Modified life cycle inventory of aluminium die casting

Aluminium die casting is a process used to transform molten aluminium material into automotive gearbox housings, wheels and electronic components, among many other uses. It is used because it is a very efficient method of achieving near net shape with the required mechanical properties. Life Cycle Assessment (LCA) is a technique used to determine the environmental impacts of a product or process. The Life Cycle Inventory (LCI) is the initial phase of an LCA and describes which emissions will occur and which raw materials are used during the life of a product or during a process. This study has improved the LCI technique by adding in manufacturing and other costs to the ISO standardised methods. Although this is not new, the novel application and allocation methods have been developed independently. The improved technique has then been applied to Aluminium High Pressure Die Casting. In applying the improved LCI to this process, the cost in monetary terms and environmental emissions have been determined for a particular component manufactured by this process. A model has been developed in association with an industry partner so this technique can be repeatedly applied and used in the prediction of costs and emissions. This has been tested with two different products. Following this, specialised LCA software modelling of the aluminium high pressure die casting process was conducted. The variations in the process have shown that each particular component will have different costs and emissions and it is not possible to generalise the process by modelling only one component. This study has concentrated on one process within die casting but the techniques developed can be used across any variations in the die casting process.

An analysis of microband orientation in hot deformed aluminium alloy AA5052 using forward and reverse torsion

The effects of strain path reversal on the macroscopic orientation of microbands in AA5052 have been studied using high resolution electron backscatter diffraction. Deformation was carried using two equal steps of forward/forward or forward/reverse torsion at a temperature of 300°C and strain rate of 1s-1 to a total equivalent tensile strain of 0.5. In both cases microbands were found in the majority of grains examined with many having more than one set. The microbands appear to cluster at specific angles to the macroscopic deformation. For the forward/forward condition microbands clustered around -20° and +45° to the maximum principle stress direction and at ± 30-35° to the principal strain direction. For the forward/reverse condition significantly more spread in microband angle was observed though peaks were visible at ±35° with respect to principal stress direction and at -40° and +30° with respect to the principal strain direction of the reverse torsion. This suggests the microbands formed in the forward deformation have or are dissolving and any new microbands formed are related to the deformation conditions of the final strain path.

Effect of orientation stability on recrystallization textures of deformed aluminium single crystals

High purity Al single crystals of the Cube (0 0 1)[1 0 0] and rotated Cube (0 1 1)[0 1 ¯ 1] orientations have been deformed in plane strain compression in a channel die. Deformation was carried out at temperatures between 25 and 600 8C up to strains of 1.2. The as-deformed microstructure has been characterised using electron microscopy and electron backscattered diffraction (EBSD).
Annealing was carried out for various times and temperatures. The recrystallized microstructure has been studied using electron microscopy, and the orientation of recrystallized grains determined using EBSD. After cold deformation and annealing both orientations exhibited a random recrystallization texture component. After hot deformation both orientations retained a similar annealing texture to their starting deformation texture. The annealing texture of deformed single crystals was found to be more sensitive to the temperature of deformation than the stability of the orientation.

Irrigation with reclaimed water at Portland Aluminium

Through extensive laboratory and field based analysis of soil chemical and physical processes, this research identified and addressed key management issues associated with the sustainable irrigation of municipal wastewater onto sandy water repellent soils, overlaying a shallow aquifer, in an environmentally significant coastal system.

Aluminium smelter wastewater : groundwater fluoride fate

This study assessed the viability of utilising groundwater systems to manage Portland Aluminium's trade waste water stream. A mathematical groundwater model was created to assess laboratory and field results. Fluoride was modelled for spatio-temporal longevity in the system. All models indicate that fluoride will ultimately exit the site to the seaward boundary.

Performance of wrought aluminium and magnesium alloy tubes in three-point bending

This present work examines the load carrying capacity, energy absorption and fracture characteristics of wrought magnesium and aluminium alloy tubes in three-point bending. Magnesium alloy AZ31, and aluminium alloys 6063 and 7075, were extruded into cylindrical tubes of both equivalent thickness and mass. A strong thickness effect was present meaning that the AZ31 tube had significantly higher load and energy absorption performance than an equivalent mass 6063 tube, albeit not as high as the 7075 tube. Hinge formation and maximum load was delayed for the magnesium alloy, meaning that a high energy absorption rate persisted to higher deformation displacements than the aluminium alloys. It was also found that fracture during deformation was dependent on the indenter diameter, tube thickness and lower support separation.

Towards a more holistic approach to quality improvements in aluminium die casting

This work evaluates the feasibility of using a holistic approach, based on dynamical system theory,
to reduce porosity defects in high pressure aluminum die casting. Quality improvements, from a
dynamical system perspective mean the ability to move the die casting process out of its natural
equilibrium to a more beneficial state and the ability to maintain this new process state. This more beneficial state may be achieved in several ways. One way is to increase the amount of forcing to overcome natural process resistance. This forcing approach is represented by typical continuous intervention policy, with modifications in die/part design and/or process parameters. An alternative approach is to reduce the amount of natural process resistance, in particular the amount of process disturbance, allowing the process to move out of its natural equilibrium with much less forcing. This alternative uses the self-regulating ability of dynamical systems thus decreasing the amount of human intervention required. In this respect, the influence of vacuum on time on chattering at the first stage of the casting shot was identified as a good process candidate for testing using dynamical system theory. A significant reduction in porosity defects was achieved, which also set the process on a path of slow but consistent self-improvement.

Ceramic-polymer interface in composite electrolytes of lithium aluminium titanium phosphate and polyetherurethane polymer electrolyte

Composite electrolytes of the lithium-ion-conducting ceramic Li_1.3Al_0.3Ti_1.7(PO₄)₃ and polyetherurethane/lithium triflate polymer electrolyte have been prepared. Microscopy has shown that adhesion between the ceramic and polymer phases is poor, with gaps up to 1 μm at the interface. When dry, the composites are no more conductive than the pure polymer electrolyte. Exposing the samples to the vapour of solvents such as DMF, acetonitrile or water produces a significant increase in conductivity, over and beyond simple plasticization of the polymer. Pretreating the ceramic with a compatibilizing agent improves adhesion at the interface with the polymer, but decreases overall conductivity in the case investigated.

Aluminium speciation in 1-Butyl-1-Methylpyrrolidinium Bis(trifluoromethylsulfonyl)amide/AlCl3 mixtures

Aluminium speciation: Aluminium speciation in NTf₂ ionic liquids has a strong influence on its electrodeposition from the liquid mixture. This work probed the nature of these species and proposes that the electroactive species involved are either [AlCl₃(NTf₂)]⁻ or [AlCl₂(NTf₂)₂]⁻ (e.g., see figure).


Electrodeposition of aluminium is possible from solutions of AlCl₃ dissolved in the 1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)amide (C₄mpyrNTf₂) ionic liquid. However, electrodeposition is dependant on the AlCl₃ concentration as it only occurs at concentrations >1.6 mol L⁻¹. At these relatively high AlCl₃ concentrations the C₄mpyrNTf₂/AlCl₃ mixtures exhibit biphasic behaviour. Notably, at 1.6 mol L⁻¹ AlCl₃, aluminium can only be electrodeposited from the upper phase. Conversely, we found that at 3.3 mol L⁻¹ aluminium electrodeposition can only occur from the lower phase. The complex chemistry of the C₄mpyrNTf₂/AlCl₃ system is described and implications of aluminium speciation in several C₄mpyrNTf₂/AlCl₃ mixtures, as deduced from Raman and ²⁷Al NMR spectroscopic data, are discussed. The ²⁷Al NMR spectra of the C₄mpyrNTf₂/AlCl₃ mixtures revealed the presence of both tetrahedrally and octahedrally coordinated aluminium species. Raman spectroscopy revealed that the level of uncoordinated NTf₂⁻ anions decreased with increasing AlCl₃ concentration. Quantum chemical calculations using density functional and ab initio theory were employed to identify plausible aluminium-containing species and to calculate their vibrational frequencies, which in turn assisted the assignment of the observed Raman bands. The data indicate that the electroactive species involved are likely to be either [AlCl₃(NTf₂)]⁻ or [AlCl₂(NTf₂)₂]⁻.

Research contributions to development of particulate reinforced MMCs by theoretical and experimental studies

This thesis is a compilation of eighty publications on analytical, experimental and numerical studies on the mechanical, tribological and corrosion behaviour of metal matrix composites (MMCs). The models based on the interface between matrix and reinforcement behaviour help accurate prediction of density and locked up hysterysis-strain in the composites at elevated temperatures.