Weldability of high strength aluminium alloys

The need for reduced intrinsic weight of structures and vehicles in the transportation industry has made aluminium research of interest. Aluminium has properties that are favourable for structural engineering, including good strength-to-weight ratio, corrosion resistance and machinability. It can be easily recycled saving energy used in smelting as compared to steel. Its alloys can have ultimate tensile strength of up to 750 MPa, which is comparable to steel. Aluminium alloys are generally weldable, however welding of high strength alloys like the 7xxx series pose considerable challenges. This paper presents research on the weldability of high strength aluminium alloys, principally the 7xxx series. The weldability with various weld processes including MIG, TIG, and FSW, is discussed in addition to consideration of joint types, weld defects and recommendations for minimizing or preventing weld defects. Experimental research was carried out on 7025-T6 and AW-7020 alloys. Samples were welded, and weld cross sections utilized in weld metallurgy studies. Mechanical tests were carried out including hardness tests and tensile tests. In addition, testing was done for the presence of Al2O3 on exposed aluminium alloy. It was observed that at constant weld heat input using a pulsed MIG system, the welding speed had little or no effect on the weld hardness. However, the grain size increased as the filler wire feed rate, welding current and welding speed increased. High heat input resulted in lower hardness of the weld profile. Weld preheating was detrimental to AW- 7020 welds; however, artificial aging was beneficial. Acceptable welds were attained with pulsed MIG without the removal of the Al2O3 layer prior to welding. The Al2O3 oxide layer was found to have different compositions in different aluminium alloys. These findings contribute useful additional information to the knowledge base of aluminium welding. The application of the findings of this study in welding will help reduce weld cost and improve high strength aluminium structure productivity by removing the need for pre-weld cleaning. Better understanding of aluminium weld metallurgy equips weld engineers with information for better aluminium weld design.

Kevyiden rakennemateriaalien soveltamismahdollisuudet metsäkoneissa

Asiakkaiden ympäristötietoisuus, metsäkoneille asetettavat korkeat vaatimukset ja kiristyvä kilpailu pakottavat metsäkoneiden valmistajat etsimään vaihtoehtoisia valmistusmateriaaleja, joita käyttämällä metsäkoneet kevenevät ja sitä kautta niiden ympäristökuormitukset ja käyttökustannukset alenevat ja kapasiteetti kasvaa. Metsäkoneiden rakenteiden keventämisessä alumiini on yksi varteenotettava vaihtoehto teräksen korvaajaksi, sillä alumiinin ominaisuus/paino -suhde on terästä parempi. Alumiinin käyttöä hitsatuissa rakenteissa ovat rajoittaneet sen korkea hinta ja melko huono väsymiskestävyys. Diplomityön tavoitteena on ollut selvittää mahdollisuuksia korvata metsäkoneiden rakenteista löytyviä teräksestä valmistettuja osia alumiinista valmistetuilla osilla. Diplomityön teoriaosassa on käsitelty rakenteiden keventämistä, metsäkoneille asetettavia vaatimuksia, alumiinien materiaaliominaisuuksia, alumiinirakenteiden valmistuksessa käytettäviä menetelmiä sekä alumiinirakenteiden suunnittelua. Lisäksi teoriaosassa on käsitelty komposiittien materiaaliominaisuuksia ja komposiittirakenteiden suunnittelua. Diplomityön kokeellisessa osassa on vertailtu nykyisiä rakennemateriaaleja ja alumiineja metsäkoneen eri osien rakennemateriaaleina osien vaatimusprofiileihin ja materiaalien ominaisuusprofiileihin perustuen. Vaatimusprofiilien perusteella on laadittu ominaisuusprofiilit alumiineille ja teräksille. Sovittamalla vaatimus- ja ominaisuusprofiilit yhteen arvoanalyysin avulla, metsäkoneista on etsitty mahdollisia kohteita, joissa nykyinen rakennemateriaali voitaisiin korvata alumiinilla. Tältä pohjalta metsäkoneista löytyi rakenteita, joissa alumiinin käyttö rakennemateriaalina teräksen sijaan olisi mahdollista. Diplomityö toimii hyvänä pohjana tutkittaessa mahdollisuuksia metsäkoneiden rakenteiden keventämiseksi.

Hitsatun alumiinirakenteen suunnittelu

Alumiiniseosten käyttö konstruktiomateriaalina lisääntyy johtuen sen lukuisista variaatioista lujuuden ja muovattavuuden suhteen. Alumiinin keveys on merkittävä kilpailuetu teräkseen nähden. Alumiiniseosten hitsattavuus on parantunut hitsausmenetelmien kehittyessä. Uusilla menetelmillä lämmöntuontia hallitaan paremmin, kuten myös alumiinin huokoisuutta sekä lujuuden laskua hitsauksen yhteydessä. Tässä diplomityössä tutkitaan alumiinin metallurgiaa, hitsausmenetelmiä, sekä alumiinin ja teräksen sekaliitoksen toteutusta. Tutkimuksella pyritään tekemään hitsatun alumiinirakenteen suunnittelua ymmärrettävämmäksi. SFS-EN standardit antavat perustuksen alumiinirakenteen suunnittelulle. Tässä diplomityössä tehdään suunnitteluesimerkki hitsatun alumiinirakenteen hitsien suunnittelusta. Suunnitteluesimerkissä tutkitaan alumiiniseoksen lujuuden laskua hitsattaessa, ja etsitään standardien antamia ratkaisuja toimivan hitsatun rakenteen toteuttamiseksi.

The effect of solidification rate on the structure of magnesium-aluminium eutectic grains

A magnesium-aluminium alloy of eutectic composition was solidified under two different cooling conditions, producing a low and a high growth rate of the eutectic solid-liquid interface. The high growth rate specimen contained smaller eutectic grains and cells, with a smaller interphase spacing compared with the low growth rate specimen. The high growth rate specimen also contained some primary Mg17Al12 dendrites, suggesting that the coupled zone is skewed towards the Mg phase with increased undercooling, A lamellar eutectic morphology was observed in the low growth rate specimen, while the morphology was fibrous in the high growth rate specimen.

Smart structure sensors based on embedded fibre Bragg grating arrays in aluminium alloy matrix by ultrasonic consolidation

Smart structure sensors based on embedded fibre Bragg grating (FBG) arrays in aluminium alloy matrix by ultrasonic consolidation (UC) technique have been proposed and demonstrated successfully. The temperature, loading and bending responses of the embedded FBG arrays have been systematically characterized. The embedded FBGs exhibit an average temperature sensitivity of ~36 pm °C-1, which is three times higher than that of normal FBGs, a bending sensitivity of 0.73 nm/m-1 and a loading responsivity of ~0.1 nm kg-1 within the dynamic range from 0 kg to 3 kg. These initial experimental results clearly demonstrate that the UC produced metal matrix structures can be embedded with FBG sensor arrays to become smart structures with capabilities to monitor the structure operation and health conditions in applications.

Structural models for yttrium aluminium borate laser glasses: NMR and EPR studies of the system (Y(2)O(3))(0.2)-(Al(2)O(3))(x)-(B(2)O(3))(0.8-x)

The structure of laser glasses in the system (Y(2)O(3))(0.2){(Al(2)O(3))(x))(B(2)O(3))(0.8-x)} (0.15 <= x <= 0.40) has been investigated by means of (11)B, (27)Al, and (89)Y solid state NMR as well as electron spin echo envelope modulation (ESEEM) of Yb-doped samples. The latter technique has been applied for the first time to an aluminoborate glass system. (11)B magic-angle spinning (MAS)-NMR spectra reveal that, while the majority of the boron atoms are three-coordinated over the entire composition region, the fraction of three-coordinated boron atoms increases significantly with increasing x. Charge balance considerations as well as (11)B NMR lineshape analyses suggest that the dominant borate species are predominantly singly charged metaborate (BO(2/2)O(-)), doubly charged pyroborate (BO(1/2)(O(-))(2)), and (at x = 0.40) triply charged orthoborate groups. As x increases along this series, the average anionic charge per trigonal borate group increases from 1.38 to 2.91. (27)Al MAS-NMR spectra show that the alumina species are present in the coordination states four, five and six, and the fraction of four-coordinated Al increases markedly with increasing x. All of the Al coordination states are in intimate contact with both the three-and the four-coordinate boron species and vice versa, as indicated by (11)B/(27)Al rotational echo double resonance (REDOR) data. These results are consistent with the formation of a homogeneous, non-segregated glass structure. (89)Y solid state NMR spectra show a significant chemical shift trend, reflecting that the second coordination sphere becomes increasingly ""aluminate-like'' with increasing x. This conclusion is supported by electron spin echo envelope modulation (ESEEM) data of Yb-doped glasses, which indicate that both borate and aluminate species participate in the medium range structure of the rare-earth ions, consistent with a random spatial distribution of the glass components.

Columnar to equiaxed transition of eutectic in hypoeutectic aluminium-silicon alloys

Directional solidification of unmodified and strontium modified binary, high-purity aluminium-7 wt% silicon and commercial A356 alloys has been carried out to investigate the mechanism of eutectic solidification. The microstructure of the eutectic growth inter-face was investigated with optical microscopy and Electron Backscattering Diffraction (EBSD). In the commercial alloys, the eutectic solidification inter-face extends in the growth direction and creates a eutectic mushy zone. A planar eutectic growth front is observed in the high-purity alloys. The eutectic aluminium has mainly the same crystallographic orientation as the dendrites in the unmodified alloys and the strontium modified high-purity alloy. A more complex eutectic grain structure is found in the strontium modified commercial alloy. A mechanism involving constitutional undercooling and a columnar to equiaxed transition explains the differences between pure and commercial alloys. It is probably caused by the segregation of iron and magnesium and the activation of nucleants in the commercial alloy. (C) 2002 Acta Materialia Inc. Published by Elsevier Science Ltd. All rights reserved.

Numerical simulation of plasmonic effects in amorphous silicon induced by embedded aluminium nanoparticles

This work reports a theoretical study aimed to identify the plasmonic resonance condition for a system formed by metallic nanoparticles embedded in an a-Si: H matrix. The study is based on a Tauc-Lorentz model for the electrical permittivity of a-Si: H and a Drude model for the metallic nanoparticles. It is calculated the The polarizability of an sphere and ellipsoidal shaped metal nanoparticles with radius of 20 nm. We also performed FDTD simulations of light propagation inside this structure reporting a comparison among the effects caused by a single nanoparticles of Aluminium, Silver and, as a comparison, an ideally perfectly conductor. The simulation results shows that is possible to obtain a plasmonic resonance in the red part of the spectrum (600-700 nm) when 20-30 nm radius Aluminium ellipsoids are embedded into a-Si: H.

Strength and damage analysis of composite-aluminium adhesively-bonded single-lap joints

With the need to find an alternative way to mechanical and welding joints, and at the same time to overcome some limitations linked to these traditional techniques, adhesive bonds can be used. Adhesive bonding is a permanent joining process that uses an adhesive to bond the components of a structure. Composite materials reinforced with fibres are becoming increasingly popular in many applications as a result of a number of competitive advantages. In the manufacture of composite structures, although the fabrication techniques reduce to the minimum by means of advanced manufacturing techniques, the use of connections is still required due to the typical size limitations and design, technological and logistical aspects. Moreover, it is known that in many high performance structures, unions between composite materials with other light metals such as aluminium are required, for purposes of structural optimization. This work deals with the experimental and numerical study of single lap joints (SLJ), bonded with a brittle (Nagase Chemtex Denatite XNRH6823) and a ductile adhesive (Nagase Chemtex Denatite XNR6852). These are applied to hybrid joints between aluminium (AL6082-T651) and carbon fibre reinforced plastic (CFRP; Texipreg HS 160 RM) adherends in joints with different overlap lengths (LO) under a tensile loading. The Finite Element (FE) Method is used to perform detailed stress and damage analyses allowing to explain the joints’ behaviour and the use of cohesive zone models (CZM) enables predicting the joint strength and creating a simple and rapid design methodology. The use of numerical methods to simulate the behaviour of the joints can lead to savings of time and resources by optimizing the geometry and material parameters of the joints. The joints’ strength and failure modes were highly dependent on the adhesive, and this behaviour was successfully modelled numerically. Using a brittle adhesive resulted in a negligible maximum load (Pm) improvement with LO. The joints bonded with the ductile adhesive showed a nearly linear improvement of Pm with LO.

Friction surfacing of aluminium alloys

Dissertação para a obtenção do grau de Mestre em Engenharia Mecânica