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Journal articles on the topic 'Manufacture of aluminium parts'
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1
Duflou, Joost R., Amar Kumar Behera, Hans Vanhove, and Liciane S. Bertol. "Manufacture of Accurate Titanium Cranio-Facial Implants with High Forming Angle Using Single Point Incremental Forming." Key Engineering Materials 549 (April 2013): 223–30. http://dx.doi.org/10.4028/www.scientific.net/kem.549.223.
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One of the key application areas of Single Point Incremental Forming is in the manufacture of parts for bio-medical applications. This paper discusses the challenges associated with the manufacture of cranio-facial implants with extreme forming angles using medical grade titanium sheets. While on one hand, the failure wall angle is an issue of concern, the parts also need to be manufactured with accuracy at the edges where the implants fit into the human body. Systematic steps taken to overcome these challenges, using intelligent intermediate part design, feature analysis and compensation, are discussed. A number of case studies illustrating the manufacture of accurate parts in aluminium, stainless steel and titanium grade-2 alloy are discussed.
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Tarasova, Tatiana, Galina Gvozdeva, and Riana Ableyeva. "Innovation in additive manufacturing of parts from aluminium matrix composites." MATEC Web of Conferences 224 (2018): 01073. http://dx.doi.org/10.1051/matecconf/201822401073.
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The laser build-up cladding is a well-known technique for additive manufacturing tasks. Modern equipment for the laser cladding enables material to be deposited with the lateral resolution of about 100 μm and to manufacture miniature parts. In this paper the laser micro cladding process was investigated to produce miniature thin-wall parts of Al-based composites. Thin walls formation process by subsequent single tracks overlapping with vertical increment was investigated. The influence of the cladding parameters on the minimal width and the quality of the fabricated thin walls was examined. The thin walls with the minimal width of 140 μm and surface roughness Ra 1,5 μm were generated. Laser micro cladding potential to manufacture lattice-shaped structures of Al-Si composites was shown. Fabricated thin-wall structures can have application in different fields e.g. aviation, automotive and tooling industries.
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Langebeck, Anika, Annika Bohlen, Hannes Freisse, and Frank Vollertsen. "Additive manufacturing with the lightweight material aluminium alloy EN AW-7075." Welding in the World 64, no. 3 (December 4, 2019): 429–36. http://dx.doi.org/10.1007/s40194-019-00831-z.
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AbstractAs a widely used additive manufacturing technique, the laser metal deposition process (LMD) also known as direct energy deposition (DED) is often used to manufacture large-scale parts. Advantages of the LMD process are the high build-up rate as well as its nearly limitless build-up volume. To manufacture large-scale parts in lightweight design with high strength aluminium alloy EN AW-7075, the LMD process has a disadvantage that must be considered. During the process, the aluminium alloy is melted and has therefore a high solubility for hydrogen. As soon as the melt pool solidifies again, the hydrogen cannot escape the melt and hydrogen pores are formed which weakens the mechanical properties of the manufactured part. To counter this disadvantage, the hydrogen must be successfully kept away from the process zone. Therefore, the covering of the process zone with shielding gas can be improved by an additional shielding gas shroud. Furthermore, the process parameters energy input per unit length as well as the horizontal overlapping between two single tracks can be varied to minimize the pore volume. Best results can be achieved in single tracks with an elevated energy input per unit length from 3000 to 6000 J/cm. To manufacture layers, a minimal horizontal overlapping will lead to lowest pore volume, although this results in a very wavy surface, as a compromise of low pore volume and a nearly even surface a horizontal overlapping of 30 to 37% leads to a pore volume of 0.95% ± 0.50%.
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Le Duigou, Julien, Sverre Gulbrandsen-Dahl, Flore Vallet, Rikard Söderberg, Benoît Eynard, and Nicolas Perry. "Optimization and lifecycle engineering for design and manufacture of recycled aluminium parts." CIRP Annals 65, no. 1 (2016): 149–52. http://dx.doi.org/10.1016/j.cirp.2016.04.111.
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Iskandar, Edi, Hafrizon Hafrizon, Wiwiek Nuralimah, Hairul Arsyad, and Lukmanul Hakim Arma. "DISAIN DAN PEMBUATAN ALAT ATOMISASI ALUMINIUM." Jurnal Teknik Mesin Sinergi 18, no. 2 (December 9, 2020): 163. http://dx.doi.org/10.31963/sinergi.v18i2.2626.
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Metal powder is the main raw material in the manufacture of powder metallurgy-based products. Powder-making is the initial step before the powder is packed and pressed in a mold to form the desired product. This research designs and fabricates an atomizer to produce powder from liquid aluminum using a pressurized water jet system. The research stage starts from the drawing of the tool design by considering the volume of liquid aluminum, the diameter of the outlet of liquid metal, the air pressure, and the angle of attack of the water beam. The second stage is the manufacture of the atomization chamber by referring to the design drawing by making parts of the tool/frame, liquid metal feeder parts, making the walls of metal plates, making the nozzle holder, and collecting the powder parts and the water exhaust channel. The third stage is assembly, which is to unite the main parts of the aluminum atomizer. The final stage is the testing of the atomization tool using 250 Psi pressurized water with variations of attack angle was 30˚, 35˚, 40˚, 45˚, and 50˚ with a metal descending channel diameter of 5 mm. The results showed that the 45o spray angle gave the highest percentage of powder amount and the lowest 40o angle resulted in the size of aluminum metal powder in the range 0.105 mm-0.5 mm. The size of the powder was obtained at an angle of attack of 35o, which is an average of 39.5 um, and the largest size of powder was obtained at a spray angle of 40o of 89.5 um. The resulting powder form is irregular in shape, flakes (flakes), spheroid (spherical), and spongy (hollow).
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D’Errico, Fabrizio, Daniele Casari, Mattia Alemani, Guido Perricone, and Mauro Tosto. "INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR." MATEC Web of Conferences 326 (2020): 06007. http://dx.doi.org/10.1051/matecconf/202032606007.
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The life cycle holistic approach for the automotive sector highlighted how much important is working on decarbonisation of Al casting processes to produce vehicle components. Broadening the use of recycled aluminium alloys, instead of high energy intensive primary aluminium alloys, is key for environment preservation. While primary aluminium alloys are preferred by automotive original equipment manufacturers (OEMs) because impurities (mainly Fe) present in secondary aluminium alloys might cause fatigue properties decay, a new semisolid state process route has been developed at Brembo to drastically reduce the sensitivity of cast aluminium to Fe impurities. Based on these premises, during the CRAL European project in the framework of the LIFE Programme, an industrial prototype machinery - a vertical high pressure die casting machine - has been designed and constructed to inject secondary aluminium in the semisolid state. A number of A357 Fe-enriched brake callipers manufactured via the new process route have been fully investigated by fatigue tests, SEM and OM analyses in order to validate the new eco-sustainable product compared to conventional ones manufactured with primary aluminium by gravity casting.
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Behrens, Bernd Arno, Klaus Georg Kosch, Conrad Frischkorn, Najmeh Vahed, and Adis Huskic. "Compound Forging of Hybrid Powder-Solid-Parts Made of Steel and Aluminum." Key Engineering Materials 504-506 (February 2012): 175–80. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.175.
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Compound forging is a technology to successfully manufacture hybrid parts by applying resource-saving process steps. During compound forging of steel-aluminum parts the formation of intermetallic phases is benefited. The thickness of these intermetallic phases influences the bonding and thus the global part quality. According to literature, specific coating elements reduce the phase seam thickness. In powder-metallurgically manufactured parts it is possible to selectively insert specific elements in the surface area. Therefore, a time intensive coating process can be avoided. The applicability of combining the technologies of powder-metallurgy and compound forging is discussed in this paper. Powder-metallurgically manufactured and solid parts made of steel and aluminum are compound forged and the influences on deformation behavior and the joining zone are investigated.
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Ponnusamy, Panneer, Rizwan Abdul Rahman Rashid, Syed Hasan Masood, Dong Ruan, and Suresh Palanisamy. "Mechanical Properties of SLM-Printed Aluminium Alloys: A Review." Materials 13, no. 19 (September 26, 2020): 4301. http://dx.doi.org/10.3390/ma13194301.
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Selective laser melting (SLM) is a powder bed fusion type metal additive manufacturing process which is being applied to manufacture highly customised and value-added parts in biomedical, defence, aerospace, and automotive industries. Aluminium alloy is one of the widely used metals in manufacturing parts in SLM in these sectors due to its light weight, high strength, and corrosion resistance properties. Parts used in such applications can be subjected to severe dynamic loadings and high temperature conditions in service. It is important to understand the mechanical response of such products produced by SLM under different loading and operating conditions. This paper presents a comprehensive review of the latest research carried out in understanding the mechanical properties of aluminium alloys processed by SLM under static, dynamic, different build orientations, and heat treatment conditions with the aim of identifying research gaps and future research directions.
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Singamneni, Sarat, Nicholas McKenna, Olaf Diegel, Darius Singh, and A. Roy Choudhury. "Rapid Manufacture in Light Metals Processing." Materials Science Forum 618-619 (April 2009): 387–90. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.387.
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As several of the free form fabrication processes progress with continuous process and material improvements, the feasibility of Rapid Manufacturing becomes more and more of a reality. Defined as the use of a Computer Aided Design (CAD) based automated additive manufacturing process to construct parts that are used directly as finished products and components, some of the rapid manufacturing processes are already competing with traditional processes such as injection moulding and progress is being made in applying the new technologies to the processing of metals, envisioning additive manufacture of high strength parts of unlimited complexity. While there have been quite a few successful attempts in the rapid production of complex medical implants using titanium alloys, 3D printing of sand moulds opens up yet another rapid manufacturing front, allowing for the rapid casting of aluminium and magnesium alloys. The effectiveness of such processes is yet to be researched in terms of process and product characteristics and the overall economy. This paper attempts to review some of the promising rapid manufacturing technologies for light metals processing and presents results of experimental investigations conducted to evaluate the effectiveness of the rapid casting process currently researched at the Rapid Product Development Centre of AUT University.
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Cerutti, Xavier, Sami Hassini, Emmanuel Duc, and Katia Mocellin. "Prediction of the Distortions Caused by the Redistribution of the Residual Stresses During Machining Using FEM." Materials Science Forum 768-769 (September 2013): 398–405. http://dx.doi.org/10.4028/www.scientific.net/msf.768-769.398.
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Aeronautic parts have generally complex structure and need high mechanical properties. Machining is an essential step to manufacture aluminium alloy aeronautical parts. To obtain parts complying with geometrical specifications, the machining process must be well understood and mastered. Indeed, many factors may induce geometrical deflections during the machining process. On large aeronautical parts, the main factor which can lead to non-complying part is the unexpected release of original residual stresses. In this work, a specific finite element solver has been developed to predict the distortion due to the redistribution of the original residual stresses during machining. Then, results obtained are compared with experimental tests to validate this approach.
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Nturanabo, Francis, Leonard M. Masu, and Gonasagren Govender. "Automotive Light-Weighting Using Aluminium Metal Matrix Composites." Materials Science Forum 828-829 (August 2015): 485–91. http://dx.doi.org/10.4028/www.scientific.net/msf.828-829.485.
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The automotive manufacturing industry, worldwide, has been engaged in a race to produce lightweight vehicles. Consequently, the industry continues to deploy significant resources in developing and utilising advanced lightweight materials and cutting-edge technologies in the manufacture of new vehicle models that are energy efficient, more reliable, safer, more user-friendly and less polluting; without compromising the other important vehicle attributes such as, size, cargo space and payload, structural integrity, power and acceleration. Mass reduction is one consistent and cost-effective strategy that can be combined with other efficiency improvement strategies and technologies to meet the requirements of fuel economy and emission reduction. The materials used in automotive light-weighting must fulfil several criteria imposed by regulation and legislation with the environment in addition to satisfying customer requirements. The choice for light, high strength automotive materials is between advanced high-strength steel (AHSS) on one hand, and composites of aluminium (aluminium metal matrix composites (AlMMCs)), magnesium and polymers, on the other. In this paper, the potential of AlMMCs as a replacement for most steels and aluminium alloys in the manufacture of automotive parts and components is discussed as well as their current status and future trends of utilisation in automotive light-weighting.
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Birol, Yucel, Onur Ilgaz, Seracettin Akdi, and Erdem Unuvar. "Comparison of Cast and Extruded Stock for the Forging of AA6082 Alloy Suspension Parts." Advanced Materials Research 939 (May 2014): 299–304. http://dx.doi.org/10.4028/www.scientific.net/amr.939.299.
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High-precision near-net shape parts with excellent surface qualities can be produced with the forging process with a minimum of finishing operations thanks to the good formability of aluminium alloys. There has been a rapid increase in the use of aluminium forgings predominantly in the automotive industry, where weight savings for reduced fuel consumption and exhaust emissions is mandated by legislation. Aluminium forgings provide, in addition to low weight, high strength, good corrosion resistance and a fibrous grain structure to improve fatigue resistance. Typical commercial forging stock is the round bars produced by the extrusion of cast billets. An alternative process route that has received increasing attention in recent years is the casting of forging stock by a horizontal direct chill casting technique to make smaller billets without the need for extrusion to reduce their diameter. The anisotropy imparted to the forging stock via extrusion, often regarded as useful for the forging, is certainly missing in the former. However, cast stock has been reported to be more resistant to the formation of coarse surface grains than the extruded counterpart. The present work was undertaken to compare the casting and extrusion routes for the manufacture of 6082 alloy forging stock.
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OKANO, Shinobu. "Energy Consumption of Some Manufacture Processes for Aluminum Alloy Parts." Journal of the Japan Society for Technology of Plasticity 48, no. 553 (2007): 96–101. http://dx.doi.org/10.9773/sosei.48.96.
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Kumar, Manoj, Georg Kirov, Florian Grabner, and Ermal Mukeli. "Sheet Forming Processes for AW-7xxx Alloys: Relevant Process Parameters." Materials Science Forum 879 (November 2016): 1036–42. http://dx.doi.org/10.4028/www.scientific.net/msf.879.1036.
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High strength AW-7xxx sheet alloys are promising candidates to manufacture crash relevant parts, but their limited formability at room temperature presents a major challenge. Formability is controlled through heating rate, heat treatment temperature and time, quenching rate, forming temperature and strain rate. In the literature retrogression forming, W-temper forming, warm forming and hot stamping processes have been proposed to improve the formability of AW-7xxx alloys. Of these the greatest improvement in formability comes from W-temper forming and hot stamping. Considering the similarity to the conventional forming processes of cold stamping for aluminium and hot stamping for steel, the W-temper forming and hot stamping of aluminium are promising for AW-7xxx alloys.
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Gu, Jiang Long, Jia Luo Ding, Bao Qiang Cong, Jing Bai, Hui Min Gu, Stewart W. Williams, and Yu Chun Zhai. "The Influence of Wire Properties on the Quality and Performance of Wire+Arc Additive Manufactured Aluminium Parts." Advanced Materials Research 1081 (December 2014): 210–14. http://dx.doi.org/10.4028/www.scientific.net/amr.1081.210.
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Wire+arc additive manufacture (WAAM) is a high build rate process for production of near-net shape components layer by layer. The performance and quality of the deposited metal are heavily affected by the properties of wires, which are the raw materials for WAAM. Therefore there may be higher requirements for the qualities and properties of wires for WAAM than for welding. External surface qualities, micro hardness, composition and microstructures of five ER4043 aluminium wires were investigated in the present research. The results indicate that the internal and external properties of the wires exert great influence on the performance of the WAAM parts.
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Sedlák, Josef, Adam Glváč, and Andrej Czán. "Design of stirling engine operating at low temperature difference." MATEC Web of Conferences 157 (2018): 04003. http://dx.doi.org/10.1051/matecconf/201815704003.
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There are many sources of free energy available in the form of heat that is often simply wasted. The aim of this paper is to design and build a low temperature differential Stirling engine that would be powered exclusively from heat sources such as waste hot water or focused solar rays. A prototype is limited to a low temperature differential modification because of a choice of ABSplus plastic as a construction material for its key parts. The paper is divided into two parts. The first part covers a brief history of Stirling engine and its applications nowadays. Moreover, it describes basic principles of its operation that are supplemented by thermodynamic relations. Furthermore, an analysis of applied Fused Deposition Modelling has been done since the parts with more complex geometry had been manufactured using this additive technology. The second (experimental) part covers 4 essential steps of a rapid prototyping method - Computer Aided Design of the 3D model of Stirling engine using parametric modeller Autodesk Inventor, production of its components using 3D printer uPrint, assembly and final testing. Special attention was devoted to last two steps of the process since the surfaces of the printed parts were sandpapered and sprayed. Parts, where an ABS plus plastic would have impeded the correct function, had been manufactured from aluminium and brass by cutting operations. Remaining parts had been bought in a hardware store as it would be uneconomical and unreasonable to manufacture them. Last two chapters of the paper describe final testing, mention the problems that appeared during its production and propose new approaches that could be used in the future to improve the project.
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Paniti, Imre, Zsolt János Viharos, Dóra Harangozó, and Sherwan Mohammed Najm. "Experimental and Numerical Investigation of Single Point Incremental Forming of Aluminium Alloy Foils." ACTA IMEKO 9, no. 1 (March 30, 2020): 25. http://dx.doi.org/10.21014/acta_imeko.v9i1.750.
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Single Point Incremental Forming (SPIF) is a flexible process to manufacture sheet metal parts that is well adapted and profitable for prototypes or small batch production. Compared to traditional sheet forming technologies this relatively slow process can be used in different applications in automotive and aircraft industries, in architecture engineering and in medical aids manufacturing. In this paper indirectly obtained axial forming force on SPIF of variable wall angle geometry were studied under different process parameters. The estimation of the forces on AlMn1Mg1 sheets with 0.22 mm initial thickness is performed by continuous monitoring of servo motor currents. The deformation states of the formed parts were analysed using the ARGUS optical strain measurement system of GOM, while the roughness measurements were carried out by a System of Mitutoyo. Some initial Finite Element Analysis simulations and a crack monitoring method together with an interaction plot of forming speed, incremental depth, tool diameter and lubrication were also reported.
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Toenjes, Anastasiya, Julien Kovac, Bernd Koehler, Axel von Hehl, Andreas Mehner, Brigitte Clausen, and Hans-Werner Zoch. "Process chain for the fabrication of hardenable aluminium-zirconium micro-components by deep drawing." MATEC Web of Conferences 190 (2018): 15013. http://dx.doi.org/10.1051/matecconf/201819015013.
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Today, micro components are used in various industrial sectors such as electronics engineering and medical applications. The final quality of such parts depends on each individual step of the production chain from the manufacturing of semi-finished parts to the post-processing. In this study, magnetron sputtering is used to manufacture thin (15-30 μm) aluminium-zirconium alloy foils for the deep drawing of high strength and hardenable micro cups, which can be, for example, employed as micro valve caps. The development of a novel process chain for the production of these parts includes four different steps, beginning with the production of Al-Zr foils by magnetron sputtering. Secondly, tensile tests are performed with the foils in order to estimate their mechanical properties. Subsequently, micro deep drawing is used to produce the cup’s shape, and finally, a heat treatment in a drop-down tube furnace adjusts the cup’s hardness during fall. It is shown in particular that Al-Zr foils produced by magnetron sputtering have an attractive cold forming and hardening potential due to a microstructure consisting essentially of an oversaturated solid solution of zirconium in the aluminium matrix. This material state enables adequate formability and simplifies the heat treatment process since no solution annealing is required.
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Cook, R., I. T. H. Chang, and C. Lucien Falticeanu. "Aluminium and Aluminium Alloy Powders for P/M Applications." Materials Science Forum 534-536 (January 2007): 773–76. http://dx.doi.org/10.4028/www.scientific.net/msf.534-536.773.
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P/M aluminium components are attracting interest in an increasing variety of industries due to the possibilities for weight saving in engineering parts. There are many processes for manufacturing from powder feedstocks that are either in production, becoming commercialised or still undergoing development. The nature of these processes and the required properties of the end products mean that powders of different particle size, shape, composition and microstructure must be produced. The requirements of various processes requiring aluminium and aluminium alloy powders for metal matrix composites, laser sintering, powder forging and metal injection moulding are discussed in relation to powder particle size and structure. The key requirement of the powder manufacturer is to supply cost effective materials for these different processes. This may require compromises to be made by the supplier and consumer while the techniques evolve from development to large scale production.
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Drobotov, Alexey, Artem Avdeev, and Andrey Shvets. "Magnetohydrodynamic pump application in complex form aluminum parts additive manufacturing." MATEC Web of Conferences 224 (2018): 01076. http://dx.doi.org/10.1051/matecconf/201822401076.
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A review of Drop-on-Demand additive manufacturing methods was held. A method of complex forms aluminum parts production through the application of magnetohydrodynamic pump and 5 axis manufacturing process was proposed. 5 axis 3D printer assembly was shown. A few operation modes were proposed for such 3D printer and a method for fill lines paths calculating, needed for G-code automatic generation, was established. The algorithm for calculating printhead moving trajectory in the cylindrical parts manufacture mode was shown.
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Fuchs, Marc. "Structural Process: Efficient Manufacture of Ductile and Weldable Die Cast Aluminum Components." Solid State Phenomena 116-117 (October 2006): 387–91. http://dx.doi.org/10.4028/www.scientific.net/ssp.116-117.387.
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Kumar, Purushottam, Shreyanshu Parhi, and Somak Datta. "Comparative Study of Al-TiB2 Composite Fabricated by Different Powder Metallurgical Methods." International Journal of Emerging Research in Management and Technology 6, no. 7 (June 29, 2018): 178. http://dx.doi.org/10.23956/ijermt.v6i7.209.
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Aluminium Metal Matrix Composites (AMMCs) are the new class of materials substituting many industrial materials. It is due to its superior qualities compared to conventional materials. AMMCs has found a versatile application because it has aluminium in matrix phase hence light in weight and also it can acquire different properties as per reinforcements used. Sintering is one of the prominent methods used to manufacture AMMCs. Sintering process is used in Powder Metallurgy in which small powdered particles are heated to bond together. The process enhances the strength as well as other mechanical and tribological properties. The technology enables us to shape materials difficult to machine, parts with complex geometries, materials having high melting point, parts with close dimensional tolerances, or to combine different materials which is not possible with any other process. The most important part is that the density of the product can be controlled according to the requirements and thus self-lubricating and wear-resistant parts are possible. The present study has attempted to see if TiB2 can be used as reinforcement in AMMCs produced through powder metallurgy route and the changes in the properties of AMMCs by the different sintering methods adopted. The compacted preforms of varying compositions of reinforcement were prepared and sintered through three different methods i.e. Microwave sintering, Conventional sintering and Hot-pressing to study the changes in the properties. A comparative study has been done between the three sintering methods to see the limitations and scope for improvement.
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Dadbakhsh, Sasan, and Liang Hao. "Effect of Layer Thickness in Selective Laser Melting on Microstructure of Al/5 wt.%Fe2O3Powder Consolidated Parts." Scientific World Journal 2014 (2014): 1–10. http://dx.doi.org/10.1155/2014/106129.
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In situreaction was activated in the powder mixture of Al/5 wt.%Fe2O3by using selective laser melting (SLM) to directly fabricate aluminium metal matrix composite parts. The microstructural characteristics of thesein situconsolidated parts through SLM were investigated under the influence of thick powder bed, 75 μm layer thickness, and 50 μm layer thickness in various laser powers and scanning speeds. It was found that the layer thickness has a strong influence on microstructural outcome, mainly attributed to its impact on oxygen content of the matrix. Various microstructural features (such as granular, coralline-like, and particulate appearance) were observed depending on the layer thickness, laser power, and scanning speed. This was associated with various material combinations such as pure Al, Al-Fe intermetallics, and Al(-Fe) oxide phases formed afterin situreaction and laser rapid solidification. Uniformly distributed very fine particles could be consolidated in net-shape Al composite parts by using lower layer thickness, higher laser power, and lower scanning speed. The findings contribute to the new development of advanced net-shape manufacture of Al composites by combining SLM andin situreaction process.
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Kampker, Achim, Johannes Triebs, Sebastian Kawollek, Peter Ayvaz, and Tom Beyer. "Direct polymer additive tooling – effect of additive manufactured polymer tools on part material properties for injection moulding." Rapid Prototyping Journal 25, no. 10 (November 11, 2019): 1575–84. http://dx.doi.org/10.1108/rpj-07-2018-0161.
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Purpose This study aims to investigate the influence of additive manufactured polymer injection moulds on the mechanical properties of moulded parts. Therefore, polymer moulds are used to inject standard specimens to compare material properties to specimens produced using a conventional aluminium tool. Design/methodology/approach PolyJet technology is used to three-dimensional (3D)-print a mould insert in Digital ABS and selective laser sintering (SLS) technology is used to 3D-print a mould insert in polyamide (PA) 3200 GF. A conventionally aluminium milled tool serves as reference. Standard specimens are produced to compare resulting mechanical properties, shrinkage behaviour and morphology. Findings The determined material characteristics of the manufactured prototypes from the additive manufactured tools show differences in terms of mechanical behaviour to those from the aluminium reference tool. The most significant differences are an up to 25 per cent lower tensile elongation and an up to 63 per cent lower elongation at break resulting in an embrittlement of the specimens produced. These differences seem to be mainly due to the different morphological structure caused by the lower thermal conductivity and greater surface roughness of the polymer tools. Research limitations/implications The determined differences in mechanical behaviour can partly be assigned to differences in surface roughness and morphological structure of the resulting parts. The exact extend of either cause, however, cannot be clearly determined. Originality/value This study provides a comparison between the part material properties from conventionally milled aluminium tools and polymer inserts manufactured via additive tooling.
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Syamza, Nandha, Abdul Khair Junaidi, and Tri Subagyo. "Production Process of Front Lights on Anoa 2 6x6 Special Vehicles at PT. Pindad (Persero)." Journal of Ocean, Mechanical and Aerospace -science and engineering- (JOMAse) 65, no. 1 (March 29, 2021): 19–22. http://dx.doi.org/10.36842/jomase.v65i3.211.
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The headlights on Anoa 2 6x6 special vehicles are used for street lighting for anoa tanks at night. The purpose of this study was discussed the steps of production process of the Anoa 2 6x6 headlights in PT. Pindad. The headlight component was made in several manufacturing processes that were carried out. It consists of many parts, which a variety of production machines for the manufacture of each part. The manufacturing of the headlight components using machining processes such as laser cutting, welding, and drilling. The type of material used for the manufacture of the headlights and parts that was Aluminum Alloy 2044 and Steel ST-37. The result components were made the headlight frame, BT protectors, the front, side, and rear components.
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Koike, Hitonobu, Katsuyuki Kida, Kenji Kanemasu, K. Itakura, Kenichi Saruwatari, Justyna Rozwadowska, and Megumi Uryu. "Influence of Wear and Backlash on Machined PEEK Polymer Bushes and 7075 Aluminium Alloy Cam Plates Used in Robot Joints." Applied Mechanics and Materials 157-158 (February 2012): 1178–85. http://dx.doi.org/10.4028/www.scientific.net/amm.157-158.1178.
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Due to constant exposure to high torque and loads toughness, compressive durability and light weight of joint parts are crucial factors for biped walking humanoid robot parts. When polymer transmission parts are used for the manufacture of humanoid robot joint, wear becomes an important factor in terms of transmission error (backlash) between the input and output axes, ex. between the motor and the robot’s leg joint. In such joint system, a polymer bushes is directly connected to a cam plate, playing an important role in the robot's movement ability. In this work, the influence of wear of reinforced poly-ether-ether-ketone (PEEK) polymer bushes in friction against 7075 aluminium alloy cam plates is investigated in order to establish the application possibilities in transmission parts in humanoid robot’s joint. The PEEK bush surface conditions as well as the input axis-output axis backlash require close examination, so that efficient systems can be built. Sliding wear tests were performed on bushes under 0-50kgfcm loaded torque while the cam plate oscillated. Based on the wear observation, it was found that in a high load range the backlash increased along with number of cycles due to PEEK bush wear. The bush surface roughness also increased during testing. Roughness of PEEK bush surface and the loaded torque for output axis were significantly related to backlash of output axis in robot joint.
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Fedulov, V. N. "NEW COMPOSITIONS OF TOOL STEELS FOR COLD AND HOT FORMING AND THEIR HARDENING CAPABILITIES." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 2 (July 7, 2018): 119–23. http://dx.doi.org/10.21122/1683-6065-2018-2-119-123.
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New compositions of tool steels of increased wear resistance for manufacturing tools of various purposes are considered. The results of this work can be used in the manufacture of cold and hot forming molds and working parts of die casting molds of aluminum and copper alloys, as well as in the manufacture of cutting tools for woodworking and even for plastics molding. In every case you selection of the steels depends on the purpose of use and the required operational life of the tool.
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Leal, Malena Ley Bun, Barbara Bermudez-Reyes, Patricia del Carmen Zambrano Robledo, and Omar Lopez-Botello. "Parameter optimization of aluminum alloy thin structures obtained by Selective Laser Melting." MRS Advances 4, no. 55-56 (2019): 2997–3005. http://dx.doi.org/10.1557/adv.2019.434.
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ABSTRACTSelective Laser Melting (SLM) involves numerous fabrication parameters, the interaction between those parameters determine the final characteristics of the resulting part and because of the latter, it is considered a complex process. Low-density components is one of the main issues of the SLM process, due to the incorrect selection of process parameters. These defects are undesired in high specialized applications (i.e. aerospace, aeronautic and medical industries). Therefore, the characterization of the defects (pores) found in aluminum parts manufacture by SLM and the relationship with fabrication parameters was performed. A robust orthogonal design of experiments was implemented to determine process parameters, and then parts were manufactured in SLM. Relative density of the samples was then characterized using the Archimedes principle and microscopy; the data was then statistically analyzed in order to determine the optimal process parameters. The main purpose of the present research was to establish the best processing parameters of an in-house SLM system, as well as to characterize the pore geometry in order to fully eliminate pores in a future research.
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Auburtin, P., N. Morin, and C. Pille. "Mechanical effects of water quenching on aluminum automotive parts." Journal de Physique IV 120 (December 2004): 761–68. http://dx.doi.org/10.1051/jp4:2004120088.
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Computer modeling is nowadays necessary in order to achieve proper automotive components in short development times and low costs. To reach the required high accuracy, process and manufacturing operations, such as heat treatments, must be included in simulations. Indeed, they generate residual stresses, which strongly influence high cycle fatigue life, as well as geometrical distortions, which need to be evaluated and corrected in order to manufacture parts within the proper dimensional tolerances. Recent developments undertaken at PSA Peugeot-Citroën have enabled the development of a methodology to evaluate the residual stresses and distortions generated during T6-T7 heat treatment of aluminum automotive components. The calculation with Abaqus finite element software, developed on a cylinder head, follows 2 different steps: a thermal analysis and a mechanical analysis. The comparison between the simulation results and experimental measures is encouraging. Moreover, coupled with high cycle fatigue life, failures encountered during engine tests can be now explained. The methodology has also been applied on other aluminum automotive components, such as cast alloy wheels and engine cradles.
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Li, Nan, Shu Ming Xing, and Pei Wei Bao. "Simulation and Research on the Rheocasting Process of 7075 Aluminum Alloy." Advanced Materials Research 129-131 (August 2010): 482–89. http://dx.doi.org/10.4028/www.scientific.net/amr.129-131.482.
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Taking the 7075 aluminum alloy as an example, this paper did some simulation work on temperature, flow field and shrinkage porosity distribution in the rheocasting process using the simulation casting software PROCAST. Effects of the casting temperature and filling speed on casting quality as well as segregation phenomenon of solid and liquid phases were discussed in this paper. Proper ranges of casting temperature and filling speed were obtained by the simulation. Good quality parts without shrinkage porosity were obtained in validation test using the casting temperature of 622~625°C and filling speed of 40mm/s. Rheocasting was an important forming method using semi-solid melt to manufacture metal parts directly. It was a promising trend of semi-solid forming industry which had shorter process, higher efficiency and lower energy consumption compared to SIMA method [1-4]. Rheocasting was generally applied to casting aluminum alloy but seldom to wrought aluminum alloys. The 7xxx series aluminum was generally manufactured though wrought or rolling technique to obtain dense parts with high strength. But few of them were produced directly through casting method without casting flaws[5-6].To process the 7xxx series aluminum by rheocasting method would further expand the application of wrought aluminum alloy, so it is essential to do some research on the rheocasting technique for wrought aluminum alloy. Taking the 7075 aluminum alloy as an example, this paper did some simulation work on temperature, flow field and shrinkage porosity distribution in the rheocasting process using the simulation casting software PROCAST. The effects of casting temperature and filling speed on the casting quality as well as the segregation phenomenon of solid and liquid phases were discussed in this paper. Proper ranges of casting temperature and filling speed were obtained by the simulation.
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Del Sol, Irene, Asuncion Rivero, and Antonio J. Gamez. "Effects of Machining Parameters on the Quality in Machining of Aluminium Alloys Thin Plates." Metals 9, no. 9 (August 24, 2019): 927. http://dx.doi.org/10.3390/met9090927.
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Nowadays, the industry looks for sustainable processes to ensure a more environmentally friendly production. For that reason, more and more aeronautical companies are replacing chemical milling in the manufacture of skin panels and thin plates components. This is a challenging operation that requires meeting tight dimensional tolerances and differs from a rigid body machining due to the low stiffness of the part. In order to fill the gap of literature research on this field, this work proposes an experimental study of the effect of the depth of cut, the feed rate and the cutting speed on the quality characteristics of the machined parts and on the cutting forces produced during the process. Whereas surface roughness values meet the specifications for all the machining conditions, an appropriate cutting parameters selection is likely to lead to a reduction of the final thickness deviation by up to 40% and the average cutting forces by up to a 20%, which consequently eases the clamping system and reduces machine consumption. Finally, an experimental model to control the process quality based on monitoring the machine power consumption is proposed.
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Pietzka, Daniel, Nooman Ben Khalifa, Stephanie Gerke, and A. Erman Tekkaya. "Composite Extrusion of Thin Aluminum Profiles with High Reinforcing Volume." Key Engineering Materials 554-557 (June 2013): 801–8. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.801.
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Extruded aluminium profiles with a variety of different cross-sections are mainly used in lightweight structures for transportation means. Examples are stringer profiles in the fuselage of airplanes or profiles in chassis of trains and cars. Nowadays, the mass reduction of a lightweight structure is an important issue to achieve lower fuel consumption and CO2 emissions. With an increased portion of aluminium profiles the mass of structures can be reduced considerably in contrast to the application of steel parts, due to the lower density of aluminium. However, this is coupled with disadvantages such as the lower specific stiffness and strength of the material. One possibility to improve the mechanical properties of aluminium profiles without a considerable increase of their weight is the embedding of reinforcing elements during the extrusion process. Special porthole extrusion dies are used to feed reinforcing elements in form of high strength steel wires separate from the aluminium material flow. In the welding chamber of the die both materials bond together to a composite profile. To achieve a high advantage of the technology for lightweight applications a high reinforcing volume of aluminium profiles is targeted. A comparatively high reinforcing volume can be reached either by a high number of reinforcing elements or through a reduction of the profile wall thickness. A high number of reinforcing elements leads to a small distance between the single elements in the profile cross-section. The paper will show the results of an experimental and numerical analysis which were carried out to determine the minimum distance between the reinforcing elements as well as the minimum profile thickness. In the trials different arrangements of the elements in the profile cross-section and profile thicknesses were considered. Main parameters which have an influence on the process stability were analyzed and a process window for the manufacture of thin profiles with high reinforcing volume was deduced.
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Ladani, Leila, and Maryam Sadeghilaridjani. "Review of Powder Bed Fusion Additive Manufacturing for Metals." Metals 11, no. 9 (September 1, 2021): 1391. http://dx.doi.org/10.3390/met11091391.
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Additive manufacturing (AM) as a disruptive technology has received much attention in recent years. In practice, however, much effort is focused on the AM of polymers. It is comparatively more expensive and more challenging to additively manufacture metallic parts due to their high temperature, the cost of producing powders, and capital outlays for metal additive manufacturing equipment. The main technology currently used by numerous companies in the aerospace and biomedical sectors to fabricate metallic parts is powder bed technology, in which either electron or laser beams are used to melt and fuse the powder particles line by line to make a three-dimensional part. Since this technology is new and also sought by manufacturers, many scientific questions have arisen that need to be answered. This manuscript gives an introduction to the technology and common materials and applications. Furthermore, the microstructure and quality of parts made using powder bed technology for several materials that are commonly fabricated using this technology are reviewed and the effects of several process parameters investigated in the literature are examined. New advances in fabricating highly conductive metals such as copper and aluminum are discussed and potential for future improvements is explored.
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Bałon, Paweł, Edward Rejman, Robert Smusz, Janusz Szostak, and Bartłomiej Kiełbasa. "Implementation of high speed machining in thin-walled aircraft integral elements." Open Engineering 8, no. 1 (June 18, 2018): 162–69. http://dx.doi.org/10.1515/eng-2018-0021.
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Abstract High speed milling (HSM) is currently one of the most important technologies used in the aviation industry, especially concerning aluminium alloys. The difference between HSM and other milling techniques is the ability to select cutting parameters – depth of the cut layer, feed rate, and cutting speed, in order to simultaneously ensure high quality, precision of the machined surface, and high machining efficiency, all of which shorten the manufacturing process of the integral components. By implementing the HSM technology, it is possible to manufacture very complex integral thin-walled aerial parts from the full quantity of the raw material. At present, aircraft structures are designed to mainly consist of integral elements which have been produced by welding or riveting of component parts in technologies utilized earlier in the production process. Parts such as ribs, longitudinals, girders, frames, coverages of fuselage and wings can all be categorized as integral elements. These parts are assembled into larger assemblies after milling. The main aim of the utilized treatments, besides ensuring the functional criterion, is obtaining the best ratio of strength to construction weight. Using high milling speeds enables economical manufacturing of integral components by reducing machining time, but it also improves the quality of the machined surface. It is caused by the fact that cutting forces are significantly lower for high cutting speeds than for standard machining techniques.
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Bigot, R., S. Leleu, and P. Martin. "Forming Machine Qualification by Analysis of Manufactured Parts Geometry: Application to Aluminium Forming Process." International Journal of Advanced Manufacturing Technology 21, no. 7 (May 1, 2003): 476–82. http://dx.doi.org/10.1007/s001700300056.
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Chuchala, Daniel, Michal Dobrzynski, Danil Yurievich Pimenov, Kazimierz A. Orlowski, Grzegorz Krolczyk, and Khaled Giasin. "Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies." Materials 14, no. 11 (June 2, 2021): 3036. http://dx.doi.org/10.3390/ma14113036.
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Lightweight alloys made from aluminium are used to manufacture cars, trains and planes. The main parts most often manufactured from thin sheets requiring the use of milling in the manufacturing process are front panels for control systems, housing parts for electrical and electronic components. As a result of the final phase of the manufacturing process, cold rolling, residual stresses remain in the surface layers, which can influence the cutting processes carried out on these materials. The main aim of this study was to verify whether the strategy of removing the outer material layers of aluminium alloy sheets affects the surface roughness after the face milling process. EN AW-6082-T6 aluminium alloy thin plates with three different thicknesses and with two directions relative to the cold rolling process direction (longitudinal and transverse) were analysed. Three different strategies for removing the outer layers of the material by face milling were considered. Noticeable differences in surface roughness 2D and 3D parameters were found among all machining strategies and for both rolling directions, but these differences were not statistically significant. The lowest values of Ra = 0.34 µm were measured for the S#3 strategy, which asymmetrically removed material from both sides of the plate (main and back), for an 8-mm-thick plate in the transverse rolling direction. The highest values of Ra = 0.48 µm were measured for a 6-mm-thick plate milled with the S#2 strategy, which symmetrically removed material from both sides of the plate, in the longitudinal rolling direction. However, the position of the face cutter axis during the machining process was observed to have a significant effect on the surface roughness. A higher surface roughness was measured in the areas of the tool point transition from the up-milling direction to the down-milling direction (tool axis path) for all analysed strategies (Ra = 0.63–0.68 µm). The best values were obtained for the up-milling direction, but in the area of the smooth execution of the process (Ra = 0.26–0.29 µm), not in the area of the blade entry into the material. A similar relationship was obtained for analysed medians of the arithmetic mean height (Sa) and the root-mean-square height (Sq). However, in the case of the S#3 strategy, the spreads of results were the lowest.
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Kłyszewski, A., J. Żelechowski, A. Frontczak, P. Rutecki, W. Szymanski, Z. Zamkotowicz, and M. Nowak. "New Rolled Aluminium Alloy Products for the Automotive Industry." Archives of Metallurgy and Materials 59, no. 1 (March 1, 2014): 393–96. http://dx.doi.org/10.2478/amm-2014-0065.
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Abstract Clad aluminium strips are used in the automotive industry to manufacture parts of heat exchangers. They are characterised by favourable strength properties, good corrosion resistance and susceptibility to plastic deformation, and can undergo surface brazing at a temperature of about 600°C. As a result of studies, the properties of alloys for the production of clad strips have been optimised. Optimising covered the alloy chemical composition and selected parameters such as the metal condition, the mechanical properties and anti-corrosion behaviour, including the methods for corrosion potential equalisation and sacrificial protection. The obtained technological results of the clad aluminium strip production were verified under the industrial conditions of Impexmetal Huta Aluminium Konin S.A. In a laboratory of the Institute of Non-Ferrous Metals (IMN), the clad strips were tested for the pre-assumed functional properties. Mechanical properties were tested, and the structure and corrosion behaviour were characterised. The reactivity of the clad layer was analysed under different technological conditions. The thermal bond produced by these clad layers was tested by simulation of the heat exchanger manufacturing process. As a result of the conducted research it has been found that all the essential characteristics of the clad strips produced under domestic conditions are in no way different from the properties of imported strips, while modification of the alloy chemical composition has contributed to the effective sacrificial protection of heat exchangers made from these strips. Clad aluminium strips are now successfully produced by the domestic aluminium industry. The improvement of materials used for the heat exchangers can contribute to the reduced overall dimensions of these products and increased efficiency, thus leading to energy savings. The results were obtained within the framework of the Task No. ZPB/38/66716/IT2/10 executed as part of the „IniTech” Project.
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Zhou, Jia, X. M. Wan, Y. Li, and Q. J. Zhao. "Optimal Design and Experimental Investigations of Aluminium Extrusion Profiles for Lightweight of Car Bumper." Key Engineering Materials 585 (December 2013): 157–64. http://dx.doi.org/10.4028/www.scientific.net/kem.585.157.
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The present study aimed at developing an aluminium car bumper unit to replace the steel ones by using optimization based on experimental and FEM simulation results. The topology optimization method and response surface methodology (RSM) were applied in order to achieve an optimized design for the cross section of the crossbeam and the crash box, respectively. The three-points bending test and crash test for bumper unit were simulated to evaluate the optimization processes. The 6061 and 6063 aluminium alloy bumper unit has a weight reduction of 67% compared to the steel ones. The new extrusion dies were manufactured to produce profiles for the crossbeam and the crash box, respectively. Then the optimized extrusion profiles of crossbeam and crash box were verified by experimental studies. The performance tests were arranged to validate the experimental product. The mechanical properties of extruded aluminium crossbeam and crash box can satisfy the design requirements of products. The results indicate that the new designed unit can change the whole design of automotive parts for crash energy absorption, and definitely contribute to drastic weight reduction of steel parts.
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Gong, Hai, Yanjie Sun, Yaoqiong Liu, Yunxin Wu, Yipeng He, Xiaoliang Sun, and Minghai Zhang. "Effect of Vibration Stress Relief on the Shape Stability of Aluminum Alloy 7075 Thin-Walled Parts." Metals 9, no. 1 (December 29, 2018): 27. http://dx.doi.org/10.3390/met9010027.
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Aluminum alloy 7075 is one of the materials widely used in the manufacture of structural components used by aviation industries. High precision is required in producing the shapes of such components due to shape stability and dimensional accuracy being difficult to maintain throughout the different stages of manufacturing. In this work, an experimental study of the effect of VSR (Vibratory Stress Relief) on the deformation and residual stresses of aluminum alloy 7075 thin-walled components is presented. It was concluded that VSR improved the shape and size stability of the material to a significant level by relieving induced residual stresses in the thin-walled parts. Finally, more uniform residual stress distribution was obtained after the VSR treatment, compared to before the VSR treatment. This proved that VSR has a significant influence on improving the shape stability of the thin-walled aluminum alloy 7075 components.
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Revilla, Reynier, Donovan Verkens, Tim Rubben, and Iris De Graeve. "Corrosion and Corrosion Protection of Additively Manufactured Aluminium Alloys—A Critical Review." Materials 13, no. 21 (October 28, 2020): 4804. http://dx.doi.org/10.3390/ma13214804.
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Metal additive manufacturing (MAM), also known as metal 3D printing, is a rapidly growing industry based on the fabrication of complex metal parts with improved functionalities. During MAM, metal parts are produced in a layer by layer fashion using 3D computer-aided design models. The advantages of using this technology include the reduction of materials waste, high efficiency for small production runs, near net shape manufacturing, ease of change or revision of versions of a product, support of lattice structures, and rapid prototyping. Numerous metals and alloys can nowadays be processed by additive manufacturing techniques. Among them, Al-based alloys are of great interest in the automotive and aeronautic industry due to their relatively high strength and stiffness to weight ratio, good wear and corrosion resistance, and recycling potential. The special conditions associated with the MAM processes are known to produce in these materials a fine microstructure with unique directional growth features far from equilibrium. This distinctive microstructure, together with other special features and microstructural defects originating from the additive manufacturing process, is known to greatly influence the corrosion behaviour of these materials. Several works have already been conducted in this direction. However, several issues concerning the corrosion and corrosion protection of these materials are still not well understood. This work reviews the main studies to date investigating the corrosion aspects of additively manufactured aluminium alloys. It also provides a summary and outlook of relevant directions to be explored in future research.
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Gómez-Parra, Álvaro, Alfredo Sanz, and Antonio Gámez. "Evaluation of the Functional Performance in Turned Workpieces: Methodology and Application to UNS A92024-T3." Materials 11, no. 8 (July 24, 2018): 1264. http://dx.doi.org/10.3390/ma11081264.
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Turning of light alloys as aluminum-based UNS A92024-T3 is broadly implemented in the manufacture of critical aircraft parts, so ensuring a good functional performance of these pieces is essential. Moreover, operational conditions of these pieces include saline environments where corrosion processes are present. In this paper, a methodology for the evaluation of the functional performance in turned pieces is proposed. Specimens affected and not affected by corrosion are compared. In addition, performance in service through tensile stress tests of these parts is considered. The results show that turning improves the functional performance of UNS A92024-T3 alloy and that corrosion can enhance the mechanical properties of this alloy.
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Kyogoku, Hideki, Kohei Yamamoto, Toshi Taka Ikeshoji, Kazuya Nakamura, and Makiko Yonehara. "Melting and Solidification Behavior of High-Strength Aluminum Alloy during Selective Laser Melting." Materials Science Forum 941 (December 2018): 1300–1305. http://dx.doi.org/10.4028/www.scientific.net/msf.941.1300.
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Additive manufacturing (AM) technology has been dramatically attracted attention because of advantages in building free-shaped parts and simplification of manufacturing process. Recently the most relevant alloys, such as TiAl6V4, Inconel 718, AlSi10Mg and so on, are able to manufacture the parts using metal AM technology. However high-strength 2024, 6061 and 7075 aluminum alloys are difficult to fabricate using selective laser melting (SLM) owing to solidification cracking during solidification. In this research, the melting and solidification behaviors of AlSi10Mg alloy during SLM process were observed under various fabrication conditions of laser power and scan speed using a high-speed camera. It was found that the melting and solidification behavior of the alloy is greatly different by the fabrication conditions. And also the mechanism of solidification cracking in 2024 and 6061 aluminum alloys is investigated by the observation of the surface morphology and microstructure of the alloys using OM, SEM and EDS, comparing with Al10SiMg alloy. As a result, crack-free 2024 and 6061 aluminum alloy parts can be obtained by fabrication at the higer enrgy density.
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Latypov, Rashit A., Evgeniy V. Ageev, and Evgeniy P. Novikov. "Preparation and Study of the Properties of Aluminum Powders, Suitable for the Manufacture of Powder Electrodes." Key Engineering Materials 839 (April 2020): 172–77. http://dx.doi.org/10.4028/www.scientific.net/kem.839.172.
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The results of the study of the shape, morphology and elemental composition of aluminum powder particles obtained in distilled water with the following electrical parameters of the electroerosive dispersion unit are presented: the capacity of discharge capacitors is 65 μF, voltage 100 V, pulse frequency 50 Hz. It is established that the powder consists of particles of regular spherical shape (or elliptical), irregular shape (conglomerates) and fragmentation, and the main elements of the powder are aluminum and oxygen. The obtained powder materials can be used for the manufacture of powder electrodes used in welding and surfacing of a wide range of parts.
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Baras, P., and J. Sawicki. "Numerical analysis of mechanical properties of 3D printed aluminium components with variable core infill values." Journal of Achievements in Materials and Manufacturing Engineering 1, no. 103 (November 1, 2020): 16–24. http://dx.doi.org/10.5604/01.3001.0014.6912.
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Purpose: The purpose of this paper is to present numerical modelling results for 3D-printed aluminium components with different variable core infill values. Information published in this paper will guide engineers when designing the components with core infill regions. Design/methodology/approach: During this study 3 different core types (Gyroid, Schwarz P and Schwarz D) and different combinations of their parameters were examined numerically, using FEM by means of the software ANSYS Workbench 2019 R2. Influence of core type as well as its parameters on 3D printed components strength was studied. The “best” core type with the “best” combination of parameters was chosen. Findings: Results obtained from the numerical static compression tests distinctly showed that component strength is highly influenced by the type infill choice selected. Specifically, infill parameters and the coefficient (force reaction/volumetric percentage solid material) were investigated. Resulting total reaction force and percentage of solid material in the component were compared to the fully solid reference model. Research limitations/implications: Based on the Finite Element Analysis carried out in this work, it was found that results highlighted the optimal infill condition defined as the lowest amount of material theoretically used, whilst assuring sufficient mechanical strength. The best results were obtained by Schwarz D core type samples. Practical implications: In the case of the aviation or automotive industry, very high strength of manufactured elements along with a simultaneous reduction of their wight is extremely important. As the viability of additively manufactured parts continues to increase, traditionally manufactured components are continually being replaced with 3D-printed components. The parts produced by additive manufacturing do not have the solid core, they are rather filled with specific geometrical patterns. The reason of such operation is to save the material and, in this way, also weight. Originality/value: The conducted numerical analysis allowed to determine the most favourable parameters for optimal core infill configurations for aluminium 3D printed parts, taking into account the lowest amount of material theoretically used, whilst assuring sufficient mechanical strength.
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Vityaz, P. A., V. I. Moiseenko, A. G. Sidorenko, M. V. Sotnikov, N. D. Shkatulo, and D. I. Haritonchik. "Experience and prospects of use of structural steels for nitridated gears." Proceedings of the National Academy of Sciences of Belarus, Physical-Technical Series 66, no. 1 (April 2, 2021): 58–65. http://dx.doi.org/10.29235/1561-8358-2021-66-1-58-65.
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The experience of using known and new steels to improve the manufacturability and strength of the main parts of machines, hardened by nitriding, is generalized. New approaches to manufacture of gear wheels hardened by nitriding, both when using aluminum-containing steels and a new material, steel 40ХМФА, are considered. To improve the efficiency and man ufacturability of parts production from aluminum-containing steel 38Х2МЮА, widely used in mechanical engineering, a fundamentally new technology of preliminary heat treatment of workpieces of parts – “incomplete hardening” has been developed, which provides both an increase in the machinability and accuracy of large-sized gear wheels, and an increase in strength due to the elimination of the brittleness of nitrided layer. The high hardness of the nitrided surface of the parts – up to 900 HV – also ensures high wear resistance of the parts. Gear wheels made of new aluminum-containing steel 20ХН4МФЮА solidified at the nitriding stage, have strength characteristics equal to cemented parts, which allows not only increasing the bearing capacity of a number of products, but significant simplification of the technology of manufacturing precise parts that are complex in shape, replacing carburizing with nitriding, thereby eliminating the necessary after-carburizing finishing operation – grinding. Steel 40ХМФА, which does not contain aluminum, has increased heat resistance, hardenability and machinability of parts, as well as the characteristics of their hardened layer. The nitrided layer of gears 0.5–0.7 mm thick does not contain brittle components, which, with a core hardness of 300–320 HB, excludes its “flaking” and subsequent destruction of parts. The use of 40ХМФА steel makes it possible to solve the problems of reliability and service life of large-sized nitrided gears, but it is also promising for the entire range of gears with internal gearing, as well as parts of movable spline gearings. These characteristics also in some cases allow replacing the carburizing of gears (modulus less than 4 mm) by nitriding when using 40ХМФА steel.
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Lee, Hee-keun, Jisun Kim, Changmin Pyo, and Jaewoong Kim. "Evaluation of Bead Geometry for Aluminum Parts Fabricated Using Additive Manufacturing-Based Wire-Arc Welding." Processes 8, no. 10 (September 26, 2020): 1211. http://dx.doi.org/10.3390/pr8101211.
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The wire arc additive manufacturing (WAAM) process used to manufacture aluminum parts has a number of variables. This study focuses on the effects of the heat input and the current and voltage ratio on the deposition efficiency. The effects of the heat input and current and voltage ratio (V/A) on the bead geometry were analyzed, depending on the cross-sectional geometry of the deposition layers, for nine different deposition conditions. The deposition efficiency was also analyzed by analyzing the cross-sectional geometry of the thin-wall parts made of aluminum. The heat input range was about 2.7 kJ/cm to 4.5 kJ/cm; the higher the heat input, the higher the deposition efficiency. The maximum deposition efficiency achieved in this study was 76%. The current and voltage ratio was used to quantify the portion of voltage (V) in the total heat input (Q), and the effect on the bead geometry was analyzed. As the portion of voltage in the quasi heat input decreased by about 10%, it was found that the deposition efficiency was decreased by 1% to 3%.
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Vanko, Branislav, Ladislav Stanček, Michal Čeretka, Eduard Sedláček, and Roman Moravčík. "Properties of EN AW-2024 Wrought Aluminum Alloy after Casting with Crystallization under Pressure." Scientific Proceedings Faculty of Mechanical Engineering 23, no. 1 (December 1, 2015): 58–65. http://dx.doi.org/10.1515/stu-2015-0009.
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Abstract Establishing of wrought aluminum alloys casting to manufacture is now a global trend, for example due to lower production costs compare to forging or due to the ability to produce parts with thinner sections and more complex shapes. The aim of using these alloys in the foundry industry is in particular the creation of castings with higher mechanical properties than achieve castings made of standard casting aluminum alloys. Most often are cast wrought aluminum alloys of the 2xxx, 6xxx and 7xxx series. In the experiment, an alloy EN AW-2024 has been cast by modified technology of casting with crystallization under pressure. They were measured basic mechanical properties of the castings in the as-cast state and after heat treatment.
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Li, Gan, Hongxing Lu, Xiaogang Hu, Feng Lin, Xinwei Li, and Qiang Zhu. "Current Progress in Rheoforming of Wrought Aluminum Alloys: A Review." Metals 10, no. 2 (February 11, 2020): 238. http://dx.doi.org/10.3390/met10020238.
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Semi-solid processing (SSP), including rheoforming and thixoforming, offers a promising opportunity to manufacture net-shaped parts with complex structure and excellent mechanical properties. Owing to its low cost and short process, rheoforming has been the subject of extensive study over the last two decades. The interest in the rheoforming of wrought aluminum alloys is progressively growing among both the research and industrial communities. This review starts with reviewing the recent efforts and advances on preparation of semi-solid slurry of wrought Al alloys, followed by discussing the correlation between microstructure and performance of these alloys. Finally, special attention is paid in the industrial application and the future trends of rheoforming of wrought aluminum alloys.
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Meng, Qing Lei, Bao Yu Wang, Lei Fu, Jing Zhou, and Jian Guo Lin. "The Influence of Process Parameters during Hot Stamping of AA6111 Aluminum Alloy Sheet." Advanced Materials Research 572 (October 2012): 255–60. http://dx.doi.org/10.4028/www.scientific.net/amr.572.255.
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The AA6111 aluminum alloy sheet is widely used in auto-body manufacture. It can make use of good plasticity under high temperature to form more complex parts by using the hot stamping. The influence of process parameters in hot stamping of AA6111 aluminum alloy sheet is investigated through numerical simulation in this paper, including blank holding force (BHF), friction coefficient, stamping velocity and initial forming temperature. Finally forming defects of numerical simulation are verified through the hot stamping experiments. The results show that it can effectively avoid wrinkling and fracture by controlling the BHF, good lubricant is in favor of forming and numerical simulation can accurately predict forming defects to guide the production.
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Flores, Victor, and Brian Keith. "Gradient Boosted Trees Predictive Models for Surface Roughness in High-Speed Milling in the Steel and Aluminum Metalworking Industry." Complexity 2019 (July 1, 2019): 1–15. http://dx.doi.org/10.1155/2019/1536716.
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High-speed machining is a technique that maintains a high interest in the manufacture of metal parts for the excellent results it provides, both in surface finish and in economic benefits. In the industry, the tendency is to incorporate data management and analysis techniques to generate information that helps improve the surface roughness results in machining. A good alternative to improve the surface quality results in the manufacture of metal parts is using predictive models of the surface roughness. In this document, we present work done with experimental data obtained from two high-speed machining (HSM) machines with different types of tools and cutting conditions, conducted under an experimental design with interest in three of factors commonly studied to generate surface roughness models: tool characteristics, cutting conditions, and characteristics of the machined material. Steel and aluminum alloys were used in the experimentation. The results are contrasted with prior experiences that use the same experimental design but with different soft computing techniques and they are also contrasted with the results of similar previous works. Our results show accuracies ranging from 61.54% to 88.51% on the datasets, which are competitive results when compared with the other approaches. We also find the axial cut-depth is the most influential feature for the slots datasets and the hardness and diameter of the cutting tool are the most influential features for the geometries datasets.