Precipitation processes in Al-Cu-Mg-Sn and Al-Cu-Mg-Sn-Ag

Microalloying trace elements into aluminum alloys have been shown to improve mechanical properties by altering the precipitation process. Here, trace amounts of Sn and (Sn + Ag) have been added to Al-1.1Cu-1.7Mg (at.%) and the effects have been investigated by a combination of hardness testing and transmission electron microscopy (TEM). Hardness testing shows that the addition of Sn increases the hardness throughout the ageing process, and in combination with Ag, further increases the hardness and shortens the time to reach the peak hardness. The increase in hardness via Sn microalloying is attributed to the homogeneous distribution of S phase (Al2CuMg) precipitates. In the alloy microalloyed with both Sn and Ag, the microstructure is dominated by homogeneously distributed Ω phase (Al2Cu) precipitates in the peak strengthened condition. Given that neither spherical β-Sn precipitates, nor any other obvious nucleation sites for the Ω phase precipitates were observed using TEM, the mechanism for development of such homogeneous precipitation remains to be determined.

Performance of constructed evaporation ponds for disposal of smelter waster water: a case study at Portland Aluminum, Victoria, Australia

The construction of evaporative ponds and wetlands for the disposal of waste water high in ionic concentrations is a waste disposal strategy currently considered by many industries. However, the design, construction and management of these ponds and wetlands are not straightforward as complex chemical interactions result in both spatial and temporal changes in water quality. The effects of evaporation and drainage on the water quality in two constructed ponds, an adjacent man-made wetland and local groundwater at Portland Aluminium were investigated. The minimum volume of water entering the ponds during the study period was 0.96±0.16 ML per month. The predicted theoretical evaporative capacity of the two ponds was calculated to be 0.30±0.07 ML per month. More water enters the ponds than it is theoretically possible to evaporate under the ambient weather conditions at Portland, yet the ponds do not overflow, suggesting percolation through the pond lining. No spatial differences in solute concentrations (fluoride, sulphate, bicarbonate, carbonate, sodium, potassium, calcium, and magnesium ions) were found within the waters of either pond, although temporal differences were apparent. The results support the conclusion that the ponds are not impermeable, and that much of the waste water entering the ponds is being lost through seepage. The impacts on local groundwater chemistry of this seepage are addressed. Significant correlations exist between solute presence within and between the ponds, wetland and groundwater. Fluoride and sulphate concentrations were significantly higher in pond waters throughout the duration of the experiment. Pond sediments revealed a high degree of spatial and temporal heterogeneity in the concentration of all monitored ions resulting from the chemical heterogeneity of the material making up the pond linings. Adsorption isotherms for fluoride indicate that the adsorption capacity of the pond linings remains high for this ion. Implications for the management of waste water by this strategy are discussed.

Protein quality and physico-functionality of Australian sweet lupin (Lupinus angustifolius cv. Gungurru) protein concentrates prepared by isoelectric precipitation or ultrafiltration

The protein quality and physico-functional properties of Australian sweet lupin protein concentrates, prepared by isoelectric precipitation or ultrafiltration, were assessed. The ultrafiltration process resulted in a higher yield of protein than did the isoelectric precipitation process. The lupin kernel and the two lupin protein concentrates had similar essential amino acid compositions that were inferior to ideal human requirements. True digestibilities of the isoelectrically precipitated (ISO) and the ultrafiltered (UF) lupin protein concentrates were similar but significantly higher (P<0.05) than that of casein. Net protein utilisations (NPU) of the ISO and UF protein concentrates were similar but significantly lower (P<0.05) than that of casein. The UF protein concentrate had higher protein solubility than did the ISO protein concentrate (P<0.05). Low foaming capacity, low viscosity, but high emulsification capacity (particularly at low pH) were observed for lupin protein concentrates.

Effects of the density on compressive properties in cellular aluminum produced by the sintering method

The cellular aluminum materials with relative densities of 0.1"-'0.25 were fabricated by the sintering method and effects of the density on mechanical properties of the cellular aluminum were investigated by compressive tests. The cellular aluminum exhibited a plateau region with a nearly constant flow stress. The stress in the plateau region increased with increasing relative density, on the other hand, the densification strain decreased with increasing relative density. Observation of the deformed cells revealed that the cell walls were bent. Besides, the stress in the plateau region was proportional to 1.9 power of the density. These suggest that plastic collapse is dominated by bending of the cell walls for the cellular aluminum produced by the sintering method.

Machine vision system for automatic inspection of surface defects in aluminum die casting

A camera based machine vision system for the automatic inspection of surface defects in aluminum die casting is presented. The system uses a hybrid image processing algorithm based on mathematic morphology to detect defects with different sizes and shapes. The defect inspection algorithm consists of two parts. One is a parameter learning algorithm, in which a genetic algorithm is used to extract optimal structuring element parameters, and segmentation and noise removal thresholds. The second part is a defect detection algorithm, in which the parameters obtained by a genetic algorithm are used for morphological operations. The machine vision system has been applied in an industrial setting to detect two types of casting defects: parts mix-up and any defects on the surface of castings. The system performs with a 99% or higher accuracy for both part mix-up and defect detection and is currently used in industry as part of normal production.

Deformation behavior of nanostructured aluminum alloy processed by severe plastic deformation

Microstructure and deformation behavior of the commercial aluminum-based Al7.5%Zn–2.7%Mg–2.3%Cu–0.15%Zr alloy subjected to high pressure torsion (HPT) were studied in the present work. A small grain size less than 100 nm, high level of internal stresses and presence of second phase nanoparticles were revealed by transmission electron microscopy (TEM) and X-ray diffraction (XRD). The nanostructured alloy processed by HPT exhibits tensile strength of 800 MPa and ductility of 20% at optimal temperature-strain rate conditions. Unusual influence of a short pre-annealing on tensile strength and ductility of as-processed alloy is discussed.

An investigation of the native oxide of aluminum alloy 7475-T7651 using XPS, AES, TEM, EELS, GDOES, RBS.

The native oxide on the rolled aerospace aluminum alloy 7475-T7651 was characterized using a variety of different techniques, including X-ray Photoelectron Spectrometry (XPS), Auger Electron Spectrometry (AES), Transmission Electron Microscopy (TEM), Electron Energy Loss Spectrometry (EELS), Glow Discharge Optical Emission Spectrometry (GDOES), and Rutherford Backscattered Spectrometry (RBS). All techniques revealed that the native oxide layer is magnesium-rich and is probably a mixture of magnesium and aluminum–magnesium oxides.1 The oxide layer was found to be of nonuniform thickness due to the rolling process involved during the manufacture of this sheet alloy; this complicates analysis using techniques which have poor spatial resolution. Direct thickness measurement from cross-sectional TEM reveals an oxide thickness which varies between 125 and 500 nm. This large variation in thickness was also evident from GDOES and AES depth profiles as well asthe RBS data. Both XPS and RBS also show evidence for the presence of heavy metals in the oxide.

Compressive deformation behaviour of a closed-cell aluminum

The mechanical properties of a closed-cell aluminium foam were investigated by compressive tests, and the deformation behaviours of the aluminium foams were studied using Xray microtomography. The results indicate that the deformation of the aluminium foams under compressive loading was localized in narrow continuous deformation bands having widths of order of a cell diameter. The cells in the deformation bands collapsed by a mixed deformation mechanism, which includes mainly bending and minor buckling and yielding. Different fractions of the three deformation modes led to variations in the peak stress and energy absorption for different foam samples with the same density. It was also found that the cell morphology affects the deformation mechanism significantly, whilst the cell size shows little influence.

Processing and mechanical properties of hollow sphere aluminum foams

Hollow sphere metallic foams are a new class of cellular material that possesses the attractive advantages of uniform cell size distribution and regular cell shape. These result in more predictable physical and mechanical properties than those of cellular materials with a random cell size distribution and irregular cell shapes. In the present study, single aluminum hollow spheres with three kinds of sphere wall thickness as 0.1 mm, 0.3 mm and 0.5 mm were processed by a new pressing method. Hollow sphere aluminum foam samples were prepared by bonding together single hollow spheres with simple cubic packing (SC) and body-centered cubic packing (BCC). Compressive tests were carried out to evaluate the deformation behaviors and mechanical properties of the hollow sphere aluminum foams. Effects of the sphere wall thickness and packing style on the mechanical properties were investigated.

Geometrical effects on residual stresses in 7050-T7451 aluminum alloy rods subject to laser shock peening

Laser shock peening (LSP) is an emerging surface treatment technology for metallic materials, which appears to produce more significant compressive residual stresses than those from the conventional shot peening (SP) for fatigue, corrosion and wear resistance, etc. The finite element method has been applied to simulate the laser shock peening treatment to provide the overall numerical assessment of the characteristic physical processes and transformations. However, the previous researchers mostly focused on metallic specimens with simple geometry, e.g. flat surface. The current work investigates geometrical effects of metallic specimens with curved surface on the residual stress fields produced by LSP process using three-dimensional finite element (3-D FEM) analysis and aluminium alloy rods with a middle scalloped section subject to two-sided laser shock peening. Specimens were numerically studied to determine dynamic and residual stress fields with varying laser parameters and geometrical parameters, e.g. laser power intensity and radius of the middle scalloped section. The results showed that the geometrical effects of the curved target surface greatly influenced residual stress fields.

Effect of surface roughness of Ti, Zr, and TiZr on apatite precipitation from simulated body fluid

Some of the critical properties for a successful orthopedic or dental implant material are its biocompatibility and bioactivity. Pure titanium (Ti) and zirconium (Zr) are widely accepted as biocompatible metals, due to their non-toxicity. While the bioactivity of Ti and some Ti alloys has been extensively investigated, there is still insufficient data for Zr and titanium-zirconium (TiZr) alloys. In the present study, the bioactivity, that is, the apatite forming ability on the alkali and heat treated surfaces of Ti, Zr, and TiZr alloy in simulated body fluid (SBF), was studied. In particular, the effect of the surface roughness characteristics on the bioactivity was evaluated for the first time. The results indicate that the pretreated Ti, Zr and TiZr alloy could form apatite coating on their surfaces. It should be noted that the surface roughness also critically affected the bioactivity of these pretreated metallic samples. A surface morphology with an average roughness of approximately 0.6 microm led to the fastest apatite formation on the metal surfaces. This apatite layer on the metal surface is expected to bond to the surrounding bones directly after implantation.

Re-examination of the effect of NbC precipitation on shape memory in Fe-Mn-Si-based alloys

Current literature pertaining to the shape memory effect in the Fe–Mn–Si-based system is critically discussed. It is argued that the
enhanced shape memory previously attributed to NbC precipitation is mainly due to the associated thermo-mechanical treatments.
It is concluded that the thermo-mechanical processing of the alloy is the dominant factor that determines the shape memory effect in
this alloy system.

Geometrical effects on residual stresses in 7050-T7451 aluminum alloy rods subject to laser shock peening

Laser shock peening (LSP) is an emerging surface treatment technology for metallic materials, which appears to produce more significant compressive residual stresses than those from the conventional shot peening (SP) for fatigue, corrosion and wear resistance, etc. The finite element method has been applied to simulate the laser shock peening treatment to provide the overall numerical assessment of the characteristic physical processes and transformations. However, the previous researchers mostly focused on metallic specimens with simple geometry, e.g. flat surface. The current work investigates geometrical effects of metallic specimens with curved surface on the residual stress fields produced by LSP process using three-dimensional finite element (3-D FEM) analysis and aluminium alloy rods with a middle scalloped section subject to two-sided laser shock peening. Specimens were numerically studied to determine dynamic and residual stress fields with varying laser parameters and geometrical parameters, e.g. laser power intensity and radius of the middle scalloped section. The results showed that the geometrical effects of the curved target surface greatly influenced residual stress fields.