Juan Asensio-Lozano

Effect of Processing Steps on the Mechanical Properties and Surface Appearance of 6063 Aluminium Extruded Products

6063 aluminum anodized extrusions may exhibit a common surface defect known as streaking, characterized by the formation of narrow bands with a surface gloss different from the surrounding material. The origin of this banding lies in the differential surface topography produced after etching during the anodizing stage, shown to be connected to certain microstructural characteristics. The present study has attempted to determine the origin of these defects and measure the mechanical properties in these zones, properties which were either barely acceptable or did not meet the specification’s requirements. Quantitative metallography and mechanical testing, both tensile and microhardness, were used for materials assessment at the different steps of the process of manufacturing 6063 anodized extrusions. The results of this research show that nonequilibrium solidification rates during billet casting could lead to the formation of coarse eutectic Mg2Si particles which have a deleterious effect on both mechanical properties and surface appearance in the anodized condition. However, differences in the size and density of the coarse Mg2Si particles have been found to exist in the streak profile compared to the surrounding zones. The study revealed the importance of these particles in explaining the origin of the marginal or sub-marginal properties and anodizing surface defects found.

Microstructure Investigations of Streak Formation in 6063 Aluminum Extrusions by Optical Metallographic Techniques

The present study investigates the effect of the solidification strategy for AA 6063 alloy on the surface appearance of anodized extrusions. The microstructure of the samples was analyzed using both light optical microscopy and scanning electron microscopy. Results show that if heavy segregation occurs from rapid solidification, coarse Mg2Si particles form, thus reducing the potential for precipitation strengthening by the finer β-Mg2Si developed in the solid state. Differentially-strained regions formed during hot extrusion induce differences in particle size for magnesium silicide (Mg2Si) precipitates. Anodizing generates surface roughness due to Mg2Si particle dissolution and AlFeSi decohesion, which is related to both particle size and deformation. During anodizing, an oxide layer forms on the surface of the extruded products, which can lead to streak formation, usually a subject of rejection due to unacceptable heterogeneous reflectivity.

Color metallography and electron microscopy techniques applied to the characterization of 413.0 aluminum alloys.

The influence on alloy 413.0 of the refinement and modification of its microstructure was analyzed by means of several microscopy techniques, as well as the effect of the application of high pressure during solidification. For each treatment and solidification pressure condition employed, the most suitable microscopy techniques for identifying and characterizing the phases present were investigated. Color metallography and electron microscopy techniques were applied to the qualitative microstructural analysis. Volume fraction and grain size of the primary α-Al were characterized by quantitative metallographic techniques. The results show that the effect caused by applying high pressure during solidification of the alloy is more pronounced than that caused by modification and refinement of the microstructure when it solidifies at atmospheric pressure. Furthermore, it has been shown that, for Al-Si alloy characterization, when aiming to characterize the primary α-Al phase, optical color metallography observed under crossed polarized light plus a sensitive tint filter is the most suitable technique. When the goal is to characterize the eutectic Si, the use of optical color metallography or electron microscopy is equally valid. The characterization of iron-rich intermetallic compounds should preferably be performed by means of backscattered electron imaging.

Evaluation of the Heat Treatment Response of a Multiphase Hot-Rolled Steel Processed by Controlled Rolling and Accelerated Cooling

The tensile properties of hot-rolled multiphase steel after heat treatment were analyzed on a laboratory scale. Subcritical treatments applied to the hot-rolled strip revealed an increase in the yield stress and elongation with increasing temperature. Normalizing of the strip at 920°C notably improved the ductile response, while both the yield stress and the anisotropy of every property evaluated at 0°, 45°, and 90° to the rolling direction in the rolling plane were significantly reduced.

The Al-Si Phase Diagram

Binary phase diagrams “map out” the relationship between composition and phase occurrence as a function of temperature under equilibrium conditions that involve very slow heating and cooling rates. While metals production involves faster heating and cooling rates, non-equilibrium conditions, the phase diagram remains the starting point for our understanding of alloy systems as it teaches us about melting and solidification temperatures, the solidification sequence, equilibrium phases that can form, solubility limits for alloy or impurity additions and dissolution temperatures for second phases.

Microstructure Optimisation of Chill Cast Al-Si Eutectic Alloys

One of the most used alloys of the Al-Si binary system is the eutectic composition. Their properties are influenced by the development of non-equilibrium microstructures under industrial processing conditions whose main features are: the grain size and volume fraction of the primary α-Al phase [1]; the particle diameter and geometry of the primary silicon phase; the morphology of the eutectic [2-4], notably the shape of the Si cuboids, as well as the morphology of second-phase Fe based intermetallics present as contaminants in the commercial alloys. In general, the mechanical properties can be improved markedly by the addition of modifier elements that change the morphology of the eutectic Si varying it from acicular platelets seen as needles in the plane of polish, to granular Si particles [2, 5]. By adding refiner elements, it is possible to reduce the size, increase the volume fraction and disperse the tougher α-Al dendrites.

Metallographic assessment of Al-12Si high-pressure die casting escalator steps.

A microstructural characterization study was performed on high-pressure die cast specimens extracted from escalator steps manufactured from an Al-12 wt.% Si alloy designed for structural applications. Black and white, color light optical imaging and scanning electron microscopy techniques were used to conduct the microstructural analysis. Most regions in the samples studied contained globular-rosette primary α-Al grains surrounded by an Al-Si eutectic aggregate, while primary dendritic α-Al grains were present in the surface layer. This dendritic microstructure was observed in the regions where the melt did not impinge directly on the die surface during cavity filling. Consequently, microstructures in the surface layer were nonuniform. Utilizing physical metallurgy principles, these results were analyzed in terms of the applied pressure and filling velocity during high-pressure die casting. The effects of these parameters on solidification at different locations of the casting are discussed.

Morphological Optimization of Graphite in Spheroidal Cast Iron with a Modulus of 4 cm used in the Manufacture of Wind Turbine Hubs

Abstract The aim of this study was the morphological optimization of graphite by generating knowledge able to determine which metallurgical manufacturing factors have a significant influence on the geometry of the graphite precipitated in spheroidal grey cast irons with a mass coefficient of 4, used in the manufacture of wind turbine hubs. The research study was conducted on an industrial scale applying a fractional Design of Experiments (DoE) with 7 factors, 16 experiments and resolution IV. The following constitute the most noteworthy novel results obtained in the study. The effect of La on the graphite “counts” is strengthened by pre-inoculation of the molten iron bath with SiC. Furthermore, graphite counts can be increased under low carbon equivalent conditions using post-inoculants containing Zr. Finally, high values of Mn lead to a reduction in the size of the precipitated graphite.

Characterization of Q & T Steel Poleshoes Manufactured by Sand Casting

Abstract This paper presents a study of the microstructural and mechanical characterization of the GS 35 CrMoV 10 4 alloy employed in the manufacture of sand-cast poleshoes for 4-pole synchronous electric power generators working at a frequency of 60 Hz. In addition, the most appropriate treatment for ensuring compliance with the technical specifications defined in DIN Standard No. 1.7755 has been designed.