Abstract: This study investigated the combined effect of cold rolling and heat treatment on the mechanical properties of Al-Ti alloy. Samples of the alloy are cast in metal mould to obtain 0.94-2.19wt% mixes of titanium. These samples are grouped into untreated (as-cast) and those that are cold rolled to fifty percent reduction, homogenized at 5000C and soaked for one hour. The cold rolled and heat treated samples are normalized (RTn) and quench-tempered (RTq-t) at 1000C. All these samples are subjected to tensile, micro-hardness and microstructural evaluation. Results show remarkable improvement in the mechanical properties of the cold rolled and heat treated samples compared to the as-cast. In particular, the RTq-t samples containing titanium in the range of 1.7-2.2% demonstrates improve tensile strength by 24.7%, yield strength, 28%, elastic modulus, 38.3% and micro-hardness, 20.5%. The Al3Ti phase being the most stable precipitate in the α-Al matrix appears to have been responsible for the significant improvement in the alloy’s mechanical properties. It is concluded that quench and temper heat treatment is an effective method of improving the strength-strain ratio of cold rolled Al-.0.9-2.2%Ti alloy.
Abstract: Asymmetric incremental sheet forming (AISF) could significantly reduce costs incurred by the fabrication of complex industrial components with a minimal environmental impact. The AISF experiments were carried out on commercially pure titanium (Ti-Gr2), Timetal (15-3-3-3) alloy, and Ti-6Al-4V (Ti-Gr5) alloy. A special testing geometry was used to characterize the titanium alloys properties from the point of view of the forming zone and titanium structure effect. The structure and properties of the materials were assessed by means of metallographic analyses and microhardness measurements.The highest differences in the parameters assessed as a function of the sampling zone were observed in the case of alpha-phase Ti-Gr2at the expense of the most substantial sheet thinning occurrence. A springback causes a smaller stored deformation in Timetal (β alloy) resulting in less pronounced microstructure refinement and microhardness increase. Ti-6Al-4V alloy exhibited early failure due to its poor formability at ambient temperature.
Abstract: Shear spinning is closely related to the asymmetric incremental sheet forming (AISF) that could significantly reduce costs incurred by the fabrication of complex aeronautical components with a minimal environmental impact. The spinning experiments were carried out on commercially pure titanium (Ti-Gr2) and Ti-6Al-4V (Ti-Gr5) alloy. Three forming modes were used to characterize the titanium alloys properties from the point of view of different spinning parameters. The structure and properties of the materials were assessed by means of metallographic analyses and microhardness measurements. The highest value wall angle failure limit was achieved using spinning parameters mode for both materials. The feed rate effect was observed only in the samples from the Ti-Gr2 material, when a refinement of the grain microstructure with lower feed rate and higher tangential speed occurred. Ti-Gr5 alloy exhibited a decrease of the microhardness at higher straining due to recovery processes.
Abstract: Taguchi approach was applied to determine the most influential control factors which will yield better tensile strength of the joints of pulse TIG welded 70/30 Cu-Ni alloy. In order to evaluate the effect of process parameters such as pulse frequency, peak current, base current and welding speed on tensile strength of Pulsed current TIG welded 70/30 Cu-Ni alloy of 5 mm thickness, Taguchi parametric design and optimization approach was used. Through the Taguchi parametric design approach, the optimum levels of process parameters were determined at 95% confidence level. The results indicate that the Pulse frequency, peak current, welding speed and base current are the significant parameters in deciding the tensile strength of the joint. The predicted optimal values of tensile strength of Pulsed current Gas tungsten arc welding (PC GTAW) of 70/30 Cu-Ni alloy welds are 368.8MPa.
Abstract: Ageing of 75% cold rolled Al-6Mg alloy with ternary 0.4 wt% scandium and quaternary zirconium and titanium has been carried out. Alloy samples are naturally, isochronally and isothermally aged for different time and temperatures. Hardness values of the differently processed alloys have been measured to understand the ageing behavior of Al-6Mg alloy with scandium and quaternary zirconium and titanium addition. Resistivity changes with annealing time and temperature were measured to understand the precipitation behavior and recovery of strain of the alloy. Attempts were also made to understand the grain refining effect of scandium in Al-6Mg alloy. It is observed that significant hardening takes place in the aged alloys due to the precipitation of scandium aluminides and the dendrites of the Al-6Mg alloy have been refined significantly due to addition of scandium.
Abstract: Tungsten Inert Gas (TIG) welding is a high quality welding process used to weld the thin metals and their alloy. 5083 Aluminium alloys play an important role in engineering and metallurgy field because of excellent corrosion properties, ease of fabrication and high specific strength coupled with best combination of toughness and formability.
TIG welding technique is one of the precise and fastest processes used in aerospace, ship and marine industries. TIG welding process is used to analyze the data and evaluate the influence of input parameters on tensile strength of 5083 Al-alloy specimens with dimensions of 100mm long x 15mm wide x 5mm thick. Welding current (I), gas flow rate (G) and welding speed (S) are the input parameters which effect tensile strength of 5083 Al-alloy welded joints. As welding speed increased, tensile strength increases first till optimum value and after that both decreases by increasing welding speed further. Results of the study show that maximum tensile strength of 129 MPa of weld joint are obtained at welding current of 240 Amps, gas flow rate of 7 Lt/min and welding speed of 98 mm/min. These values are the optimum values of input parameters which help to produce efficient weld joint that have good mechanical properties as a tensile strength.
Abstract: This paper presents the results of a study aimed at establishing the temperature distribution during the welding of aluminum alloy plates by Pulsed Current Gas Tungsten Arc Welding (PCGTAW) and Constant Current Gas Tungsten Arc Welding (CCGTAW) processes. Pulsing of the GTA welding current influences the dimensions and solidification rate of the fused zone, it also reduces the weld pool volume hence a narrower bead. In this investigation, the base material considered was aluminum alloy AA 6351 T6, which is finding use in aircraft, automobile and high-speed train components. A finite element analysis was carried out using ANSYS, and the results of the FEA were compared with the experimental results. It is evident from the study that the finite element analysis using ANSYS can be effectively used to model PCGTAW process for finding temperature distribution.
Abstract: Metal matrix composites consists of a metallic matrix combined with dispersed particulate phase as reinforcement. Aluminum alloys have been the primary material of choice for structural components of aircraft since about 1930. Well known performance characteristics, known fabrication costs, design experience, and established manufacturing methods and facilities, are just a few of the reasons for the continued confidence in 7XXX Al alloys that will ensure their use in significant quantities for the time to come. Particulate MMCs are of special interest owing to the low cost of their raw materials (primarily natural river sand here) and their ease of fabrication, making them suitable for applications requiring relatively high volume production. 7XXX Al alloys are precipitation hardenable and therefore amenable for thermomechanical treatment. Al–Zn alloys reinforced with particulate materials are used in aerospace industries in spite of the drawbacks of susceptibility to stress corrosion, poor wettability, poor weldability and poor fatigue resistance. The resistance offered by these particulates for the moving dislocations impart secondary hardening in turn contributes strain hardening. Cold deformation increases lattice defects, which in turn improves the properties of solution treated alloy. In view of this, six different Al–Zn–Mg alloy composites reinforced with silica (3 wt. % and 5 wt. %) are prepared by conventional semisolid synthesizing process. The cast alloys are solution treated and aged. The solution treated alloys are further severely cold rolled to enhance the properties. The hardness and strength values are analyzed and compared with silica free Al – Zn-Mg alloys. Precipitation hardening phenomena is accelerated due to the increased number of potential sites for precipitation. Higher peak hardness and lesser aging time are the characteristics of thermo mechanically treated samples. For obtaining maximum hardness, optimum number and volume of precipitate particles are required. The Al-5Zn-1Mg with 5% SiO2 alloy composite shows better result.
Abstract: Existence of plastic equation of state has been investigated by performing a series of load relaxation tests at various temperatures using an Al-Li alloy. A plastic equation of state is first developed from a simple kinetics consideration for a mechanical activation process of a leading dislocation piled up against grain boundaries. A series of load relaxation test has been conducted at temperatures ranging from 200 to 530oC to obtain the stress-strain rate curves. A plastic equation of state has been derived from a simple consideration of dislocation kinetics and confirmed by experimental results.
Abstract: An experimental study is presented on the effect
of microstructural change on the Portevin-Le Chatelier effect
behaviour of Al-2.5%Mg alloy. Tensile tests are performed on
the as received and heat treated (at 400 ºC for 16 hours)
samples for a wide range of strain rates. The serrations
observed in the stress-time curve are investigated from
statistical analysis point of view. Microstructures of the
samples are characterized by optical metallography and X-ray
diffraction. It is found that the excess vacancy generated due
to heat treatment leads to decrease in the strain rate sensitivity
and the increase in the number of stress drop occurrences per
unit time during the PLC effect. The microstructural
parameters like domain size, dislocation density have no
appreciable effect on the PLC effect as far as the statistical
behavior of the serrations is considered.
Abstract: Minimum Quantity Lubrication (MQL) technique
obtained a significant attention in machining processes to reduce
environmental loads caused by usage of conventional cutting fluids.
Recently nanofluids are finding an extensive application in the field
of mechanical engineering because of their superior lubrication and
heat dissipation characteristics. This paper investigates the use of a
nanofluid under MQL mode to improve grinding characteristics of
Ti-6Al-4V alloy. Taguchi-s experimental design technique has been
used in the present investigation and a second order model has been
established to predict grinding forces and surface roughness.
Different concentrations of water based Al2O3 nanofluids were
applied in the grinding operation through MQL setup developed in
house and the results have been compared with those of conventional
coolant and pure water. Experimental results showed that grinding
forces reduced significantly when nano cutting fluid was used even at
low concentration of the nano particles and surface finish has been
found to improve with higher concentration of the nano particles.
Abstract: In this paper fatigue crack initiation and propagation in notched plate under constant amplitude loading through tensile residual stress field of 2024 T351 Al-alloy plate were investigated. Residual stress field was generated by plastic deformation using finite element method (FEM) where isotropic hardening in Von Mises model was applied. Simulation of fatigue behavior was made on AFGROW code. It was shown that the fatigue crack initiation and propagation were affected by level of residual stress filed. In this investigation, the presence of tensile residual stresses at notch (hole) reduces considerably the total fatigue life. It was shown that the decreasing in stress reduces the fatigue crack growth rates.
Abstract: Abrasive waterjet is a novel machining process capable of processing wide range of hard-to-machine materials. This research addresses modeling and optimization of the process parameters for this machining technique. To model the process a set of experimental data has been used to evaluate the effects of various parameter settings in cutting 6063-T6 aluminum alloy. The process variables considered here include nozzle diameter, jet traverse rate, jet pressure and abrasive flow rate. Depth of cut, as one of the most important output characteristics, has been evaluated based on different parameter settings. The Taguchi method and regression modeling are used in order to establish the relationships between input and output parameters. The adequacy of the model is evaluated using analysis of variance (ANOVA) technique. The pairwise effects of process parameters settings on process response outputs are also shown graphically. The proposed model is then embedded into a Simulated Annealing algorithm to optimize the process parameters. The optimization is carried out for any desired values of depth of cut. The objective is to determine proper levels of process parameters in order to obtain a certain level of depth of cut. Computational results demonstrate that the proposed solution procedure is quite effective in solving such multi-variable problems.
Abstract: In this paper, a set of experimental data has been used to assess the influence of abrasive water jet (AWJ) process parameters in cutting 6063-T6 aluminum alloy. The process variables considered here include nozzle diameter, jet traverse rate, jet pressure and abrasive flow rate. The effects of these input parameters are studied on depth of cut (h); one of most important characteristics of AWJ. The Taguchi method and regression modeling are used in order to establish the relationships between input and output parameters. The adequacy of the model is evaluated using analysis of variance (ANOVA) technique. In the next stage, the proposed model is embedded into a Simulated Annealing (SA) algorithm to optimize the AWJ process parameters. The objective is to determine a suitable set of process parameters that can produce a desired depth of cut, considering the ranges of the process parameters. Computational results prove the effectiveness of the proposed model and optimization procedure.
Abstract: The current of professional bicycle pedal-s
manufacturing model mostly used casting, forging, die-casting
processing methods, so the paper used 7075 aluminum alloy which is
to produce the bicycle parts most commonly, and employs the
rigid-plastic finite element (FE) DEFORMTM 3D software to simulate
and to analyze the professional bicycle pedal design. First we use Solid
works 2010 3D graphics software to design the professional bicycle
pedal of the mold and appearance, then import finite element (FE)
DEFORMTM 3D software for analysis. The paper used rigid-plastic
model analytical methods, and assuming mode to be rigid body. A
series of simulation analyses in which the variables depend on
different temperature of forging billet, friction factors, forging speed,
mold temperature are reveal to effective stress, effective strain, damage
and die radial load distribution for forging bicycle pedal. The analysis
results hope to provide professional bicycle pedal forming mold
references to identified whether suit with the finite element results for
high-strength design suitability of aluminum alloy.
Abstract: In this study, we used shape memory alloys as
actuators to build a biomorphic robot which can imitate the motion of
an earthworm. The robot can be used to explore in a narrow space.
Therefore we chose shape memory alloys as actuators. Because of the
small deformation of a wire shape memory alloy, spiral shape memory
alloys are selected and installed both on the X axis and Y axis (each
axis having two shape memory alloys) to enable the biomorphic robot
to do reciprocating motion. By the mechanism we designed, the robot
can increase the distance as it moves in a duty cycle. In addition, two
shape memory alloys are added to the robot head for controlling right
and left turns. By sending pulses through the I/O card from the
controller, the signals are then amplified by a driver to heat the shape
memory alloys in order to make the SMA shrink to pull the mechanism
to move.
Abstract: The fabrication of porous NiTi shape memory alloys (SMAs) from elemental powder compacts was conducted by selfpropagating high temperature synthesis (SHS). Effects of the preheating temperature and the chamber pressure on the combustion characteristics as well as the final morphology and the composition of products were studied. The samples with porosity between 56.4 and 59.0% under preheating temperature in the range of 200-300°C and Ar-gas chamber pressure of 138 and 201 kPa were obtained. The pore structures were found to be dissimilar only in the samples processed with different preheating temperature. The major phase in the porous product is NiTi with small amounts of secondary phases, NiTi2 and Ni4Ti3. The preheating temperature and the chamber pressure have very little effect on the phase constituent. While the combustion temperature of the sample was notably increased by increasing the preheating temperature, they were slightly changed by varying the chamber pressure.
Abstract: Laser beam forming is a novel technique developed for the joining of metallic components. In this study, an overview of the laser beam forming process, areas of application, the basic mechanisms of the laser beam forming process, some recent research
studies and the need to focus more research effort on improving the
laser-material interaction of laser beam forming of titanium and its
alloys are presented.
Abstract: In this paper, we proposed a method for detecting consistency violation between UML state machine diagrams and communication diagrams using Alloy. Using input language of Alloy, the proposed method expresses system behaviors described by state machine diagrams, message sequences described by communication diagrams, and a consistency property. As a result of application for an example system, we confirmed that consistency violation could be detected using Alloy correctly.
Abstract: Superplastic deformation and high temperature load
relaxation behavior of coarse-grained iron aluminides with the
composition of Fe-28 at.% Al have been investigated. A series of load
relaxation and tensile tests were conducted at temperatures ranging
from 600 to 850oC. The flow curves obtained from load relaxation
tests were found to have a sigmoidal shape and to exhibit stress vs.
strain rate data in a very wide strain rate range from 10-7/s to 10-2/s.
Tensile tests have been conducted at various initial strain rates ranging
from 3×10-5/s to 1×10-2/s. Maximum elongation of ~500 % was
obtained at the initial strain rate of 3×10-5/s and the maximum strain
rate sensitivity was found to be 0.68 at 850oC in binary Fe-28Al alloy.
Microstructure observation through the optical microscopy (OM) and
the electron back-scattered diffraction (EBSD) technique has been
carried out on the deformed specimens and it has revealed the
evidences for grain boundary migration and grain refinement to occur
during superplastic deformation, suggesting the dynamic
recrystallization mechanism. The addition of Cr by the amount of 5
at.% appeared to deteriorate the superplasticity of the binary iron
aluminide. By applying the internal variable theory of structural
superplasticity, the addition of Cr has been revealed to lower the
contribution of the frictional resistance to dislocation glide during high
temperature deformation of the Fe3Al alloy.