Materials

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27 pages, 20161 KiB

Open AccessArticle

Optimizing the Morphology and Solidification Behavior of Fe-Rich Phases in Eutectic Al-Si-Based Alloys with Different Fe Contents by Adding Mn Elements

by Lei Luo, Yingchun Tang, Xiao Liang, Yanqing Su, Youwei Zhang and Huasheng Xie

Materials 2024, 17(16), 4104; https://doi.org/10.3390/ma17164104 - 19 Aug 2024

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Abstract

A high Fe content easily produces Fe-rich phases with a harmful morphology, resulting in a huge detrimental effect on the properties and recycling ability of Al-Si alloys. Therefore, finding ways to effectively transform Fe-rich phases to form a beneficial phase or shape is [...] Read more.

A high Fe content easily produces Fe-rich phases with a harmful morphology, resulting in a huge detrimental effect on the properties and recycling ability of Al-Si alloys. Therefore, finding ways to effectively transform Fe-rich phases to form a beneficial phase or shape is of great significance. Accordingly, Al-Si-based alloys with Fe contents ranging from 0.1 wt.% to 2.0 wt.% were modified by different Mn additions. Moreover, experiments combined with simulations were utilized to comprehensively analyze the mechanism of Mn on the morphology and microstructural evolution of Fe-rich phases from different perspectives. The current findings determine that adding different Fe contents changes the phase-transition reactions in alloys. Without Mn, and by increasing the Fe content from 0.1 wt.% to 2.0 wt.%, the Fe-rich phases gradually convert from a skeleton-shaped α-Al₈Fe₂Si (<0.25 wt.%) to β-Al₉Fe₂Si₂ with a fibrous (0.5 wt.%), needle-like (1.0 wt.%) and plate-like shape without curvatures (2.0 wt.%). The maximum length and mean aspect ratio increase from 12.01 μm to 655.66 μm and from 1.96 to 84.05, while the mean curvature decreases from 8.66 × 10⁻² μm⁻¹ to 8.25 × 10⁻⁴ μm⁻¹. The addition of 0.35 wt.% Mn promotes a new Chinese-character and petal-shaped α-Al₁₅(FeMn)₃Si₂, with an atomic ratio of Fe and Mn of 1:1 when the Fe content is lower than 0.5 wt.%, while it transforms to β-Al₁₅(FeMn)₃Si₂ with an atomic ratio of 5:1, presenting as a refined plate-like shape with a certain curvature, as the Fe content increases to 2.0 wt.%. Mn alters the phase reactions and increases the threshold of the Fe content required for β-Al₁₅(FeMn)₃Si₂, limiting the formation and growth of them simultaneously in time and space. The enrichment of Mn atoms and solute diffusion at the growth front of β-Al₁₅(FeMn)₃Si₂, as well as the strong atomic-binding ability, can deflect the growth direction of β-Al₁₅(FeMn)₃Si₂ for it to have a certain curvature. Additionally, the enriched Mn atoms easily form α-Al₁₅(FeMn)₃Si₂ and cause the long β-Al₁₅(FeMn)₃Si₂ to be broken and refined to further reduce the damages caused to the alloy’s performance. Ultimately, the maximum length and mean aspect ratio can be effectively reduced to 46.2% and 42.0%, respectively, while the mean curvature can be noticeably increased by 3.27 times with the addition of Mn. Full article

(This article belongs to the Special Issue Advances in High-Performance Non-ferrous Materials—2nd Volume)

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17 pages, 4281 KiB

Open AccessArticle

Research on Hot Deformation Rheological Stress of Al-Mg-Si-Mn-Sc Aluminium Alloy

by Wei Sun, Yu Zhang, Fang Yu, Lingfei Yang, Dongfu Song, Guozhong He, Weiping Tong and Xiangjie Wang

Materials 2024, 17(13), 3159; https://doi.org/10.3390/ma17133159 - 27 Jun 2024

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Abstract

The hot compression simulation testing machine was utilized to conduct compression experiments on an Al-Mg-Si-Mn alloy containing the rare earth element Sc at a deformation temperature ranging from 450 to 550 °C and a strain rate of 0.01 to 10 s⁻¹. [...] Read more.

The hot compression simulation testing machine was utilized to conduct compression experiments on an Al-Mg-Si-Mn alloy containing the rare earth element Sc at a deformation temperature ranging from 450 to 550 °C and a strain rate of 0.01 to 10 s⁻¹. The study focused on the hot deformation behavior of the aluminum alloy, resulting in the determination of the optimal range of deformation process parameters for the alloy. The relationship between material flow stress, deformation temperature, and strain rate was described using the Arrhenius relationship containing thermal activation energy based on the stress-strain curve of hot compression deformation of aluminum alloy. This led to calculations for structural factor A, stress index n, and stress level parameters as well as thermal deformation activation energy to establish a constitutive Formula for hot deformation rheological stress of aluminum alloy and calculate the power dissipation factor η. Through this process, an optimized range for the optimal deformation process parameter for aluminum alloy was determined (deformation temperature: 490~510 °C; strain rate: 0.05 s⁻¹) and verified in combination with mechanical properties and microstructure through hot extrusion deformation trial production. Full article

(This article belongs to the Special Issue Advances in High-Performance Non-ferrous Materials—2nd Volume)

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26 pages, 32591 KiB

Open AccessArticle

Integrating Experimental and Computational Analyses for Mechanical Characterization of Titanium Carbide/Aluminum Metal Matrix Composites

by Waqas Farid, Hailin Li, Zhengyu Wang, Huijie Cui, Charlie Kong and Hailiang Yu

Materials 2024, 17(9), 2093; https://doi.org/10.3390/ma17092093 - 29 Apr 2024

Cited by 1 | Viewed by 1267

Abstract

This study investigates the mechanical properties of titanium carbide/aluminum metal matrix composites (AMMCs) using both experimental and computational methods. Through accumulative roll bonding (ARB) and cryorolling (CR) processes, AA1050 alloy surfaces were reinforced with TiCp particles to create the Al–TiCp composite. The experimental [...] Read more.

This study investigates the mechanical properties of titanium carbide/aluminum metal matrix composites (AMMCs) using both experimental and computational methods. Through accumulative roll bonding (ARB) and cryorolling (CR) processes, AA1050 alloy surfaces were reinforced with TiCp particles to create the Al–TiCp composite. The experimental analysis shows significant improvements in tensile strength, yield strength, elastic modulus, and hardness. The finite element analysis (FEA) simulations, particularly the microstructural modeling of RVE−1 (the experimental case model), align closely with the experimental results observed through scanning electron microscopy (SEM). This validation underscores the accuracy of the computational models in predicting the mechanical behavior under identical experimental conditions. The simulated elastic modulus deviates by 5.49% from the experimental value, while the tensile strength shows a 6.81% difference. Additionally, the simulated yield strength indicates a 2.85% deviation. The simulation data provide insights into the microstructural behavior, stress distribution, and particle–matrix interactions, facilitating the design optimization for enhanced performance. The study also explores the influence of particle shapes and sizes through Representative Volume Element (RVE) models, highlighting nuanced effects on stress–strain behavior. The microstructural evolution is examined via transmission electron microscopy (TEM), revealing insights regarding grain refinement. These findings demonstrate the potential of Al–TiCp composites for lightweight applications. Full article

(This article belongs to the Special Issue Advances in High-Performance Non-ferrous Materials—2nd Volume)

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19 pages, 8231 KiB

Open AccessArticle

Effect of Mn/Ag Ratio on Microstructure and Mechanical Properties of Heat-Resistant Al-Cu Alloys

by Xiangzhou Fu, Hailong Yang, Hanzhang Wang, Chifu Huang, Yongbin Chen, Qiangang Huang, Anmin Li and Liwen Pan

Materials 2024, 17(6), 1371; https://doi.org/10.3390/ma17061371 - 17 Mar 2024

Cited by 1 | Viewed by 1298

Abstract

This paper mainly investigated the effect of the Mn/Ag ratio on the microstructure and room temperature and high-temperature (350 °C) tensile mechanical properties of the as-cast and heat-treated Al-6Cu-xMn-yAg (x + y = 0.8, wt.%) alloys. The as-cast alloy has α-Al, Al₂ [...] Read more.

This paper mainly investigated the effect of the Mn/Ag ratio on the microstructure and room temperature and high-temperature (350 °C) tensile mechanical properties of the as-cast and heat-treated Al-6Cu-xMn-yAg (x + y = 0.8, wt.%) alloys. The as-cast alloy has α-Al, Al₂Cu, and a small amount of Al₇Cu₂ (Fe, Mn) and Al₂₀Cu₂ (Mn, Fe)₃ phases. After T6 heat treatment, a massive dispersive and fine θ′-Al₂Cu phase (100~400 nm) is precipitated from the matrix. The Mn/Ag ratio influences the quantity and size of the precipitates; when the Mn/Ag ratio is 1:1, the θ′-Al₂Cu precipitation quantity reaches the highest and smallest. Compared with the as-cast alloy, the tensile strength of the heat-treated alloy at room temperature and high temperature is greatly improved. The strengthening effect of the alloy is mainly attributed to the nanoparticles precipitated from the matrix. The Mn/Ag ratio also affects the high-temperature tensile mechanical properties of the alloy. The high-temperature tensile strength of the alloy with a 1:1 Mn/Ag ratio is the highest, reaching 135.89 MPa, 42.95% higher than that of the as-cast alloy. The analysis shows that a synergistic effect between Mn and Ag elements can promote the precipitation and refinement of the θ′-Al₂Cu phase, and there is an optimal ratio (1:1) that obtains the lowest interfacial energy for co-segregation of Mn and Ag at the θ′/Al interface that makes θ′-Al₂Cu have the best resistance to coarsening. Full article

(This article belongs to the Special Issue Advances in High-Performance Non-ferrous Materials—2nd Volume)

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15 pages, 7276 KiB

Open AccessArticle

Investigation on Creep Deformation and Age Strengthening Behavior of 304 Stainless Steel under High Stress Levels

by Lihua Zhan, Hao Xie, Youliang Yang, Shuai Zhao, Zhilong Chang, Yunni Xia, Zeyu Zheng and Yujie Zhou

Materials 2024, 17(3), 642; https://doi.org/10.3390/ma17030642 - 28 Jan 2024

Cited by 1 | Viewed by 1444

Abstract

The creep deformation behavior and age strengthening behavior of 304 stainless steel under high stress levels were systematically studied by uniaxial creep test, tensile test, XRD diffraction test and transmission electron microscopy. The results show that the total creep strain and the initial [...] Read more.

The creep deformation behavior and age strengthening behavior of 304 stainless steel under high stress levels were systematically studied by uniaxial creep test, tensile test, XRD diffraction test and transmission electron microscopy. The results show that the total creep strain and the initial creep strain rate increase with the increase in stress level, and the creep strain in the whole aging process is mainly produced in the initial creep stage. The calculated stress exponent shows that the main mechanism of creep deformation of 304 stainless steel at 453 K is dislocation slip. The strength and plasticity of 304 stainless steel after creep aging are improved simultaneously. Microstructural observations indicate an increase in dislocation density and martensite content, as well as austenite and twins, leading to an improvement in strength and plasticity, respectively. In addition, considering the influence of dislocation density on creep behavior, the relative dislocation density increase is introduced into the hyperbolic sine creep model, and a simple mechanism-based creep aging constitutive model is established. The creep strain predicted by the model is in good agreement with the experimental data of 304 stainless steel. The findings can provide theoretical support for the application of creep age forming in 304 stainless steel parts. Full article

(This article belongs to the Special Issue Advances in High-Performance Non-ferrous Materials—2nd Volume)

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16 pages, 8032 KiB

Open AccessArticle

Forming Characteristics of Tailor Rolled Blank of Aluminum Alloy during Three-Point Bending

by Ying Zhi, Yue Feng, Dong Wang, Xianlei Hu, Tao Sun and Xianghua Liu

Materials 2024, 17(3), 591; https://doi.org/10.3390/ma17030591 - 25 Jan 2024

Cited by 1 | Viewed by 984

Abstract

This paper presents an investigation on the forming characteristics of the tailor rolled blank of an aluminum alloy (Al-TRB) during three-point bending at room temperature through experiments and finite element simulations. The strain distribution, spring-back characteristics, and metal flow law of 6000 series [...] Read more.

This paper presents an investigation on the forming characteristics of the tailor rolled blank of an aluminum alloy (Al-TRB) during three-point bending at room temperature through experiments and finite element simulations. The strain distribution, spring-back characteristics, and metal flow law of 6000 series Al-TRB during three-point bending are explored. The prepared Al-TRB has good bending properties, and no surface cracks appear in the bending region of the Al-TRB when bent to 180°. Surface roughening occurs on the outside of the bending region. Since the strain in the thick zone is greater than that in the thin zone, the surface roughening in the thick zone is more obvious than that in the thin zone. The spring-back angle in the thin zone is higher than that in the thick zone after three-point bending, and the overall spring-back angle of Al-TRB becomes larger with an increasing bending angle. When the transition zone of Al-TRB is centered and the length of the transition zone is certain, as the length of the equal-thickness zone increases, the spring-back angle of the thin zone is larger, while the spring-back angle of the thick zone is smaller. Under the premise of a certain total length of Al-TRB and the length of the transition zone, the larger the length proportion of the thin zone, the larger the overall spring-back angle of Al-TRB, and the larger the length proportion of the thick zone, the smaller the overall spring-back angle of Al-TRB. In addition, a slight metal flow phenomenon exists during three-point bending, which shows that the metal in the bending region will flow to the thick zone, and the metal at the edge will flow to the thin zone. At the same time, there are localized thickening and thinning phenomena in Al-TRB. This study is helpful because it provides theoretical guidance for designing molds for the actual production of Al-TRB parts for automotives. Full article

(This article belongs to the Special Issue Advances in High-Performance Non-ferrous Materials—2nd Volume)

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13 pages, 7405 KiB

Open AccessArticle

Microstructure and Mechanical Properties of AA1050/AA6061 Laminated Composites Fabricated through Three-Cycle Accumulative Roll Bonding and Subsequent Cryorolling

by Lingling Song, Haitao Gao, Zhengyu Wang, Huijie Cui, Charlie Kong and Hailiang Yu

Materials 2024, 17(3), 577; https://doi.org/10.3390/ma17030577 - 25 Jan 2024

Cited by 1 | Viewed by 1547

Abstract

In this study, AA1050/AA6061 laminated composites were prepared by three-cycle accumulative roll bonding (ARB) and subsequent rolling. The effects of the rolling process on the microstructure evolution and mechanical properties of AA1050/AA6061 laminated composites were systematically investigated. The results indicate that the mechanical [...] Read more.

In this study, AA1050/AA6061 laminated composites were prepared by three-cycle accumulative roll bonding (ARB) and subsequent rolling. The effects of the rolling process on the microstructure evolution and mechanical properties of AA1050/AA6061 laminated composites were systematically investigated. The results indicate that the mechanical properties of the laminated composites can be effectively improved by cryorolling compared with room-temperature rolling. The microstructure analysis reveals that cryorolling can suppress the necking of the hard layer to obtain a flat lamellar structure. Moreover, the microstructure characterized by transmission electron microscopy shows that cryorolling can inhibit the dynamic recovery and significantly refine the grain size of the constituent layers. Meanwhile, the tensile fracture surface illustrates that AA1050/AA6061 laminated composites have the optimal interfacial bonding quality after cryorolling. Therefore, the laminated composites obtain excellent mechanical properties with the contribution of these factors. Full article

(This article belongs to the Special Issue Advances in High-Performance Non-ferrous Materials—2nd Volume)

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16 pages, 5519 KiB

Open AccessArticle

Analysis of Hot Tensile Fracture and Flow Behaviors of Inconel 625 Superalloy

by Xin-Zhe Pan, Xiao-Min Chen and Meng-Tao Ning

Materials 2024, 17(2), 473; https://doi.org/10.3390/ma17020473 - 19 Jan 2024

Cited by 1 | Viewed by 1028

Abstract

In this work, Inconel 625 alloy is explored regarding high-temperature tensile deformation and fracture behaviors at a strain rate of 0.005–0.01 s⁻¹ under a deformation temperature ranging from 700–800 °C. The subsequent analysis focuses on the impact of deformation parameters on flow [...] Read more.

In this work, Inconel 625 alloy is explored regarding high-temperature tensile deformation and fracture behaviors at a strain rate of 0.005–0.01 s⁻¹ under a deformation temperature ranging from 700–800 °C. The subsequent analysis focuses on the impact of deformation parameters on flow and fracture characteristics. The fractured surface reveals that ductile fracture is dominated by the nucleation, growth, and coalescence of microvoids as the primary failure mechanisms. The elevated deformation temperature and reduced strain rate stimulate the level of dynamically recrystallized (DRX) structures, resulting in intergranular fractures. The Arrhenius model and the particle swarm optimization-artificial neural network (PSO-ANN) model are developed to predict the hot tensile behavior of the superalloy. It indicates that the PSO-ANN model exhibits a correlation coefficient (R) as high as 0.9967, surpassing the corresponding coefficient of 0.9344 for the Arrhenius model. Furthermore, the relative absolute error of 9.13% (Arrhenius) and 1.85% (PSO-ANN model) are recorded. The developed PSO-ANN model accurately characterizes the flow features of the Inconel 625 superalloy with high precision and reliability. Full article

(This article belongs to the Special Issue Advances in High-Performance Non-ferrous Materials—2nd Volume)

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