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The Effects of Scandium and Zirconium Additions on Aluminum Mechanical Properties

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The Effects of Scandium and Zirconium Additions on Aluminum Mechanical Properties The Effects of Scandium and Zirconium Additions on Aluminum Mechanical Properties, Post-Braze Grain Structure, and Extrusion A thesis presented to the faculty of the Russ College of Engineering and Technology of Ohio University In partial fulfillment of the requirements for the degree Master of Science Cory R. Williams March 2012 © 2012 Cory R. Williams. All Rights Reserved. 2 This thesis titled The Effects of Scandium and Zirconium Additions on Aluminum Mechanical Properties, Post-Braze Grain Structure, and Extrusion by CORY R.WILLIAMS has been approved for the Department of Mechanical Engineering and the Russ College of Engineering and Technology by Frank F. Kraft Associate Professor of Mechanical Engineering Dennis Irwin Dean, Russ College of Engineering and Technology 3 Abstract WILLIAMS, CORY R., M.S., March 2012, Mechanical Engineering The Effects of Scandium and Zirconium Additions on Aluminum Mechanical Properties, Post-Braze Grain Structure, and Extrusion Director of Thesis: Frank F. Kraft The purpose of this work was to evaluate the ability of Sc and Zr to inhibit recrystallization and grain growth of cold-worked aluminum parts that are brazed into assemblies. Extruded, multi-channel tube, used for automotive climate control systems, are sized and straightened prior to assembly into heat exchangers. This small amount of plastic strain (cold-work) is the driving force for recrystallization and large grain growth during the brazing process, which takes place at approximately 600°C. This generally coincides with a significant decrease in part strength. A 1000 series aluminum alloy with additions of 0.2% Sc and 0.05% Zr was evaluated with respect to the brazing thermal cycle and a typical amount of cold-work imposed during straightening and sizing. The effect on extrusion was considered, and a comparison was made to AA 3102, a typical alloy for this application. Approved: _____________________________________________________________ Frank F. Kraft Associate Professor of Mechanical Engineering 4 ACKNOWLEDGMENTS I would like to thank Dr. Frank Kraft for his guidance on this project, in the classroom, and also in life. While working with Dr. Kraft I learned many subtle life lessons in addition to the regular curriculum. For serving on my committee, I would like to thank Dr. Israel Urieli, Dr. Daniel Gulino, and Dr. Hugh Richardson. This project would not have been possible without the generosity of Alcan, Inc. and Dr. Nick Parson by providing the material and extrusion data. Alcan, Inc. is a Canadian mining company and aluminum manufacturer. For the use of their labs and for sparking my interest in the material field during my internship, I would like to thank Gary Pruett, Robert Bianco, and Hector Cirilo at Goodrich Corporation. Goodrich Corporation is an American aerospace manufacturing company. Most importantly, I would like to thank my wife, Sadie, my daughter, Paisley, my parents, Randy and Sandra, my brother, Brad, and my family for always supporting me and helping me achieve everything I have accomplished. 5 TABLE OF CONTENTS Page Acknowledgments............................................................................................................... 4 List of Tables ...................................................................................................................... 7 List of Figures ..................................................................................................................... 8 Chapter 1: Introduction ..................................................................................................... 10 1.1 Background of Brazed Automotive Heat Exchangers ...................................... 10 1.2 Background of Aluminum-Scandium Alloys ................................................... 13 1.3 Objectives ......................................................................................................... 17 Chapter 3: Experimental Approach .................................................................................. 20 3.1 Cold Rolling ...................................................................................................... 20 3.2 Simulated Brazing ............................................................................................. 21 3.3 Aging Heat Treatment....................................................................................... 23 Chapter 4: Mechanical Testing and Procedures................................................................ 25 4.1 Sample Preparation ........................................................................................... 25 4.2 Tensile Testing .................................................................................................. 27 4.3 Burst Testing ..................................................................................................... 31 4.4 Metallography ................................................................................................... 35 Chapter 5: Results And Analysis ...................................................................................... 38 5.1 Extrusion ................................................................................................................. 38 5.2 Microstructure Analysis .......................................................................................... 39 6 5.3 Tensile Testing ........................................................................................................ 42 5.4 Burst Testing ........................................................................................................... 49 Chapter 6: Conclusions ..................................................................................................... 52 Chapter 7: Future Work .................................................................................................... 54 References ......................................................................................................................... 55 7 LIST OF TABLES Page Table 1: AlSc alloy composition in weight % ...............................................................18 Table 2: AA 3102 alloy composition in weight % ........................................................18 Table 3: Extrusion parameters .......................................................................................19 Table 4: Measurements taken during sample preparation .............................................26 Table 5: Summary of extrusion results ...........................................................................38 Table 6: Results of burst tested samples .........................................................................50 8 LIST OF FIGURES Page Figure 1: Parallel Heat Exchanger and Tube Cross-Section ...........................................11 Figure 2: Pre-Braze and Post-Braze AA 3102 Tube .......................................................12 Figure 3: Inner Wall Failure of Post-Braze AA 3102 Tube ............................................12 Figure 4: The Effects of Roll-Sizing on Failure Pressure on AA 3102 Tube .................13 Figure 5: Al-Sc Phase Diagram and Solvus Close-Up ...................................................15 Figure 6: Alloying Additions Effects on Recrystallization Temperature .......................16 Figure 7: AlSc multi-channel tube cross-section ............................................................19 Figure 8: Thermolyne tube furnace with samples partially inserted ...............................21 Figure 9: Simulated brazing apparatus ...........................................................................22 Figure 10: Simulated brazing thermal cycle on AlSc tube samples ...............................23 Figure 11: Aging heat treatment data..............................................................................24 Figure 12: Tinius Olsen 1000 tensile test machine with extensometer ..........................27 Figure 13: Personal DaqView data acquisition software ................................................28 Figure 14: Yield strength graph ......................................................................................31 Figure 15: Burst testing apparatus using MTS machine .................................................33 Figure 16: Sample graph of burst test pressure over time ..............................................34 Figure 17: Mounted and polished samples of AlSc multi-channel tube .........................36 Figure 18: Microstructure of as-extruded AlSc multi-channel tube ...............................37 Figure 19: Detailed extrusion results ..............................................................................39 Figure 20: Microstructure of as-extruded AA 3102 .......................................................40 9 Figure 21: Microstructure of as-extruded AlSc ..............................................................40 Figure 22: AlSc alloy longitudinal sections ....................................................................41 Figure 23: Microstructure of AA 3102 samples with 4% reduction ...............................42 Figure 24: Tensile test results for experimental AlSc tube samples ...............................44 Figure 25: Tensile test results for AlSc alloy samples ....................................................45 Figure 26: Tensile test results for AA 3102 alloy samples .............................................47 Figure 27: Tensile test results for AA 3102 and AlSc ....................................................49
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