Pub Date : 2019-11-27DOI: 10.5772/intechopen.86077
P. J. Ramulu
Industrial revolution toward weight reduction and fuel efficiency of the automotive and aerospace vehicles is the major concern to replace heavy metals with light weight metals without affecting much strength. For this, aluminum alloys are the major contributors to those industries. Moreover, aluminum alloys are majorly categorized as 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx based on major alloying elements. Among all, 2xxx, 5xxx, 6xxx, and 7xxx are having majority of applications in the abovementioned industries. For manufacturing any engineering deformable components, forming characteristics are must. Forming behavior of aluminum alloys has been evaluated through different processes including deep drawing, stretching, incremental forming, bending, hydro forming etc., under different process conditions (cold, warm, and hot conditions) and process parameters. Each process has its own process feasibility to evaluate the formability without any forming defects in products. The present chapter discusses a few important processes and their parameter effect on the aluminum alloys through the experimenta-tions and simulation works.
{"title":"Aluminum Alloys Behavior during Forming","authors":"P. J. Ramulu","doi":"10.5772/intechopen.86077","DOIUrl":"https://doi.org/10.5772/intechopen.86077","url":null,"abstract":"Industrial revolution toward weight reduction and fuel efficiency of the automotive and aerospace vehicles is the major concern to replace heavy metals with light weight metals without affecting much strength. For this, aluminum alloys are the major contributors to those industries. Moreover, aluminum alloys are majorly categorized as 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx based on major alloying elements. Among all, 2xxx, 5xxx, 6xxx, and 7xxx are having majority of applications in the abovementioned industries. For manufacturing any engineering deformable components, forming characteristics are must. Forming behavior of aluminum alloys has been evaluated through different processes including deep drawing, stretching, incremental forming, bending, hydro forming etc., under different process conditions (cold, warm, and hot conditions) and process parameters. Each process has its own process feasibility to evaluate the formability without any forming defects in products. The present chapter discusses a few important processes and their parameter effect on the aluminum alloys through the experimenta-tions and simulation works.","PeriodicalId":377033,"journal":{"name":"Aluminium Alloys and Composites","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-11-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121203815","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-11-23DOI: 10.5772/intechopen.89994
D. Weiss
Aluminum alloys containing small amounts of cerium have been investigated to improve the grain refining, casting characteristics, and mechanical properties of aluminum alloys. These additions were usually made at levels of 1% or less but did not produce appreciable improvements. Recent work has shown that additions between 4% and the approximate eutectic composition of 10% improve the high-temperature performance of aluminum alloys. Corrosion performance of aluminum alloys can also be improved through the addition of Ce. Traditional aluminum alloying elements such as magnesium and silicon can be used to control casting characteristics and thermal and physical properties. Cerium oxide is the predominate oxide in rare earth mining. Much of it is discarded after separation from the heavy rare earth oxides containing Nd and Dy. The beneficial use of Ce should reduce the cost of the more desirable rare earths. Results of using Ce as an addition to aluminum in mul-tiple manufacturing methods such as additive manufacturing, extrusion, and casting are explored. The results show significant strengthening and improved mechanical property retention at higher temperatures than in other aluminum alloys and, in some compositions, show complete recovery of mechanical properties at room temperature when exposed to elevated temperatures as high as 500°C for 1000 hours.
{"title":"Composites and Alloys Based on the Al-Ce System","authors":"D. Weiss","doi":"10.5772/intechopen.89994","DOIUrl":"https://doi.org/10.5772/intechopen.89994","url":null,"abstract":"Aluminum alloys containing small amounts of cerium have been investigated to improve the grain refining, casting characteristics, and mechanical properties of aluminum alloys. These additions were usually made at levels of 1% or less but did not produce appreciable improvements. Recent work has shown that additions between 4% and the approximate eutectic composition of 10% improve the high-temperature performance of aluminum alloys. Corrosion performance of aluminum alloys can also be improved through the addition of Ce. Traditional aluminum alloying elements such as magnesium and silicon can be used to control casting characteristics and thermal and physical properties. Cerium oxide is the predominate oxide in rare earth mining. Much of it is discarded after separation from the heavy rare earth oxides containing Nd and Dy. The beneficial use of Ce should reduce the cost of the more desirable rare earths. Results of using Ce as an addition to aluminum in mul-tiple manufacturing methods such as additive manufacturing, extrusion, and casting are explored. The results show significant strengthening and improved mechanical property retention at higher temperatures than in other aluminum alloys and, in some compositions, show complete recovery of mechanical properties at room temperature when exposed to elevated temperatures as high as 500°C for 1000 hours.","PeriodicalId":377033,"journal":{"name":"Aluminium Alloys and Composites","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-11-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128937488","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-10-24DOI: 10.5772/intechopen.89797
P. Hema
Aluminum and aluminum composites play important role in aerospace, automo-bile, marine and structural applications. Literature shows that some of the con-ventional fusion welding processes in joining of aluminum metals result in defects like porosity, distortion owing to elevated thermal conductivity and solidification shrinkage. To overcome such issues, experimental investigations are conducted using Friction Stir Welding (FSW) process in joining of metal plates of aluminum 6061 alloy. Weld joint samples are cut to required sizes and secured them in position by mechanical clamps. The setup is loaded onto Vertical Machining Centre. Nonconsumable tool tips of four different shapes of tungsten carbide and H13 materials are prepared and attached to the spindle. The machine is started and allowed spindle to rotate the tool to plunge onto metal plates along joint line. An axial force is continuously applied until sufficient heat is generated at mating surfaces for joining. Experiments are repeated at different levels by varying welding parameters. Joints are tested for their mechanical properties. The microstructural analysis is studied by SEM. Artificial Neural Network (ANN) simulation model is developed for validation. ANOVA is applied for validation of output results of mechanical properties and optimal process parameters are determined. Research shows that joints are influenced by profile of tool pin and, therefore, the rotational speed of the tool.
{"title":"Experimental Investigations on AA 6061 Alloy Welded Joints by Friction Stir Welding","authors":"P. Hema","doi":"10.5772/intechopen.89797","DOIUrl":"https://doi.org/10.5772/intechopen.89797","url":null,"abstract":"Aluminum and aluminum composites play important role in aerospace, automo-bile, marine and structural applications. Literature shows that some of the con-ventional fusion welding processes in joining of aluminum metals result in defects like porosity, distortion owing to elevated thermal conductivity and solidification shrinkage. To overcome such issues, experimental investigations are conducted using Friction Stir Welding (FSW) process in joining of metal plates of aluminum 6061 alloy. Weld joint samples are cut to required sizes and secured them in position by mechanical clamps. The setup is loaded onto Vertical Machining Centre. Nonconsumable tool tips of four different shapes of tungsten carbide and H13 materials are prepared and attached to the spindle. The machine is started and allowed spindle to rotate the tool to plunge onto metal plates along joint line. An axial force is continuously applied until sufficient heat is generated at mating surfaces for joining. Experiments are repeated at different levels by varying welding parameters. Joints are tested for their mechanical properties. The microstructural analysis is studied by SEM. Artificial Neural Network (ANN) simulation model is developed for validation. ANOVA is applied for validation of output results of mechanical properties and optimal process parameters are determined. Research shows that joints are influenced by profile of tool pin and, therefore, the rotational speed of the tool.","PeriodicalId":377033,"journal":{"name":"Aluminium Alloys and Composites","volume":"9 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-10-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134645861","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-10-09DOI: 10.5772/intechopen.89554
S. Magibalan
The current research work is focused on fabrication of Aluminium Alloy 8011 with 4% fly ash composite (AA8011-4% FA) by using the stir casting method. Wear behaviour and description of the composite are evaluated in different process parameters by using a pin-on-disc at room temperature. Fly ash (FA) in the range of (4 wt. %, average micron size 10 – 30 μ m) is included into the matrix, and its sensitivity analysis is investigated. Three level of Central Composite Design model is developed by using Response Surface Methodology equation with different process parameters via load, time and sliding velocity are separate in the range of (5 – 15 N), (5 – 15 min) and (1.5 – 4.5 m/s) respectively. The surface plot shows that wear rate increases with increasing load, time and sliding velocity. A sensitivity analysis is also carried out and compared with the relative impact of input parameters on wear behaviour in order to verify the measurement errors on the values of the uncertainty in estimated parameters of three inputs such as normal load, time and sliding velocity on wear rate (WR) and coefficient of friction (COF). The result shows that normal load is more sensitive than the other parameters. The variation of load causes more changes in wear rate.
{"title":"Wear Behaviour of Aluminium Alloy 8011 with 4% Fly Ash Composites by Using Sensitivity Analysis","authors":"S. Magibalan","doi":"10.5772/intechopen.89554","DOIUrl":"https://doi.org/10.5772/intechopen.89554","url":null,"abstract":"The current research work is focused on fabrication of Aluminium Alloy 8011 with 4% fly ash composite (AA8011-4% FA) by using the stir casting method. Wear behaviour and description of the composite are evaluated in different process parameters by using a pin-on-disc at room temperature. Fly ash (FA) in the range of (4 wt. %, average micron size 10 – 30 μ m) is included into the matrix, and its sensitivity analysis is investigated. Three level of Central Composite Design model is developed by using Response Surface Methodology equation with different process parameters via load, time and sliding velocity are separate in the range of (5 – 15 N), (5 – 15 min) and (1.5 – 4.5 m/s) respectively. The surface plot shows that wear rate increases with increasing load, time and sliding velocity. A sensitivity analysis is also carried out and compared with the relative impact of input parameters on wear behaviour in order to verify the measurement errors on the values of the uncertainty in estimated parameters of three inputs such as normal load, time and sliding velocity on wear rate (WR) and coefficient of friction (COF). The result shows that normal load is more sensitive than the other parameters. The variation of load causes more changes in wear rate.","PeriodicalId":377033,"journal":{"name":"Aluminium Alloys and Composites","volume":"8 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115753615","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-08-09DOI: 10.5772/INTECHOPEN.86553
K. Velmanirajan, K. Anuradha
Aluminium and its alloys are preferred materials, because of its varied desirable properties, availability and inexpensiveness. Aluminium alloys exist in several different grades available in the market commercially, from pure (about 99% Al content) to specific varieties based on the impurities contained in it by chemical composition. The properties are differing in nature which can be scientifically seen and justified in different perspectives. The properties such as forming, fracture mode, tensile, etc. can be seen through the metallurgical aspect, chemical aspect, crystallographic texture, forming limits and mechanical properties. The truth of its properties can be viewed by interlinking/correlating nature of its different studies. The purpose of this chapter is to show the correlating nature of different properties of aluminium of same and different grades.
{"title":"Aluminium and Its Interlinking Properties","authors":"K. Velmanirajan, K. Anuradha","doi":"10.5772/INTECHOPEN.86553","DOIUrl":"https://doi.org/10.5772/INTECHOPEN.86553","url":null,"abstract":"Aluminium and its alloys are preferred materials, because of its varied desirable properties, availability and inexpensiveness. Aluminium alloys exist in several different grades available in the market commercially, from pure (about 99% Al content) to specific varieties based on the impurities contained in it by chemical composition. The properties are differing in nature which can be scientifically seen and justified in different perspectives. The properties such as forming, fracture mode, tensile, etc. can be seen through the metallurgical aspect, chemical aspect, crystallographic texture, forming limits and mechanical properties. The truth of its properties can be viewed by interlinking/correlating nature of its different studies. The purpose of this chapter is to show the correlating nature of different properties of aluminium of same and different grades.","PeriodicalId":377033,"journal":{"name":"Aluminium Alloys and Composites","volume":"84 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-08-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121226078","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-06-28DOI: 10.5772/INTECHOPEN.86017
A. Raja, R. Jayaganthan, A. Tiwari, Ch. Srinivasa Rakesh
The superplastic deformation exhibited by metals with different grain sizes and their corresponding deformation mechanism influences the industrial metal-forming processes. The coarse-grained materials, which contain grain size greater than 20 μ m, exhibited superplastic deformation at high homologous temperature and low strain rate of the order of 10 − 4 s − 1 . Fine grain materials (1–20 μ m) are generally considered as favorable for superplastic deformation. They possess high-strain-rate sensitivity “m” value, approximately, equal to 0.5 at the temperature of 0.5 times the melting point and at a strain rate of 10 − 3 to 10 − 4 s − 1 . Ultrafine grains (100 nm to less than 1 μ m) exhibit superplasticity at high strain rate as well as at low temperature when compared to fine grain materials. It is attributed to the fact that both temperature and strain rates are inversely proportional to the grain size in Arrhenius-type superplastic constitute equation. The superplastic phenomenon with nano-sized grains (10 nm to less than 100 nm) is quite different from their higher-scale counterparts. It exhibits high ductility with high strength. Materials with mixed grain size distribution (bimodal or layered) are found to exhibit superior superplasticity when compared to the homogeneous grain-sized material. The deformation mechanisms governing these superplastic deformations with different scale grain size microstructures are discussed in this chapter.
{"title":"Effect of Grain Size on Superplastic Deformation of Metallic Materials","authors":"A. Raja, R. Jayaganthan, A. Tiwari, Ch. Srinivasa Rakesh","doi":"10.5772/INTECHOPEN.86017","DOIUrl":"https://doi.org/10.5772/INTECHOPEN.86017","url":null,"abstract":"The superplastic deformation exhibited by metals with different grain sizes and their corresponding deformation mechanism influences the industrial metal-forming processes. The coarse-grained materials, which contain grain size greater than 20 μ m, exhibited superplastic deformation at high homologous temperature and low strain rate of the order of 10 − 4 s − 1 . Fine grain materials (1–20 μ m) are generally considered as favorable for superplastic deformation. They possess high-strain-rate sensitivity “m” value, approximately, equal to 0.5 at the temperature of 0.5 times the melting point and at a strain rate of 10 − 3 to 10 − 4 s − 1 . Ultrafine grains (100 nm to less than 1 μ m) exhibit superplasticity at high strain rate as well as at low temperature when compared to fine grain materials. It is attributed to the fact that both temperature and strain rates are inversely proportional to the grain size in Arrhenius-type superplastic constitute equation. The superplastic phenomenon with nano-sized grains (10 nm to less than 100 nm) is quite different from their higher-scale counterparts. It exhibits high ductility with high strength. Materials with mixed grain size distribution (bimodal or layered) are found to exhibit superior superplasticity when compared to the homogeneous grain-sized material. The deformation mechanisms governing these superplastic deformations with different scale grain size microstructures are discussed in this chapter.","PeriodicalId":377033,"journal":{"name":"Aluminium Alloys and Composites","volume":"5 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116170369","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-05-10DOI: 10.5772/INTECHOPEN.86225
Francis Nturanabo, L. Masu, J. Kirabira
Advanced materials have offered the materials designer a wide range of options in the specification and selection of materials for various applications. Material properties are continually being improved to meet safety and operational standards in line with prevailing technological developments. Modern technological requirements, together with the consumers’ demands for systems and machines that are more energy efficient, stronger, light-weight, cost-effective, etc., dictate that the search for new and advanced materials will remain a subject of interest all the time. The dif-ficulty in designing materials for such stringent specifications cannot be overstated, owing to the conflicting nature of these specifications. Aluminium metal matrix composites (AlMMCs) are a class of materials that have proven successful in meeting most of the rigorous specifications in applications where light-weight, high stiffness and moderate strength are the requisite properties. With a variety of reinforcement materials and flexibility in their primary processing, AlMMCs offer great potential for the development of composites with the desired properties for certain applications. In this review, the development, utilisation and future potential of AlMMCs in various industrial and commercial applications is discussed, together with the existing challenges hindering their full market penetration.
{"title":"Novel Applications of Aluminium Metal Matrix Composites","authors":"Francis Nturanabo, L. Masu, J. Kirabira","doi":"10.5772/INTECHOPEN.86225","DOIUrl":"https://doi.org/10.5772/INTECHOPEN.86225","url":null,"abstract":"Advanced materials have offered the materials designer a wide range of options in the specification and selection of materials for various applications. Material properties are continually being improved to meet safety and operational standards in line with prevailing technological developments. Modern technological requirements, together with the consumers’ demands for systems and machines that are more energy efficient, stronger, light-weight, cost-effective, etc., dictate that the search for new and advanced materials will remain a subject of interest all the time. The dif-ficulty in designing materials for such stringent specifications cannot be overstated, owing to the conflicting nature of these specifications. Aluminium metal matrix composites (AlMMCs) are a class of materials that have proven successful in meeting most of the rigorous specifications in applications where light-weight, high stiffness and moderate strength are the requisite properties. With a variety of reinforcement materials and flexibility in their primary processing, AlMMCs offer great potential for the development of composites with the desired properties for certain applications. In this review, the development, utilisation and future potential of AlMMCs in various industrial and commercial applications is discussed, together with the existing challenges hindering their full market penetration.","PeriodicalId":377033,"journal":{"name":"Aluminium Alloys and Composites","volume":"154 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127510386","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2018-11-05DOI: 10.5772/INTECHOPEN.78789
Yingyi Zhang, Y. Qi, Jiaxin Li
Bauxite is the main source for alumina production. With the rapid development of iron and steel industry and aluminum industry, high-quality iron ore and bauxite resources become increasingly tense. However, a lot of iron-rich bauxite and Bayer red mud resources have not been timely and effectively recycled, resulting in serious problems of environmental pollution and wastage of resources. The comprehensive utilization of iron- rich bauxite and red mud is still a worldwide problem. The industrial stockpiling is not a fundamental way to solve the problems of iron-rich bauxite and red mud. As to the recovery of valuable metals from iron-rich bauxite and red mud, there are a lot of technical and cost problems, which are serious impediments to industrial development. Applying red mud as construction materials like cement, soil ameliorant applications face the problem of Na, Cr, As leaching into the environment. However, the high-temperature reduction, smelting and alkaline leaching process is a feasible method to recover iron and alumina from iron-rich bauxite and red mud. This chapter intends to provide the reader an overview on comprehensive utilization technology of the low-grade iron-rich bauxite and Bayer red mud sources.
{"title":"Aluminum Mineral Processing and Metallurgy: Iron-Rich Bauxite and Bayer Red Muds","authors":"Yingyi Zhang, Y. Qi, Jiaxin Li","doi":"10.5772/INTECHOPEN.78789","DOIUrl":"https://doi.org/10.5772/INTECHOPEN.78789","url":null,"abstract":"Bauxite is the main source for alumina production. With the rapid development of iron and steel industry and aluminum industry, high-quality iron ore and bauxite resources become increasingly tense. However, a lot of iron-rich bauxite and Bayer red mud resources have not been timely and effectively recycled, resulting in serious problems of environmental pollution and wastage of resources. The comprehensive utilization of iron- rich bauxite and red mud is still a worldwide problem. The industrial stockpiling is not a fundamental way to solve the problems of iron-rich bauxite and red mud. As to the recovery of valuable metals from iron-rich bauxite and red mud, there are a lot of technical and cost problems, which are serious impediments to industrial development. Applying red mud as construction materials like cement, soil ameliorant applications face the problem of Na, Cr, As leaching into the environment. However, the high-temperature reduction, smelting and alkaline leaching process is a feasible method to recover iron and alumina from iron-rich bauxite and red mud. This chapter intends to provide the reader an overview on comprehensive utilization technology of the low-grade iron-rich bauxite and Bayer red mud sources.","PeriodicalId":377033,"journal":{"name":"Aluminium Alloys and Composites","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2018-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122856688","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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