essentially identical in both alloys whether they were sintered in a controlled laboratory setting or an industrial production environment. Furthermore, DSC data indicated that S (Al2CuMg)-type phases were the dominant precipitates formed during heat treatment. The effects of elevated temperature exposure were assessed in the final stage of research. Both alloys were found to exhibit comparable behaviour when exposed to the lowest (120°C) and highest (280°C) temperatures considered. Here, the alloys showed no obvious degradation at 120°C. Conversely, exposure at 280°C prompted a steady decline in yield strength for both alloys with significant precipitate coarsening noted as well. Despite these similarities, differences emerged during isochronal tests at intermediate temperatures. Here, DSC data indicated that the precipitates present in the pre-alloyed material were stable at temperatures up to 160°C while those in the unmodified alloy had begun to overage under the same exposure conditions. These differences were accompanied by increased stability in tensile yield strength for the pre-alloyed material. In all, this study has indicated that the use of Al powder pre-alloyed with Fe/Ni additions is feasible for press-and-sinter PM technology and that the sintered product exhibits improved elevated temperature stability under certain conditions.

Al-Mg alloys spontaneously infiltrate into porous ceramic preform in a nitrogenous atmosphere above 750 °C with Mg either pre-alloyed or introduced at the interface to initiate the process. The governing process variables are temperature, alloy composition, atmosphere and particle size of the porous preform. The present study investigates the flow kinetics of Al-Mg melts into porous Al2O3 preforms as a function of particle size of the preform from the standpoint of a physical phenomena fluid flow through a non-uniform capillary. Pressureless infiltration involves two major stages: (a) initiation associated with an incubation period and, (b) continuation where the melt infiltrates the preform. Long (~1 hr) and irreproducible incubation periods are typically observed in the Al- Mg/Al2O3 system when the samples are slowly heated in N2 atmosphere. Such lengthy periods prior to infiltration also lead to excessive Mg loss from the system. In order to accurately measure infiltration rates during the continuation stage, the incubation period was minimized by upquenching samples in air under self-sealing conditions. Interrupted experiments reveal that infiltration occurs within 5 mins. Different phenomena are expected to dictate the capillary rise kinetics through the porous ceramic post-incubation (more specifically, retard the melt movement) (a) triple-point ridging of the melt meniscus on the alumina surface (meniscus pinning) (b) interfacial reaction limited wetting and infiltration (c) pore size and distribution of the porous ceramic (d) melt (Al-Mg) / atmosphere (N2) reaction to form products inside the pore space (decrease in permeability) (e) time-dependent loss of Mg from the system (time-dependent contact angle) Some of the above phenomena viz., fluid flow inside the porous medium and chemical reaction of the melt with the reinforcement are invariably coupled in a complex manner. The contribution of each phenomenon to the kinetics of infiltration (a) and (e) was investigated separately. Triple-line ridging Al sessile drops on alumina substrate spread 4-5 orders of magnitude slower than that predicted by hydrodynamic equilibrium. The melt is pinned by ridges leading to spreading rates of 0.4-4 mm/hr in contrast to viscous drag controlled spreading rates of 1-10 mm/sec. In order to detect ridging in the Al-Mg/Al2O3 reactive couple, uniform Al2O3 capillaries were infiltrated. Experiments were conducted under sealed configuration with metal on both sides of the capillary and Mg turnings at the interface. The uniform capillary itself was placed inside an alumina preform and the assembly upquenched to 800-900 °C to minimize evaporative loss of Mg. Examination of the inner walls of the capillary after leaching away the infiltrated metal shows rough, granular features on the polycrystalline Al2O3 surface. No continuous ridges were seen. EDS of the granular phase suggested stoichiometry of spinel, MgAl2O4, formed as a result of the reaction between the melt and the capillary. From interrupted experiments the average infiltration rate inside the uniform capillary was calculated to be in the ballpark range of 2-6 µm/sec (which is a lower limit to the meniscus velocity), an order of magnitude faster than the spreading rates observed during triple-line ridging (0.1 – 1 µm/sec) indicating that the melt front pinning was not the operative mechanism for influencing infiltration kinetics. Pore size distribution of porous medium Additionally, infiltration was found to be faster in uniform channels (fractures in a preform, annular spaces and aligned pores in freeze-cast preforms) compared to the randomly packed bed itself. The effect of pore size on infiltration kinetics was studied by varying the particle size of the packed bed. Experiments were conducted for two systems (a) non-reactive liquid polyethylene glycol PEG 600 (b) reactive Al-Mg melts into packed alumina beds as a function of particle size and temperature. The PEG 600 / Al2O3 ‘model’ system was used to benchmark the effect of pore size and distribution of the particle bed on flow kinetics from a purely physical standpoint. Typically, a Washburn type of ‘parabolic’ kinetics was observed for the non-reactive couple and the ‘effective’ hydrodynamic radius, reff was extracted. (For a uniform capillary, reff and the physical radius of the capillary are the same). Surprisingly, the ‘Washburn’ radius was found to be 1-2 orders of magnitude smaller than the average pore size and even smaller than the minimum average pore size of the compact. The ‘Washburn’ radii for infiltration of Al-Mg melts was a further order of magnitude smaller than the corresponding values for infiltration of non-reactive PEG 600 through the same packed beds. Non-uniform capillary model To predict the infiltration kinetics through porous media, a sinusoidal capillary model was developed based on the pore size distribution. The input parameters for the model were the average pore neck size and average pore bulge size, which were extracted from the experimentally measured pore size distribution. The flow was assumed to be quasi-steady state and laminar. Hagen-Poiseuille’s equation was employed to calculate the total pressure drop, which was equated with the instantaneous pressure drop across the meniscus. The meniscus velocity within the non-uniform capillary was solved numerically based on the instantaneous pressure drop. The infiltration profile for the sinusoidal capillary displayed jumps associated rise in the narrow segments of the profile while the rise through the broad segment was considerably slow. The overall infiltration profile could be fitted by a parabolic Washburn-type equation. The ‘effective’ hydrodynamic radius of such a sinusoidal capillary was found to be 2-3 orders of magnitude smaller than the average capillary size and even smaller than the narrowest opening of the sinusoidal capillary. The overall kinetics was limited by flow through the broad segment of the profile where the capillary driving force is the lowest coupled with a large viscous retarding force due to the narrow feeding segment thereby leading to extremely slow flow rates. The calculated ‘effective’ radius of the sinusoidal capillary (reff = 0.03 µm) based on the pore size distribution of the 25-37 µm (1.4-10.8 µm) packed bed was similar to the experimentally observed ‘effective’ radius for flow in the non-reactive couple (reff = 0.06 µm) implying good agreement between experiments and modeling. The model was extended for the case of pressure infiltration of Al melts into SiC & TiC compacts reported in the literature, under conditions where chemical reactions are negligible. A good agreement to within a factor of 4 between the observed kinetics and the ones predicted by the current model is observed. In order to understand the origin of this ‘unphysical’ radius dictating capillary rise, the physics of flow through a stepped capillary was analysed. The kinetics of flow through the wide segment could be expressed by an ‘effective’ drodynamic radius r 4min based on geometrical parameters of the stepped capillary as: reff= r3max (Wetting situation) where rminand rmax are the radii of the narrow and broad segments of the capillary. The ‘effective’ radius from the above equation matched well with the numerically derived ‘effective’ radius for flow through the stepped capillary. A r 2 similar expression for flow under applied pressure was derived as: reff= min rmax (non- wetting situation) which is strictly correct for large values of applied pressure. Chemical reactions influencing infiltration kinetics: Upquenched samples (time-dependent contact angle due to Mg loss) The previous investigation of fluid flow in porous media from a purely physical standpoint reveals the dominant role of the pore size and distribution in the porous medium in controlling infiltration kinetics. This however, is accurate only if chemical factors are minimized. In case of the upquenched experiments for the Al-Mg/Al2O3 system, the ‘effective’ radius was determined to be an order of magnitude smaller than that for the PEG 600/Al2O3 couple implying additional chemical factors influencing flow kinetics in this reactive system. Experiments with Mg turnings mixed with the powder bed shows faster infiltration compared to the ones where the entire Mg was placed at the interface showing that local availability of Mg was responsible for slower infiltration kinetics. Diminishing Mg at the melt front, leads to increase of surface tension and increase in contact angle. This was modeled by incorporating a kinetics (time-dependent) contact angle into the sinusoidal capillary model developed for non-reactive infiltration. The infiltration kinetics was found to be retarded in the case of a kinetic contact angle. Thus, both flow retardation through a packed bed and time-dependent variations of contact angle due to Mg loss from the system are responsible for slow pressureless infiltration kinetics of Al-Mg melts inside Al2O3 preforms. The infiltration kinetics predicted by the sinusoidal capillary model thus defines an upper envelope to the rate of infiltration and subsequent composite formation for such a process governed by fluid flow; all other factors if present in effect, retard the kinetics further. Samples processed in N2 atmosphere (reduced permeability due to AlN formation) The more practical case of composite fabrication (PRIMEXTM process) by pressureless infiltration of Al-Mg melts in a flowing N2 containing atmosphere was also examined. The kinetics of infiltration of Al-Mg melts in a flowing N2-H2 atmosphere (pO2 ~ 10-20atm) for different particle sizes of the packed bed was investigated. A large scatter in the infiltrated heights was observed and the absolute infiltration rates could not be established. Moreover, incubation periods were seen to range from 1-2 hours for different particle sizes. Post-incubation, the infiltration kinetics for a wide range of particle sizes was found to be approximately an order of magnitude slower than that for the upquenched samples. Microstructural investigations of the etched samples revealed significant AlN formation at the start of the composite near the preform/billet interface. This reduced the cross-sectional area available for melt flow and possibly led to long incubation periods encountered in the process. AlN formation was also detected in the matrix on the particle surfaces as well as in the interior of the matrix. This reduced the permeability of the compact and increased the hydrodynamic resistance for flow through the porous compact leading to slower infiltration kinetics. Thus both AlN formation in the matrix and Mg loss from the melt retard capillary flow of the melt through the porous ceramic over and above the intrinsic hydrodynamic resistance for flow through the packed bed. Role of atmosphere on the pressureless infiltration process The role of atmosphere in promoting the pressureless infiltration process was examined by using different processing atmospheres such as vacuum, N2-H2 and Ar and combinations thereof. It is known that the pressureless infiltration of Al melts into porous Al2O3 preforms requires both N2 and a critical level of Mg in the system. Samples heated under vacuum and Ar to 900 °C under open conditions did not infiltrate. Rather these showed discoloration related to the formation of MgAl2O4 on the particle surface due to reduction of Al2O3 by Mg vapour. Moreover, samples heated in Ar upto 500 °C followed by heating up in N2-H2 till 900 °C did not infiltrate indicating irreversible changes. Interestingly enough, if the samples were heated in vacuum upto 700 °C followed by N2-H2 at 900 °C, infiltration was observed. Dewetted regions of the compact were seen too adjacent to the preform-billet interface. This indicated a minimum critical partial pressure of N2, which promotes infiltration. From an analysis of the different interfacial energies and their dependence on atmosphere, it was concluded that either an increase in the solid-vapour interfacial energy (~ 10%) or a decrease in the solid-liquid interfacial energy (~ 10%) would lead to a decrease in the contact angle, θ, by 10°, large enough to ensure wettability and infiltration in certain atmospheres. It was also established that Mg infiltrates into porous Al2O3 both in N2-H2 as well as Ar under sealed conditions. So the presence of a minimum partial pressure of N2 favouring wettability was specific to the Al-Mg/Al2O3 system. (pl see the original document for formulas)