Influence of heat treatment and mechanical cycling on hardness and fracture analysis of Ti35Nb5Zr casting alloy

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Effect of Si additions and heat treatment on the mechanical behaviour of an Al-5Mg casting alloy

Adding 1%Si to binary Al-5Mg alloy slightly increases the yield stress in comparison with the Si free alloy but dramatically reduces the ductility and tensile strength due to the formation of brittle eutectic Mg2Si and pi-Al8FeMg3Si6 particles. Adding 3%Si slightly reduces the yield stress, presumably due to some of the Mg being tied up in the Mg2Si, and further reduces the ductility due to the increased volume fraction of intermetallics. Solution heat treatment at 436degreesC decreases the yield stress of both Si containing alloys, and slightly increases the ductility in the alloy with 3%Si. Subsequent ageing at 180degreesC has no further effects on the strength or ductility. The loss in strength of the heat treated alloys seems to be due to overageing Of Mg2Si precipitates dispersed in the bulk of the alloy. (C) 2004 W. S. Maney Son Ltd.

A Comparison of Deep Drawing and Ironing of Metal Alloy Strip Produced conventionally and Non-conventionally via Semi Solid Material Processing

A semi solid thin strip continuous casting process was used to obtain 50%wt Pb/50%wtSn strip by single and twin roll processing at speed of 15 m/min. A 50%wt Pb/50%wtSn plate ingot was also cast for rolling conventionally into strips of 1.4 mm thickness and 45 mm width for comparison with those achieved non-conventionally. This hypoeutectic alloy has a solidification interval and fusion temperature of approximately 31 degrees C and 215 degrees C respectively. The casting alloy temperature was around 280 degrees C as measured by a type K immersion thermocouple prior to pouring into a tundish designed to maintain a constant melt flow on the cooling slope during semi solid material production. A nozzle with a weir ensures that the semi solid material is dragged smoothly by the lower roll, producing strip with minimum contamination of slag/oxide. The temperatures of the cooling slope and the lower roll were also monitored using K type thermocouples. The coiled semi solid strip, which has a thickness of 1.5 mm and 45 mm width, was rolled conventionally in order to obtain 1.2 mm thick strip. The coiled thixorolled strip had a thickness of 1.2 mm and achieved practically the same width as the conventional strips. Blanks of 40 mm diameter were cut from the strips in a mechanical press, ready for deep drawing and ironing for mechanical characterization. All the strips achieved from non-conventional processing had the same mechanical performance as those achieved conventionally. The limiting drawing ratio (LDR) achieved was approximately 2.0 for all strips. Microscopy examination was made in order to observe phase segregation during processing.

Chemical composition modification of casting aluminium alloys for engine applications

The research activities were focused on evaluating the effect of Mo addition to mechanical properties and microstructure of A354 aluminium casting alloy. Samples, with increasing amount of Mo, were produced and heat treated. After heat treatment and exposition to high temperatures samples underwent microstructural and chemical analyses, hardness and tensile tests. The collected data led to the optimization of both casting parameters, for obtaining a homogeneous Mo distribution in the alloy, and heat treatment parameters, allowing the formation of Mo based strengthening precipitates stable at high temperature. Microstructural and chemical analyses highlighted how Mo addition in percentage superior to 0.1% wt. can modify the silicon eutectic morphology and hinder the formation of iron based β intermetallics. High temperature exposure curves, instead, showed that after long exposition hardness is slightly influenced by heat treatment while the effect of Mo addition superior to 0,3% is negligible. Tensile tests confirmed that the addition of 0.3%wt Mo induces an increase of about 10% of ultimate tensile strength after high temperature exposition (250°C for 100h) while heat treatments have slight influence on mechanical behaviour. These results could be exploited for developing innovative heat treatment sequence able to reduce residual stresses in castings produced with A354 modified with Mo.

Influence of calcium on the microstructure and properties of an Al-7Si-0.3Mg-xFe alloy

The effect of Ca addition on the microstructure, physical characteristics (density/porosity), and mechanical properties (tensile and impact strength) has been investigated in an Al-7Si-0.3Mg-xFe (x = 0.2, 0.4, and 0.7) alloy. The size of Al-Fe intermetallic platelets (beta-Al5FeSi) increased with increasing Fe content. The addition of Ca modified the eutectic microstructure and also reduced the size of intermetallic Fe-platelets, causing improved elongation and impact strengths. A low level of Ca addition (39 ppm) reduced the porosity of the alloys. The tensile strength was decreased marginally with Ca addition. However, Ca addition improved the ductility of the alloy by 18.3, 16.7, and 44 pet and the impact strength by 44, 48, and 15.8 pct for Fe contents of 0.2, 0.4, and 0.7 pct, respectively.

Dissolution, recovery and fade of Sr master alloys in Al-7Si-0.5Mg casting alloys

A number of commercial Al-Sr master alloys of differing Sr content and product form have been added to Al-7Si-0.5Mg casting alloy melts and held at constant temperature for periods up to 7 hours following the addition. The master alloys were added to achieve a specific Sr target level of 200 ppm, and the melts were held at various temperatures (most at 710ºC, but also 670, 690, 740 and 770ºC). A total of thirty six melt trials were conducted and during each trial chill-cast disc samples were taken throughout for subsequent chemical analysis. The Sr concentration versus time data of each trial has been considered in terms of Sr dissolution/recovery behaviour, as well as Sr loss/fade. Trends in the data are identified and discussed, and implications for industrial practices are suggested.

Knowledge-based system for casting process selection

Design of casting entails the knowledge of various interacting factors that are unique to casting process, and, quite often, product designers do not have the required foundry-specific knowledge. Casting designers normally have to liaise with casting experts in order to ensure the product designed is castable and the optimum casting method is selected. This two-way communication results in long design lead times, and lack of it can easily lead to incorrect casting design. A computer-based system at the discretion of a design engineer can, however, alleviate this problem and enhance the prospect of casting design for manufacture. This paper proposes a knowledge-based expert system approach to assist casting product designers in selecting the most suitable casting process for specified casting design requirements, during the design phase of product manufacture. A prototype expert system has been developed, based on production rules knowledge representation technique. The proposed system consists of a number of autonomous but interconnected levels, each dealing with a specific group of factors, namely, casting alloy, shape and complexity parameters, accuracy requirements and comparative costs, based on production quantity. The user interface has been so designed to allow the user to have a clear view of how casting design parameters affect the selection of various casting processes at each level; if necessary, the appropriate design changes can be made to facilitate the castability of the product being designed, or to suit the design to a preferred casting method.

Análise mecânica e microestrutural das ligas de cobalto-cromo de uso odontológico após sucessivas refundições

The cobalt-chromium alloy is extensively used in the Odontology for the confection of metallic scaffolding in partial removable denture. During the last few years, it has been reported an increasing number of premature imperfections, with a few months of prosthesis use. The manufacture of these components is made in prosthetic laboratories and normally involves recasting, using parts of casting alloy and parts of virgin alloy. Therefore, the objective of the present study was to analyze the mechanical properties of a commercial cobalt-chromium alloy of odontological use after successive recasting, searching information to guide the dental prosthesis laboratories in the correct manipulation of the cobalt-chromium alloy in the process of casting and the possible limits of recasting in the mechanical properties of this material. Seven sample groups were confectioned, each one containing five test bodies, divided in the following way: G1: casting only with virgin alloy; G2: casting with 50% of the alloy of the G1 + 50% of virgin alloy; G3: casting with 50% of the alloy of the G2 + 50% of virgin alloy; G4: casting with 50% of the alloy of the G3 + 50% of virgin alloy; G5: 50% of alloy of the G4 + 50% of virgin alloy; G6: 50% of alloy of the G5 + 50% of virgin alloy and finally the G7, only with recasting alloy. The modifications in the mechanical behavior of the alloy were evaluated. Moreover, it was carried the micro structural characterization of the material by optic and electronic scanning microscopy, and X ray diffraction.and fluorescence looking into the correlatation of the mechanical alterations with structural modifications of the material caused by successive recasting process. Generally the results showed alterations in the fracture energy of the alloy after successive recasting, resulting mainly of the increasing presence of pores and large voids, characteristic of the casting material. Thus, the interpretation of the results showed that the material did not reveal significant differences with respect to the tensile strength or elastic limit, as a function of successive recasting. The elastic modulus increased from the third recasting cycle on, indicating that the material can be recast only twice. The fracture energy of the material decreased, as the number of recasting cycles increased. With respect to the microhardness, the statistical analyses showedno significant differences. Electronic scanning microscopy revealed the presence of imperfections and defects, resulting of the recasting process. X ray diffraction and fluorescence did not show alterations in the composition of the alloy or the formation of crystalline phases between the analyzed groups. The optical micrographs showed an increasing number of voids and porosity as the material was recast. Therefore, the general conclusion of this study is that the successive recasting of of Co-Cr alloys affects the mechanical properties of the material, consequently leading to the failure of the prosthetic work. Based on the results, the best recommendadition is that the use of the material should be limited to two recasting cycles

Considerações gerais sobre prótese fixa adesiva

The success rate of resin-bonded fixed partial dentures is directly related to the adhesive system and the tooth preparation design for good retention. These resin-bonded bridges represent a prosthodontic alternative, based on their costeffectiveness, conservative techniques, and ease of laboratory manufacturing. Through a thorough review of the literature, this study aimed to report on cavity designs, types of materials used, and the advantages and disadvantages of the resin-bonded fixed partial denture. One of significant advantages of the resin-bonded fixed partial dentures is the conservation of the tooth structure, whereas its main disadvantage includes aesthetic limitations, given that the alloy may in fact be visible. Preparation design, cement type, and casting alloy type, as well as surface treatment, are among the factors that influence the longevity of resin-bonded fixed partial dentures. Treatments with resin-bonded fixed partial dentures present a bright outlook regarding the conservation of tooth structures, as well as a high level of success.

Manufacture of high pressure die-cast radio frequency filter bodies

The manufacture of a radio frequency filter box using high pressure die casting (HPDC) is compared to the traditional high speed machining route. This paper describes an industrial exercise that concluded HPDC to be an economical and appropriate method to produce larger volumes of thin-walled telecommunications components. Modifications to the component design were made to make the component suitable for the HPDC process. Development of the die design through simulation modelling is described. The wrought alloy was replaced by near-eutectic Al-Si die casting alloy that was found to give better temperature stability performance. Apart from the economic benefits, HPDC was found to give lower filter efficiency losses through better surface finish. The effects of HPDC process variables, such as intensification pressure and injection piston velocity, on component quality, particularly porosity levels, were investigated. The pressure was analysed in terms of HPDC machine set pressure and the pressure measured in the die cavity by pressure sensors. Porosity was found to decrease with increased pressure and slightly increase with higher casting velocities.

Damping in zinc-based alloys

The damping behaviour of the cold chamber pressure-die-casting alloy: M3, ZA8, ZA27, ZM11, Cosmal, Supercosmal and newly developed ZA27H1 and ZA27H2 was investigated at room temperature and elevated temperatures of up to 90 degrees C. The damping properties of the alloys were established at all temperatures. Formulas were established to predict damping properties of each alloy at any given temperature. The prediction formulae were found to be very accurate. All of the experimental alloys were heterogenous with varying microstructure and grain size; this was the major contribution and dominated the damping properties of the alloys. Super cosmal and ZA27 possessed the highest tensile strength but ZA27H1, ZA27H2 and ZM11 showed the highest damping properties. The relationship between microstructure and damping capacity of all alloys was also examined using back-scattered electron on the SEM. Further more detailed examinations of the microstructures of alloys ZM11, Cosmal and Supercosmal were carried out on the transmission electron microscope in order to establish the phases present in all alloys. These helped to obtain the mechanism of damping in the experimental alloys. The main damping mechanism in most of the experimental alloys was due to grain-boundary-sliding. Micro structural examinations also revealed the absence of -phase in the Cosmal and Supercosmal. This was thought to be due to a change in solid solubility of the alloys, which could have been caused by the addition of Si.

Análise mecânica e microestrutural das ligas de cobalto-cromo de uso odontológico após sucessivas refundições

The cobalt-chromium alloy is extensively used in the Odontology for the confection of metallic scaffolding in partial removable denture. During the last few years, it has been reported an increasing number of premature imperfections, with a few months of prosthesis use. The manufacture of these components is made in prosthetic laboratories and normally involves recasting, using parts of casting alloy and parts of virgin alloy. Therefore, the objective of the present study was to analyze the mechanical properties of a commercial cobalt-chromium alloy of odontological use after successive recasting, searching information to guide the dental prosthesis laboratories in the correct manipulation of the cobalt-chromium alloy in the process of casting and the possible limits of recasting in the mechanical properties of this material. Seven sample groups were confectioned, each one containing five test bodies, divided in the following way: G1: casting only with virgin alloy; G2: casting with 50% of the alloy of the G1 + 50% of virgin alloy; G3: casting with 50% of the alloy of the G2 + 50% of virgin alloy; G4: casting with 50% of the alloy of the G3 + 50% of virgin alloy; G5: 50% of alloy of the G4 + 50% of virgin alloy; G6: 50% of alloy of the G5 + 50% of virgin alloy and finally the G7, only with recasting alloy. The modifications in the mechanical behavior of the alloy were evaluated. Moreover, it was carried the micro structural characterization of the material by optic and electronic scanning microscopy, and X ray diffraction.and fluorescence looking into the correlatation of the mechanical alterations with structural modifications of the material caused by successive recasting process. Generally the results showed alterations in the fracture energy of the alloy after successive recasting, resulting mainly of the increasing presence of pores and large voids, characteristic of the casting material. Thus, the interpretation of the results showed that the material did not reveal significant differences with respect to the tensile strength or elastic limit, as a function of successive recasting. The elastic modulus increased from the third recasting cycle on, indicating that the material can be recast only twice. The fracture energy of the material decreased, as the number of recasting cycles increased. With respect to the microhardness, the statistical analyses showedno significant differences. Electronic scanning microscopy revealed the presence of imperfections and defects, resulting of the recasting process. X ray diffraction and fluorescence did not show alterations in the composition of the alloy or the formation of crystalline phases between the analyzed groups. The optical micrographs showed an increasing number of voids and porosity as the material was recast. Therefore, the general conclusion of this study is that the successive recasting of of Co-Cr alloys affects the mechanical properties of the material, consequently leading to the failure of the prosthetic work. Based on the results, the best recommendadition is that the use of the material should be limited to two recasting cycles

Sviluppo e caratterizzazione microstrutturale e meccanica di leghe innovative di magnesio

Le attività di ricerca svolte nel corso del dottorato di ricerca, sono state focalizzate principalmente sullo studio dell’evoluzione microstrutturale, delle proprietà meccaniche e tribologiche di una particolare lega da fonderia, EV31A, con alte percentuali di terre rare (Nd e Gd > 4% in peso). Le analisi microstrutturali sono state eseguite tramite microscopia ottica (OM), elettronica in scansione (SEM) ed elettronica in trasmissione (TEM), mentre le proprietà meccaniche sono state determinate attraverso prove di trazione e prove di fatica a flessione rotante. Al fine di incrementare le proprietà tribologiche delle leghe di magnesio è stata valutata l’efficacia del trattamento PEO sia sulla lega EV31A, sia sulle più comuni leghe AZ80 e AZ91D, effettuando test tribologici in modalità pattino su cilindro (Block on Ring). Infine è stato condotto uno studio sull’efficacia del trattamento di fusione superficiale laser (LSM), analizzandone gli effetti sia sull’evoluzione microstrutturale, sia sulle proprietà meccaniche e sulla resistenza a corrosione. Le attività svolte nel corso del dottorato di ricerca sono state svolte presso il Dipartimento di Ingegneria Industriale DIN della Scuola di Ingegneria e Architettura dell’Università di Bologna sotto la supervisione della Prof. ssa Lorella Ceschini.