Diran Apelian

Fatigue behavior of A356-T6 aluminum cast alloys. Part I. Effect of casting defects

Abstract The influence of casting defects on the room temperature fatigue performance of a Sr-modified A356-T6 casting alloy has been studied using un-notched polished cylindrical specimens. The numbers of cycles to failure of materials with various secondary arm spacings (SDAS) were investigated as a function of stress amplitude, stress ratio, and casting defect size. To produce pore-free samples, HIP-ed and Densal™ treatments were applied prior to the T6 heat treatment. It was observed that casting defects have a detrimental effect on fatigue life by shortening not only the crack propagation period, but also the initiation period. Castings with defects show at least an order of magnitude lower fatigue life compared to defect-free ones. The decrease in fatigue life is directly correlated to the increase of defect size. HIP-ed alloys show much longer fatigue lives compared to non-HIP-ed ones. There seems to exist a critical defect size for fatigue crack initiation, below which fatigue crack initiates from other competing initiators such as eutectic particles and slip bands. A fracture mechanics approach has been used to determine the number of cycles necessary to propagate a fatigue crack from a casting defect to final failure. Fatigue life of castings containing defects can be quantitatively predicted using the size of the defects. Moreover, the fatigue fracture behavior of aluminum castings is well described by Weibull statistics. Crack originating from different defects (such as porosity and oxide films) can be readily identified from the Weibull modulus and the characteristic fatigue life. Compared with oxide films, porosity is more detrimental to fatigue life.

Analysis of the spray deposition process

Abstract Net or near net shape products can be manufactured by technologies involving solidification processing, metal forming, paniculate processing, and droplet consolidation. One example of droplet consolidation is spray deposition in the Osprey tm mode. In this process, a stream of liquid metal is atomized by an inert gas to form a spray of molten droplets; these are accelerated towards a substrate where they impinge and consolidate. An integral model for the Osprey tm spray deposition process has been developed using established theoretical principles. Mathematical models describe the interconnected processes of droplet-gas interactions in flight and subsequent droplet consolidation on the substrate. The models predict droplet velocity and temperature as a function of flight distance, the extent of droplet solidification on arrival at the substrate, and temperature distribution in the consolidated material during deposition. This approach demonstrates the utility of modeling studies in order to establish quantitative guidelines for optimization of the process in terms of the evolution of microstructure in droplet consolidation.

Fatigue behavior of A356/357 aluminum cast alloys. Part II – Effect of microstructural constituents

Abstract A quantitative study of the interactions between microstructural features such as secondary dendrite arm spacing (SDAS), eutectic structure, matrix strength, and fatigue behavior of two Al–7% Si–Mg casting alloys with magnesium contents of 0.4% and 0.7%, respectively, has been conducted. In the absence of casting defects, the influence of microstructural features on the fatigue performance becomes more pronounced. The degree and rate of microdamage (microcracking) is strongly affected by the strength of the matrix, and especially by the eutectic particle size, morphology, and distribution (clustering). A soft matrix (under-aged alloys) will generate more local microdamage compared to a peak-aged one. Large and elongated eutectic particles present in unmodified alloys result in lower fatigue lives. A decrease of fatigue life with increasing Mg and Fe content is observed, mainly due to the increased sizes of Fe-rich intermetallic particles. Microstructures with similar eutectic particle size and morphology as the Sr-modified ones, show a minimum fatigue life at intermediate SDAS values (∼60 μm), which is related to the continuity of particles on the dendrite cell boundaries. For coarser microstructures ( SDAS >60 μ m), the increase in fatigue life is attributed to the reduced damage rate along the cell boundaries.

Processing-microstructure relationships in compocast magnesium/SiC

Compocasting experiments were conducted to investigate the feasibility of the process as applied to the AZ91 D magnesium alloy-SiC particles system. Processing-macro/ microstructure relationships were examined. Three temperature-time processing sequences were investigated: stirring temperature maintained above liquidus; stirring temperature in the semi-solid temperature range; and lastly, an imposed temperature rise above the liquidus after stirring in the mushy zone. Stirring temperature and particle size significantly affect spatial particle distribution and porosity level. The easy incorporation and even dispersion of particles in the matrix suggest good wetting of SiC particles by the magnesium matrix. Impact fracture surfaces show strong bonding at the particle/matrix interface. A reaction takes place at the matrix/particle interface whilst stirring at temperatures above the liquidus. Reaction products have been identified. Finally, the mechanical properties of a compocast ingot which was extruded have been studied and are reported. This work clearly points out that there is a preferred procedure to follow during compocasting to obtain an optimum microstructure. The procedure is to add the reinforcing materials to the semi-solid alloy followed by stirring above the liquidus temperature.

Spray casting : an integral model for process understanding and control

Abstract This paper discusses the scientific and technological aspects of spray casting. An integral model is presented which encompasses and addresses each unit stage of the overall process, namely atomization, spray, consolidation, shape, pre-form solidification and microstructure. The atomization model uses an empirical relationship to correlate the droplet size distribution with spray-forming process parameters. The spray model quantities the condition of the spray upon impact with the substrate; the condition of the spray is represented in terms of the fraction of liquid in the spray and the proportion of solid, mushy and liquid droplets. The sticking efficiency is obtained from the consolidation model and was found to be a critical parameter which governs the yield, shape and microstructure of sprayed deposits. The shape model dynamically predicts the evolution of pre-form shape for different combinations of substrate and spray motion. The model for pre-form solidification uses a two-dimensional heat transfer analysis to compute temperature-liquid fraction profiles in the perform. The microstructure model predicts the final grain or cell size in sprayed deposits as a function of the local solidification time. Individual models are interlinked to identify and asses the effect of critical process parameters on the integrity of spray-cast product.

A novel method to recycle mixed cathode materials for lithium ion batteries

The rechargeable lithium ion (Li-ion) battery market was

Processing Effects in Spray Casting of Steel Strip

11.8 billion in 2011 and is expected to increase to

SPRAY CASTING OF STEEL STRIP : PROCESS ANALYSIS

50 billion by 2020. With developments in consumer electronics as well as hybrid and electric vehicles, Li-ion batteries demand will continue to increase. However, Li-ion batteries are not widely recycled because currently it is not economically justifiable (in contrast, at present more than 97% lead-acid batteries are recycled). So far, no commercial methods are available to recycle Li-ion batteries with different cathode chemistries economically and efficiently. Considering our limited resources, environmental impact, and national security, Li-ion batteries must be recycled. A new low temperature methodology with high efficiency is proposed in order to recycle Li-ion batteries economically and thus commercially feasible regardless of cathode chemistry. The separation and synthesis of cathode materials (the most valuable material in Li-ion batteries) from the recycled components are the main focus of this study. The results show that the developed recycling process is practical with high recovery efficiencies, and that it is viable for commercial adoption.

Molten metal processing of advanced cast aluminum alloys

Spray cast strip of AISI 1026 and M2 has been produced by the Osprey™ process under controlled conditions of deposition. Droplet flight distance was varied over the range 325 to 475 mm and strip was spray cast onto either planar or roller substrates of copper and steel. Substrate surface speed was in the range of 0.02 to 1 m/s, which produced strip of 0.025 to 0.0007 m thickness, respectively, with a width of 0.1 m. Surface condition, microstructure, and extent of porosity in the strip were characterized as a function of distance from top and bottom surfaces. The microstructure of the strip is comprised of three regions —a ‘chill zone’ at the bottom surface consisting of fine grains of ferrite and pearlite with numerous pores; a middle region containing equiaxed or columnar grains, Widmanstätten plates, and fine pores; and a top region made up of equiaxed grains comprising Widmanstätten plates and a few pores. Process variables of primary importance with respect to microstructural integrity and surface condition of the strip are substrate velocity, the surface condition of the substrate, flight distance, and the uniformity of droplet flux in the spray cone. Flight distance determines the amount of cooling of the droplets by the atomizing gas and, therefore, the average temperature of the spray incident on the substrate. Microstructure is determined by convective cooling of the spray, and, to a lesser extent, by the substrate velocity and temperature. The processing conditions required to spray cast strip with a homogeneous microstructure and uniform thickness/surface condition have been established.

Magnesium rheocasting: a study of processing-microstructure interactions

Near-net shape manufacturing (NNSM) of thin steel sections by spray casting eliminates casting as a separate step with attendant improved microstructures and properties and significant energy savings. The process involves atomization of a stream of liquid metal and deposition of droplets in the generated spray on a moving substrate at mass flow rates of 0.25 to 2.5 kg/s. In this paper, NNSM of steel strip by the Osprey spray casting process is investigated by combining numerical simulation and experiments. Critical input parameters for the computation are quantified utilizing existing state-of-the-art mathematical models and specific experiments. Numerical computation of the consolidation of the spray at the substrate during manufacture of thin sections is conducted using bothcontinuum anddiscrete event (“splat solidification”) approaches to predict: (1) variation of strip thickness in the transverse dimension and (2) isotherms and cooling rates across the strip thickness. Predicted geometries of the strip simulated by the continuum model are in good agreement with measurements. Predicted isotherms in narrow strip by the continuum approach are in reasonable agreement with thermocouple measurements for intermediate thicknesses (2 to 5 mm), and the observed microstructure is consistent with predicted cooling rates. The discrete event model predicts significantly higher cooling rates than the continuum model in the basal portion of the strip. This is consistent with the observed grain size in thin strip (<l-mm thick) and in the basal portion of thick strip. Beyond a threshold thickness, however, the discrete event model confirms the formation and persistence of a partially liquid layer at the growing surface of the deposit with an attendant decrease in the cooling rate. The influence of critical parameters on “splat solidification” is analyzed and assessed.