Precipitation and solute clustering in aluminium: advanced characterisation techniques

Recent development of characterisation techniques and computer simulation has extended our ability to access atomic scale information regarding materials microstructure evolution. New results from such techniques have significantly progressed our knowledge about solute behaviour during the earliest stages of decomposition of the solid solution. This chapter updates current understanding about solute clustering and discusses the effect of solute clustering and micro-alloying on precipitate microstructure evolution in aluminium alloys. In addition, a brief review is given on the effect of severe plastic deformation on precipitate evolution in Al alloys.

The effect of crack closure on the grain size dependence of fatigue crack growth threshold

Recent studies (I-7) clearly indicate a strong dependence of fatigue threshold parameter, A K on grain size in several alloy systems. Attempts to explain these observations on the basis of crat~tortuosity (1,8), fracture surface roughness (5,9) and crack closure (6) appear to present a fairly clear picture of the mechanisms that cause a reduction in crack growth rates at threshold. In general, it has been shown that coarse grained microstructures exhibit higher fatigue threshold in low carbon steels (1,5) aluminium alloys (7) and titanium alloys (6). In spite of these observations, there exists (10-1#) considerable uncertainity about the manner in which the AK~L depends on prior austenitic grain size in quenched and tempered steels. Studies in quenched and tempered steels demonstrating both an increase (3,12,14) as well as a decrease (11,12) in AKth with an increase in prior austenitic grain size can be sought to illustrate this point. Occasionally , the absence of any sensitivity of AKth to the variations in prior austenitJc grain size has also been reported (11,13). While a few investigators (5-7) comfortably rationalised the grain size effects on AK~L on the basis of crack closure by a comparison in terms of the closure-free component of the thresho~Ifc~, AK -f such an approach has yet to be extended to high strength steels, An attempt has been made in t~et ,pthrg sent study to explai. n the effect of pri, or austeniti.c grain size on &Kth on the basis of crack closure measurements in a high strength steel.

Wear lip formation during dry sliding

A pin-on-disc test configuration has been used to examine the formation of the strain-hardened projection, or wear lips, especially at the trailing edge of the pin during dry sliding of aluminium alloys against steel discs. The mechanism of formation of such wear lips is studied with the aid of optical and electron microscopes. The plastic deformation of the pin, growth and eventual removal of the wear lip as wear debris are elucidated. The size and shape of the wear lips in pins of different shapes, i.e. square, rectangular, triangular and circular cross-sections, are described.

Positional dependence of material flow in friction stir welding: analysis of joint line remnant and its relevance to dissimilar metal welding

Understanding material flow in friction stir welding is important for production of sound dissimilar metal welding that control the intermixing of two alloys being welded and consequent formation of new constituents which influences the weld properties. In the present experimental investigation material flow patterns are visualised using dissimilar and similar aluminium alloys using a simple innovative ,experiment. The experimental results reveal that only a portion of material transported from the leading edge undergoes chaotic flow and the remaining is deposited systematically in the trailing edge of the weld. Using this information it is shown that the formation of a friction stir welding defect, joint line remnant, does not occur only when the weld interface is on the advancing side. The material flow visualisation study has been utilised to analyse the mechanism of weld formation and its usefulness in improving fatigue properties and for dissimilar metal welds.

Alloy design for fracture resistance

Several methods for improving the strength of metallic materials are available and correlations between strength and various microstructural features have been established. The purpose of this paper is to review parallel developments favouring improved fracture resistance. Resistance to fracture in monotonie loading, cyclic loading and when fracture is environment-aided have been considered in steels, aluminium alloys and anisotropic materials. Finally, the question of optimising alloy behaviour is discussed.

Effect Of Electroslag Refining On Microstructure And Mechanical-Properties Of Is-7670 Alloy

The electroslag refining technique is one of the modern tools which is capable of imparting superior mechanical and chemical properties to metals and alloys. Refining usually results in the elimination of a number of casting or solidification defects, such as shrinkage porosity, gas porosity, pipe, micro- and macro segregation. Remelting also imparts a directional grain structure apart from refining the size of the inclusions, grains and precipitates. This technique has over the years been used widely and successfully to improve the mechanical and chemical properties of steels and alloy steels which are used in the nuclear, missile, aerospace and marine industries for certain critical applications. But the application of ESR to aluminium and its alloys is only recent. This paper investigates the response of an aluminium alloy (corresponding to the Indian Specification IS: 7670) to ESR. Based on theoretical considerations and microstructural evidence it elucidates how ESR of aluminium alloys differs from that of ferrous alloys. The improvement achieved in mechanical properties of the alloy is correlated with the microstructure.

A Study of The Fatigue, Impact and fracture-Toughness Characteristics of Electroslag Refined IS-7670 Alloy

The nuclear, aerospace, naval and missile industries place emphasis on materials with high structural integrity and reliable performance so as to meet certain stringent requirements in service. Strength is not the only criterion for selection. Properties such as fatigue resistance. impact toughness and fracture toughness are equally important. Electroslag refining (ESR) has been used widely and successfully over the years for improving the fatigue resistance, creep resistance, impact strength and fracture toughness of steels and alloy steels. But application of ESR to aluminium alloys is only a recent endeavour. A high-strength aircraft aluminium alloy IS: 7670 was therefore chosen for studies on the fatigue strength and the impact and fracture toughness. The results indicate that the fatigue resistance is considerably improved after refining and that the impact strength and fracture toughness of the refined alloy are comparable with that of the unrefined alloy.

Appraisal of PD6493:1991 fracture assessment procedures

PD6493:1991 fracture assessment have been performed for a range of large-scale fracture mechanics tests conducted at TWI in the past. These tests cover several material groups, including pressure vessel steels, pipeline steels, stainless steels and aluminium alloys, including parent material and weldments. Ninety-two wide plate and pressure vessel tests have been assessed, following Levels 1, 2 and 3 PD6493:1991 procedures. In total, over 400 assessments have been performed, examining many features of the fracture assessment procedure including toughness input, proof testing, residual stress assumptions and stress state (tension, bending and biaxial). In all cases the large scale tests have been assessed as one would actual structures: i.e., based on lower bound toughness values obtained from small scale fracture toughness specimens.