Corrosion of magnesium alloys in commercial engine coolants

A number of magnesium alloys show promise as engine block materials. However, a critical issue for the automotive industry is corrosion of the engine block by the coolant and this could limit the use of magnesium engine blocks. This work assesses the corrosion performance of conventional magnesium alloy AZ91D and a recently developed engine block magnesium alloy AM-SC1 in several commercial coolants. Immersion testing, hydrogen evolution measurement, galvanic current monitoring and the standard ASTM D1384 test were employed to reveal the corrosion performance of the magnesium alloys subjected to the coolants. The results show that the tested commercial coolants are corrosive to the magnesium alloys in terms of general and galvanic corrosion. The two magnesium alloys exhibited slightly different corrosion resistance to the coolants with AZ91D being more corrosion resistant than AM-SC1. The corrosivity varied from coolant to coolant. Generally speaking. an oraganic-acid based long life coolant was less corrosive to the magnesium alloys than a traditional coolant. Among the studied commercial coolants. Toyota long, life coolant appeared to be the most promising one. In addition. it was found that potassium fluoride effectively inhibited corrosion of the magnesium alloys in the studied commercial coolants. Both general and galvanic corrosion rates were significantly decreased by addition of KF, and there were no evident side effects on the other engine block materials, such as copper, solder. brass. steel and aluminium alloys, in terms of their corrosion performance. The ASTM D 1384 test further confirmed these results and suggested that Toyota long life coolant with 1%wt KF addition is a promising coolant for magnesium engine blocks.

Cracking and distortion of water jackets in engine blocks

This thesis investigated the cracking and distortion of water jackets in engine blocks. The Taguchi method was utilized to improve production process and in doing so, reducing the scrap of water jacket cores by over 60%. Further, by altering core material and pouring temperature, casting distortion was improved.

Corrosion behaviour of magnesium in ethylene glycol

Corrosion of magnesium engine components by coolant is an important issue in the automotive industry where magnesium alloys may be used. It is of significance to understand the corrosion behaviour of pure magnesium in ethylene glycol solutions, as this can provide a basis for developing new coolants for magnesium alloy engine blocks. In this paper, through corrosion and electrochemical tests, it was found that the corrosion rate of magnesium decreased with increasing concentration of ethylene glycol. Individual contaminants, such as NaCl, NaHCO3, Na2SO4 and NaCl can make aqueous ethylene glycol solution more corrosive to magnesium. However, in NaCl contaminated ethylene glycol, NaHCO3 and Na2SO4 showed some inhibition effect. The solution resistivity played an important role in the corrosion of magnesium in ethylene glycol solutions, and the competitive adsorption of ethylene glycol and the contaminants on the magnesium surface was also responsible for the observed corrosion behaviours. The corrosion of magnesium in ethylene glycol can be effectively inhibited by addition of fluorides that react with magnesium and form a protective film on the surface. (C) 2003 Elsevier Ltd. All rights reserved.

Estudo da utilização de ferramentas a base de nitreto de silício (Si3N4) e alumina (Al2O3) na usinagem do ferro fundido vermicular

Machining is one of the most commonly manufacturing processes used in the modern world, consuming millions of dollars annually. Because of this, it is crucial for the automotive industry to reduce costs on their heat-resistant alloy machining processes, such as compacted graphite iron (CGI), which has shown an increasing trend of its application in diesel engine blocks, brakes disks, among other applications, due to its superior mechanical properties to gray cast iron. Despite this advantage, its use is still limited due to its difficulty of machining, moreover, cutting tools are displayed as the main factor in increasing the machining cost. Seeking an alternative to a better machinability of CGI, this paper aims to study two types of ceramic tools developed in Brazil, and benchmark their performance by dry turning. For this, were used CGI class 450 and two tools: ceramic of silicon nitride (Si3N4) and alumina-based (Al2O3), with a cutting speed (Vc) of 300, 400 and 500 m / min; feed (f) of 0.2 mm / rev and depth of cut (ap) of 0.5 mm, using three replicates and starting with new cutting edges. The results showed that the Al2O3 tool had the best performance in Vc of 500 m / min, while the Si3N4 tool had the best results in Vc of 300 m / min. This can be explained by the tool of Si3N4 based include soft intergranular phase, called amorphous, while alumina has higher abrasion resistance due to its high refractoriness. The results make it clear that the tools have significant potential for machining of compacted graphite iron, being necessary a strict control of the cutting parameters used

Estudo da utilização de ferramentas a base de nitreto de silício (Si3N4) e alumina (Al2O3) na usinagem do ferro fundido vermicular

Machining is one of the most commonly manufacturing processes used in the modern world, consuming millions of dollars annually. Because of this, it is crucial for the automotive industry to reduce costs on their heat-resistant alloy machining processes, such as compacted graphite iron (CGI), which has shown an increasing trend of its application in diesel engine blocks, brakes disks, among other applications, due to its superior mechanical properties to gray cast iron. Despite this advantage, its use is still limited due to its difficulty of machining, moreover, cutting tools are displayed as the main factor in increasing the machining cost. Seeking an alternative to a better machinability of CGI, this paper aims to study two types of ceramic tools developed in Brazil, and benchmark their performance by dry turning. For this, were used CGI class 450 and two tools: ceramic of silicon nitride (Si3N4) and alumina-based (Al2O3), with a cutting speed (Vc) of 300, 400 and 500 m / min; feed (f) of 0.2 mm / rev and depth of cut (ap) of 0.5 mm, using three replicates and starting with new cutting edges. The results showed that the Al2O3 tool had the best performance in Vc of 500 m / min, while the Si3N4 tool had the best results in Vc of 300 m / min. This can be explained by the tool of Si3N4 based include soft intergranular phase, called amorphous, while alumina has higher abrasion resistance due to its high refractoriness. The results make it clear that the tools have significant potential for machining of compacted graphite iron, being necessary a strict control of the cutting parameters used

Improving the Accuracy of 3-D Reconstruction in Robotic Vision Applications

Thesis (Ph.D.)--University of Washington, 2016-08

Performance of magnesia cements in porous blocks in acid and magnesium environments

The performance of porous blocks containing three different reactive magnesia-based cements - namely magnesia alone, magnesium oxide: Portland cement (PC) in 1:1 ratio, cured in ambient conditions, and magnesia alone, cured at elevated carbon dioxide conditions, in hydrochloric acid and magnesium sulfate solution - was investigated. Different aggressive chemical solution conditions were used, to which the samples were exposed for up to 12 months and then tested for strength and microstructure. The performance was also compared with that of standard PC-based blocks. The results showed the significant resistance to chemical attack offered by magnesia, both alone and with PC blend in the porous blocks when cured under ambient carbon dioxide conditions, and confirmed the much poorer performance of blocks made from PC alone. The blocks of solely magnesia cured in elevated carbon dioxide conditions, at 20% concentration, showed slightly lower resistance to acid attack than PC; however, the resistance to sulfate attack was much higher. © 2012 Thomas Telford Ltd.

The Corrosion Performance of Magnesium Alloy AM-SC1 in Automotive Engine Block Applications

The magnesium alloy AM-SC1 has been developed as a creep-resistant automotive engine block material. This paper outlines its corrosion performance under laboratory test conditions, considering corrosion on both the external and internal surfaces. This study found that AM-SC1 has a corrosion performance comparable to AZ91 when subjected to an aggressive salt-spray environment or in galvanic-coupling environments. This article further demonstrates that, with the appropriate selection of a commercially available engine coolant, the internal corrosion of AM-SC1 can be maintained at a tolerable level. In addition, internal corrosion resistance can be significantly improved by the addition of fluorides to the coolant solution. It is concluded that AM-SC1 can be successfully used in an engine environment provided that some simple corrosion-prevention strategies are adopted.

Impact of hydrated magnesium carbonate additives on the carbonation of reactive MgO cements

Reactive magnesia (MgO) cements have emerged as a potentially more sustainable and technically superior alternative to Portland cement due to their lower production temperature and ability to sequester significant quantities of CO2. Porous blocks containing MgO were found to achieve higher strength values than PC blocks. A number of variables are investigated to achieve maximum carbonation and associated high strengths. This paper focuses on the impact of four different hydrated magnesium carbonates (HMCs) as cement replacements of either 20 or 50%. Accelerated carbonation (20 C, 70-90% RH, 20% CO2) is compared with natural curing (20 C, 60-70% RH, ambient CO2). SEM, TG/DTA, XRD, and HCl acid digestion are utilized to provide a thorough understanding of the performance of MgO-cement porous blocks. The presence of HMCs resulted in the formation of larger size carbonation products with a different morphology than those in the control mix, leading to significantly enhanced carbonation and strength. © 2013 Elsevier Ltd.

Particle emission from heavy-duty engine fuelled with blended diesel and biodiesel

In this study, particulate matter (PM) were characterized from a place impacted by heavy-duty vehicles (Bus Station) fuelled with diesel/biodiesel fuel blend (B3) in the city of Londrina, Brazil. Sixteen priority polycyclic aromatic hydrocarbons (PAH) concentrations were analyzed in the samples by their association with atmospheric PM, mass size distributions and major ions (fluorite, chloride, bromide, nitrate, phosphate, sulfate, nitrite, oxalate; fumarate, formate, succinate and acetate; lithium, sodium, potassium, magnesium, calcium and ammonium). Results indicate that major ions represented 21.2% particulate matter mass. Nitrate, sulfate, and ammonium, respectively, presented the highest concentration levels, indicating that biodiesel may also be a significant source for these ions, especially nitrate. Dibenzo[a,h]anthracene and indeno[1,2,3,-cd]pyrene were the main PAH found, and a higher fraction of PAH particles was found in diameters lower than 0.25 mu m in Londrina bus station. The fine and ultrafine particles were dominant among the PM evaluated, suggesting that biodiesel decreases the total PAH emission. However, it does also increase the fraction of fine and ultrafine particles when compared to diesel.

In vivo degradation of magnesium plate/screw osteosynthesis implant systems: Soft and hard tissue response in a calvarial model in miniature pigs.

Biodegradable magnesium plate/screw osteosynthesis systems were implanted on the frontal bone of adult miniature pigs. The chosen implant geometries were based on existing titanium systems used for the treatment of facial fractures. The aim of this study was to evaluate the in vivo degradation and tissue response of the magnesium alloy WE43 with and without a plasma electrolytic surface coating. Of 14 animals, 6 received magnesium implants with surface modification (coated), 6 without surface modification (uncoated), and 2 titanium implants. Radiological examination of the skull was performed at 1, 4, and 8 weeks post-implantation. After euthanasia at 12 and 24 weeks, X-ray, computed tomography, and microfocus computed tomography analyses and histological and histomorphological examinations of the bone/implant blocks were performed. The results showed a good tolerance of the plate/screw system without wound healing disturbance. In the radiological examination, gas pocket formation was found mainly around the uncoated plates 4 weeks after surgery. The micro-CT and histological analyses showed significantly lower corrosion rates and increased bone density and bone implant contact area around the coated screws compared to the uncoated screws at both endpoints. This study shows promising results for the further development of coated magnesium implants for the osteosynthesis of the facial skeleton.

Advances in wrought magnesium alloys: Fundamentals of processing, properties and applications

This important book summarises the wealth of recent research on our understanding of process-property relationships in wrought magnesium alloys and the way this understanding can be used to develop a new generation of alloys for high-performance applications. After an introductory overview of current developments in wrought magnesium alloys, part one reviews fundamental aspects of deformation behaviour. These chapters are the building blocks for the optimisation of processing steps covered in part two, which discusses casting, extrusion, rolling and forging technologies. The concluding chapters cover applications of wrought magnesium alloys in automotive and biomedical engineering. With its distinguished editors, and drawing on the work of leading experts in the field, Advances in wrought magnesium alloys is a standard reference for those researching, manufacturing and using these alloys.