DOCSLIB.ORG

Optimization of Mechanical Properties in A356 Via Simulation And

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text

Load more

OPTIMIZATION OF MECHANICAL PROPERTIES IN A356 VIA SIMULATION AND PERMANENT MOLD TEST-BARS By CHIA-JUNG CHEN Submitted in partial fulfillment of the requirements for the degree of Doctor of Philosophy Dissertation Adviser: Professor David Schwam Department of Materials Science and Engineering CASE WESTERN RESERVE UNIVERSITY January, 2014 CASE WESTERN RESERVE UNIVERSITY SCHOOL OF GRADUATE STUDIES We hereby approve the thesis/dissertation of Chia-Jung Chen Doctor of Philosophy candidate for the degree *. John Lewandowski David Schwam Gerhard Welsch Malcolm Cooke 11/15/2013 (date) *We also certify that written approval has been obtained for any proprietary material contained therein. TABLE OF CONTENTS Content Page TABLE OF CONTENTS [1] LIST OF TABLES [5] LIST OF FIGURES [6] ACKNOWLEDGEMENTS [12] ABSTRACT [13] 1. Chapter 1: Aluminum Cast Alloys 1 1.1. Introduction 1 1.1.1 3xx Alloy 2 1.2. Intrinsic effects on mechanical properties of 3xx alloys (element effects) 3 1.2.1. Grain Refining of 3xx alloys 3 1.2.2. Factors Effect on Grain Size 4 1.2.3. Microstructural Modification 6 1.2.3.1. Modification of A356 alloy 7 1.2.3.2. Modification of 319 alloy 8 [1] Content Page 1.2.4. Heat Treatment of A356 Alloy 9 1.3. Extrinsic effects on mechanical properties of 3xx alloy (porosity and 14 inclusion effects) 1.3.1. Effect of Porosity on Mechanical Properties of A356 14 1.3.1.1. Hydrogen in Molten Aluminum Alloys (gas porosity) 17 1.3.1.2. Shrinkage Porosity 20 1.3.1.3. Element effects on shrinkage porosity 20 1.3.1.4.The Removal of gas porosity 21 1.3.2. Effect of Inclusions on Mechanical Properties 22 1.3.2.1. Measurement of inclusion content 22 1.3.2.2. Methods of Inclusion Removal from Molten Aluminum 25 1.4 Quality Index for Aluminum Alloy Castings 28 2. Literature Review of Effects on Mechanical Properties of A356 and 319 28 Alloys 2.1. Effect of Microstructural Modification and Heat Treatment on 32 Mechanical properties 2.2. Effect of SDAS (Grain Size) on Mechanical Properties 34 2.3 Effect of Porosity on Mechanical Properties 36 2.4. Inclusion Effect on Mechanical Properties 38 3. Experimental Procedure 40 [2] Content Page 3.1. Melt Preparation 40 3.2. Mold Preparation 42 3.3. Filter Preparation 48 3.4. Reduced Pressure Test 49 3.5. PoDFA 50 3.6. Experimental Cooling Rate 50 3.7. Tensile Test 54 3.8. Fatigue Test 55 3.9. Magma Simulation 57 4. Results and Discussions 59 4.0. Hypotheses and Objectives 59 4.1. Characterization of Defects 59 4.1.1. Reduced Pressure Test 59 4.2. Improvement in Mechanical Properties of A356 Alloy 61 4.2.1. Gating System Effect on Mechanical Properties 62 4.2.1.1. Sprue Size Effect 62 4.2.1.2. Effect of the Knfie Ingate 72 4.2.2. The Effect of Coating the Gage Section 79 [3] Content Page 4.2.3. Filtration Effect 82 4.2.4. Best Mechanical Properties of A356 Alloy from Each Mold 83 4.2.5. Quality Index 88 4.3. Improvement in Mechanical Properties of 319 Alloy 91 4.3.1. Effect of Mg and Mn addition in 319Alloy 91 4.3.2. Effect of the Knife Ingate 92 4.3.3. Filtration Effect 95 4.4. Improving Fatigue Properties with HIP 97 5. Conclusions 100 6. References 103 [4] LIST OF TABLES Table Page 1.1. Series of Cast and Wrought Aluminum Alloys 1 1.2. Composition of A356 and 319 Alloys 2 1.3. Heat Treating Temper Code 11 1.4. Typical Inclusions in Aluminum Cast Alloys 16 1.5. Summary of trends in porosity distribution and level 21 2.1. Gas Levels, Solidification Rates and Tensile Properties of CA-B135-T6 38 Sand Cast Step Castings Table Page 2.2. Inclusion/oxide - Mechanical Properties Relationships for A356.2 Alloy 39 4.1. Reduced pressure test relationship to Alspek reading of A356 alloy 60 4.2. Compositions of A356 Alloy in This Study 61 4.3. Compositions of 319 Alloy in This Study 91 [5] LIST OF FIGURES Figures Page 1.1. Phase diagram of aluminum and silicon alloy 3 1.2. Hall-Petch relationship diagram 4 1.3. Grain refiner effect on undercooling 5 1.4. Ti content effect on average grain size 5 1.5. Polarized light micrographs showing the effect of B addition on the A356 grain structure 6 1.6. Typical microstructure of as-cast A356 alloy 7 1.7. Eutectic Si structure observed in 319 alloy 8 1.8. SEM microstructures observed in the 319 type aluminum alloys 9 after T6 heat treatment 1.9. Artificial aging of aluminum alloys 12 1.10. SEM micrograph of A356 alloy solutionized in conventional furnace for 6 hours at 1000oF and aged at 340oF 13 1.11. BFTEM image and [001] SAD pattern from the 319 alloy 13 1.12. Typical shrinkage pore surrounded by dendrites and eutectic phase 15 1.13. Typical gas pore 15 1.14. Effect of temperature on solubility of hydrogen in pure aluminum 17 1.15. A schematic figure of reduced pressure test apparatus 19 1.16. Cross section of RPT samples 21 1.17. Schemetic picture of degassing device 22 [6] Figures Page 1.18. PoDFA (Porous disc filtration apparatus) 23 1.19. Typical micrograph of a sectioned PoDFA sample 24 1.20. Higher magnification on cake section 24 1.21. Effect of time and temperature on oxidation of aluminum 26 1.22. Schematic figure of a fluxing system 26 1.23. Modes of inclusions capture 27 1.24. Yield strength-elongation relationship of A356/A357 alloys 29 1.25. Schematic illustration of the quality index, QT, as the ratio of the experimentally observed elongation as a fraction of the maximum possible 30 elongation QT = eF/eF(max) at the given level of yield strength, σY. 1.26. The nomogram with iso- QT lines for A356/A357 alloy castings shows four distinct regions 31 2.1. UTS and elongation as a function of solution time 33 2.2. Ultimate tensile strength and % elongation of Mg-free and Mg-containing 34 samples 2.3. The average UTS and elongation of cast A356-T6 aluminum alloy curves 35 2.4. S/N curves of E319 with low SDAS and 70μm SDAS 36 2.5. Ultimate tensile and yield strengths versus gas content and per cent voids for 37 remelted A356 alloy 3.1. Electric resistance furnace 40 3.2. Recycled A356 aluminum 41 3.3. Degassing treatment 41 [7] Figures Page 3.4. Fluxing and skimming 42 3.5. ALSPEK hydrogen system 42 3.6. Electrical heater 43 3.7. Oxy-hydrogen flam 43 3.8. Standard Sthal mold 44 3.9. Stahl mold with large round shape sprue (Stahl HS Mold) 44 3.10. Case mold version.1 45 3.11. Case mold version.2 46 3.12. Case mold version.3 46 3.13. Schematic of the cast bars from Case mold version.3 and version.4 47 3.14. Grinding of the knife ingate 47 3.15. In-mold filters 48 3.16. Top view of the in-crucible filter box (black) immersed in Al 48 3.17. RPT test equipment 49 3.18. PoDFA equipments 50 3.19. (a) Dimensions of the step casting and (b) Illustration of the set-up for 51 cooling rate measurement 3.20. Respective cooling rates 52 3.21. Typical cooling rates for various casting processes 53 3.22. Sthal and Case mold version.1 and step mold test bars 54 [8] Figure Page 4.1. PoDFA results for five different conditions 61 4.2. The fracture surface of Case mold v1 test bar 63 4.3. The fracture surface of a Stahl mold test bar 64 4.4. Reduction in melt front velocity of Case Mold v.2 65 4.5. Standard Stahl mold and Stahl HS mold 66 4.6. Filling time in Stahl mold and Stahl HS mold 67 4.7. Melt front velocity of Stahl mold and Stahl HS mold 68 4.8. The effect of sprue size on mechanical properties of A356 alloy on Stahl 69 mold 4.9. Sprue size of Case mold v.2 and v.3 70 4.10. Effect of sprue size on mechanical properties of A356 alloy on Case mold 71 4.11. Macrograph of Stahl mold and Stahl HS mold 72 4.12. Case mold v.3 and v.4 73 4.13. Solidification time of Case mold v.3 and v.4 74 4.14. Micro porosity of Case mold v.3 and v.4 74 4.15. SDAS of Case mold v.3 and v.4 75 4.16. The effect of the knife gate on mechanical properties of A356 alloy 76 4.17. Fracture surface of Stahl mold and Case mold v.4 77 4.18. Shrinkage porosity in Stahl mold test bars 78 4.19. Perfectly broken of Case mold V4 test bars 78 4.20. Test bar after removal of the knife ingate 79 [9] Figure Page 4.22. The micro-porosity at gage section of Case mold V4 with two kinds of 81 coating 4.23. Applying a coating on the gage section effects on the fracture surfaces of 82 tensile test bars of A356 alloy in different molds 4.24. In-mold filter effect on mechanical properties of A356 alloy 83 4.25. Schematic of the step mold and step casting 84 4.26. Micro-porosity prediction in three different molds 85 4.27.
Recommended publications
  • Troubleshooting Decorative Electroplating Installations, Part 5

    Troubleshooting Decorative Electroplating Installations, Part 5

    Troubleshooting Decorative Electroplating Installations, Part 5: Plating Problems Caused Article By Heat & Bath Temperature Fluctuations by N.V. Mandich, CEF, AESF Fellow Technical Technical In previous parts of this series, emphasis was given The fast-machining steels must then be carburized to troubleshooting of the sequences for pre-plating or case-hardened to obtain a surface with the hardness and electroplating over metals, Parts 1 and 2;1 required to support the top chromium electroplate. the causes, symptoms and troubleshooting for Case hardening is the generic term covering several pores, pits, stains, blistering and “spotting-out” processes applicable to steel or ferrous alloys. It changes phenomena, Part 3;2 and troubleshooting plating on the surface composition of the top layer, or case, by plastic systems, Part 4.3 Here in Part 5, causes and adsorption of carbon, nitrogen or a mixture of the two. some typical examples of problems that occur in By diffusion, a concentration gradient is created. The electroplating as a result of a) thermal, mechanical heat-treatments and the composition of the steel are surface treatments, b) the metallurgy of the part to additional variables that should be addressed and taken be plated or c) effects of plating bath temperature into account in the electroplating procedure. on plating variables and quality of the deposits When discussing the effect of heat-treatment on are discussed. subsequent electroplating processes it is necessary to zero in on the type of heat-treatment involved. We Nearly every plater has at one time or another had the can defi ne the heat-treatment process as changing the experience of trying to plate parts that simply would characteristics of the parts by heating above a certain not plate.
  • Permanent Mold

    Permanent Mold

    PERMANENT MOLD CASTING PROCESSES Many variations of the permanent mold process are well-suited for mass production of high-integrity light metal castings for automotive components. This article is based on “High Integrity Permanent Mold Casting Processes: Current and Future,” a presentation at the American Foundry Society’s 6th International Conference on Permanent Mold Casting of Aluminum and Magnesium. J. L. Jorstad* JLJ Technologies Inc. This Chrysler NS cross member was cast on a tilt permanent mold machine. Richmond, Virginia However, with the incorporation of ceramic-foam filters and their ability Permanent mold casting consists of several basic to smooth melt flow (Fig. 1), opportu- processes. In this article, key characteristics of nities become available to top-pour each will be considered in terms of their impact with significantly fewer entrapped ox- on high-integrity products. ides and other quality detractors. Turbulent flow Combining filters with down-sprue GRAVITY FILLING PROCESSES and runner designs proposed by Prof. Gravity pouring, whether manual, via auto- Campbell has made it possible to pour ladles, or robotic pouring, can be susceptible to reasonably high-integrity aluminum turbulence, which has a negative effect on high- castings, perhaps most suitable for a Pintegrity castings. It is nearly impossible to have variety of less-critical automotive molten aluminum free fall more than a few cen- applications. timeters without initially exceeding a safe flow Static top-pouring has another velocity of about 0.5 to 1 m/s. Note that a free fall downside too, an ever-diminishing of less than 0.1 m will accelerate to more than 1 effective metal head as fill progresses.
  • Ats 34 and 154 Cm Stainless Heat Treat Procedure

    Ats 34 and 154 Cm Stainless Heat Treat Procedure

    ATS 34 AND 154 CM STAINLESS HEAT TREAT PROCEDURE This is an oil hardening grade of steel which will require oil quenching. The oil should be a warm, thin quenching oil that contains a safe flash point. Olive oil has been used as a sub­ stitute. As a rule of thumb, there should be a gallon of oil for each pound of steel. For , warming the oil before quenching, you may heat a piece of steel and drop it in the oil. 1.) Wrap blades in stainless tool wrap and leave an extra two inches on each end of the package. (This will be for handling purposes going into the quench as described below.) We suggest a double wrap for this grade. The edges of the foil should be double crimped, being careful to avoid hav­ ing even a pin hole in the wrap. 2 . ) Place in the furnace and heat to 1900"F. After reaching this temperature, immediately start timing the soak time of 25-30 minutes. 3.) After the soak time has elapsed, very quickly and carefully pull the package out with tongs~ place over the quench tank and snip the end of the package allowing the blades to drop into the oil. You should have a wire basket in the quench tank for raising and lowering the blades rather than have them lie s till. Gases are released in the quench and would form a "trap" around the steel unless you keep them movi~g for a minute or so. *IMPORTANT--It is very important that the blades enter the oil quench as quickly as possible after leaving the furnace ! Full hardness would not be reached if this step is not followed.
  • Radel® PPSU, Udel® PSU, Veradel® PESU & Acudel® Modified PPSU

    Radel® PPSU, Udel® PSU, Veradel® PESU & Acudel® Modified PPSU

    Radel ® | Udel ® | Veradel ® | Acudel ® Radel® PPSU, Udel® PSU, Veradel® PESU & Acudel® modified PPSU Processing Guide SPECIALT Y POLYMERS 2 \ Sulfone Polymers Processing Guide Table of Contents Introduction ............................. 5 Part Ejection . 14 Draft . 14 Ejector pins and/or stripper plates . 14 Sulfone Polymers........................ 5 Udel® Polysulfone (PPSU) . 5 Injection Molding Equipment ............. 15 ® Veradel Polyethersulfone (PESU) . 5 Controls . 15 ® Radel Polyphenylsulfone (PPSU) . 5 Clamp . 15 ® Acudel modified PPSU . 5 Barrel Capacity . 15 Press Maintenance . 15 Resin Drying . .6 Screw Design . 15 Rheology................................ 8 Screw Tips and Check Valves . 15 Viscosity-Shear Rate ..................... 8 Nozzles . 16 Molding Process . 16 Resin Flow Characteristics . 9 Melt flow index . 9 Polymer Injection or Mold Filling . 16 Spiral flow . 9 Packing and Holding . 17 Injection Molding . .10 Cooling . 17 Molds and Mold Design .................. 10 Machine Settings ....................... 17 Tool Steels . 10 Barrel Temperatures . 17 Mold Dimensions . 10 Mold Temperature . 18 Mold Polishing . 10 Residence Time in the Barrel . 18 Mold Plating and Surface Treatments . 10 Injection Rate . 18 Tool Wear . 10 Back Pressure . 18 Mold Temperature Control . 10 Screw Speed . 18 Mold Types . 11 Shrinkage . 18 Two-plate molds . 11 Three-plate molds . 11 Regrind ............................... 19 Hot runner molds . 11 Cavity Layout . 12 Measuring Residual Stress ............... 19 Runner Systems . 12 Extrusion............................... 22 Gating . 12 Sprue gating . 12 Edge gates . 13 Predrying ............................. 22 Diaphragm gates . 13 Tunnel or submarine gates . 13 Extrusion Temperatures ................. 22 Pin gates . 13 Screw Design Recommendations . 22 Gate location . 13 Venting . 14 Sulfone Polymers Processing Guide / 3 Die Design ............................. 22 Extruded Product Types . 23 Wire . 23 Film . 23 Sheet . 23 Piping and tubing . 23 Start-Up, Shut-Down, and Purging .......
  • Aluminum Alloy AA-6061 and RSA-6061 Heat Treatment for Large Mirror Applications

    Aluminum Alloy AA-6061 and RSA-6061 Heat Treatment for Large Mirror Applications

    Utah State University DigitalCommons@USU Space Dynamics Lab Publications Space Dynamics Lab 1-1-2013 Aluminum Alloy AA-6061 and RSA-6061 Heat Treatment for Large Mirror Applications T. Newsander B. Crowther G. Gubbels R. Senden Follow this and additional works at: https://digitalcommons.usu.edu/sdl_pubs Recommended Citation Newsander, T.; Crowther, B.; Gubbels, G.; and Senden, R., "Aluminum Alloy AA-6061 and RSA-6061 Heat Treatment for Large Mirror Applications" (2013). Space Dynamics Lab Publications. Paper 102. https://digitalcommons.usu.edu/sdl_pubs/102 This Article is brought to you for free and open access by the Space Dynamics Lab at DigitalCommons@USU. It has been accepted for inclusion in Space Dynamics Lab Publications by an authorized administrator of DigitalCommons@USU. For more information, please contact [email protected]. Aluminum alloy AA-6061 and RSA-6061 heat treatment for large mirror applications T. Newswandera, B. Crowthera, G. Gubbelsb, R. Sendenb aSpace Dynamics Laboratory, 1695 North Research Park Way, North Logan, UT 84341;bRSP Technology, Metaalpark 2, 9936 BV, Delfzijl, The Netherlands ABSTRACT Aluminum mirrors and telescopes can be built to perform well if the material is processed correctly and can be relatively low cost and short schedule. However, the difficulty of making high quality aluminum telescopes increases as the size increases, starting with uniform heat treatment through the thickness of large mirror substrates. A risk reduction effort was started to build and test a ½ meter diameter super polished aluminum mirror. Material selection, the heat treatment process and stabilization are the first critical steps to building a successful mirror. In this study, large aluminum blanks of both conventional AA-6061 per AMS-A-22771 and RSA AA-6061 were built, heat treated and stress relieved.
  • Fire Protection of Steel Structures: Examples of Applications

    Fire Protection of Steel Structures: Examples of Applications

    Fire protection of steel structures: examples of applications Autor(en): Brozzetti, Jacques / Pettersson, Ove / Law, Margaret Objekttyp: Article Zeitschrift: IABSE proceedings = Mémoires AIPC = IVBH Abhandlungen Band (Jahr): 7 (1983) Heft P-61: Fire protection of steel structures: examples of applications PDF erstellt am: 06.10.2021 Persistenter Link: http://doi.org/10.5169/seals-37489 Nutzungsbedingungen Die ETH-Bibliothek ist Anbieterin der digitalisierten Zeitschriften. Sie besitzt keine Urheberrechte an den Inhalten der Zeitschriften. Die Rechte liegen in der Regel bei den Herausgebern. Die auf der Plattform e-periodica veröffentlichten Dokumente stehen für nicht-kommerzielle Zwecke in Lehre und Forschung sowie für die private Nutzung frei zur Verfügung. Einzelne Dateien oder Ausdrucke aus diesem Angebot können zusammen mit diesen Nutzungsbedingungen und den korrekten Herkunftsbezeichnungen weitergegeben werden. Das Veröffentlichen von Bildern in Print- und Online-Publikationen ist nur mit vorheriger Genehmigung der Rechteinhaber erlaubt. Die systematische Speicherung von Teilen des elektronischen Angebots auf anderen Servern bedarf ebenfalls des schriftlichen Einverständnisses der Rechteinhaber. Haftungsausschluss Alle Angaben erfolgen ohne Gewähr für Vollständigkeit oder Richtigkeit. Es wird keine Haftung übernommen für Schäden durch die Verwendung von Informationen aus diesem Online-Angebot oder durch das Fehlen von Informationen. Dies gilt auch für Inhalte Dritter, die über dieses Angebot zugänglich sind. Ein Dienst der ETH-Bibliothek ETH Zürich, Rämistrasse 101, 8092 Zürich, Schweiz, www.library.ethz.ch http://www.e-periodica.ch J% IABSE periodica 2/1983 IABSE PROCEEDINGS P-61/83 69 Fire Protection of Steel Structures — Examples of Applications Protection contre le feu des structures acier — Quelques exemples d'applications Brandschutz der Stahlkonstruktionen — Einige Anwendungsbeispiele Jacques BROZZETTI Margaret LAW Dir., Dep.
  • WELD 1030 Pattern Development

    WELD 1030 Pattern Development

    PELLISSIPPI STATE COMMUNITY COLLEGE MASTER SYLLABUS PATTERN DEVELOPMENT WELD 1030 Class Hours: 2.0 Credit Hours: 2 Laboratory Hours: 2.0 Revised: Spring 2017 Catalog Course Description With an emphasis on the practical applications of pattern development, students construct basic forms using parallel line pattern development techniques. The course also introduces students to tools of the trade, geometric construction and bend allowance computations. Prerequisites NONE Corequisites MATH 1010 or MATH 1530 or MATH 1630 or MATH 1710 or MATH 1720 or MATH 1730 or MATH 1830 or MATH 1910 Textbook(s) and Other Course Materials Sheet Metal, Latest Edition, Leo A. Meyer, American Technical Publishers, Week/Unit/Topic Basis Week Topic 1. Introduction, Sheet Metal Working Tools and Machinery 2. Fasteners for Sheet Metal, Using Patterns and Cutting Metal 3. Punching, Drilling, and Riveting Folding Edges and Making Seams 4. Turning, Barring and Raising, Forming, Crimping, Beading and Grooving 5. Soldering 6. Drawing for Pattern Drafting 7. Making and Notching Simple Patterns 8. Parallel Line Development 9. Lab Projects 10. Review / Final Exam Welding Technology General Outcomes (Educational objectives) 1. Reach their full potential in the welding field. 2. Use the correct procedure in setting up equipment, and the skills used in welding. 3. Use Shielded Metal Arc Welding, Gas Metal Arc Welding, and Gas Tungsten Arc Welding machines in both pipe and plate welding. 4. Explain the physical characteristics of different metals 5. Develop the cognitive and physical skills necessary to pass certification tests. 6. Apply welding knowledge to effectively utilize problem solving skills as it relates to the operation of equipment in the industry.
  • Love That Door Catalog

    Love That Door Catalog

    Welcome Home. Nothing adds a “wow” factor to a new home design like wrought iron doors and this is the #1 reason many homeowners make this front door statement. The juxtaposition of iron with brick construction visually suggests a permanence that no synthetic building material can emulate. The single or double wrought iron doors, manufactured by Love That Door and available from Acme Brick Stone & Tile stores, have multi-hued designs that demand attention, especially when framed by the rich patina of brick. We have over 100 designs to choose from and can custom design and build anything you desire in wrought iron access doors, iron garages and access gates, iron wine cellar doors, lighting fixtures and more. Wrought Iron Access Gates and Doors offer greater security than traditional wood doors. Keep your family and office more secure with a low maintenance, durable and custom iron door while increasing your curb appeal. Wrought Iron makes a fine choice for many reasons, but none more important than security. 2 lovethatdoor.com • brick.com 3 Transform Your Home Customers are amazed by the transformation that their iron dooor makes to their property. Versatile, robust and beautiful, it’s little wonder that a growing number of individuals are deciding on iron doors as the best option. We ensure that every single component of your iron entry door is tested and styled for optimal performance and durability. From compression tested locks to heavy duty barrel hinges, every part of the products we produce is fashioned with an exemplary end result in mind. 4 lovethatdoor.com • brick.com 5 Within an Arm’s Reach.
  • Implementation of Metal Casting Best Practices

    Implementation of Metal Casting Best Practices

    Implementation of Metal Casting Best Practices January 2007 Prepared for ITP Metal Casting Authors: Robert Eppich, Eppich Technologies Robert D. Naranjo, BCS, Incorporated Acknowledgement This project was a collaborative effort by Robert Eppich (Eppich Technologies) and Robert Naranjo (BCS, Incorporated). Mr. Eppich coordinated this project and was the technical lead for this effort. He guided the data collection and analysis. Mr. Naranjo assisted in the data collection and analysis of the results and led the development of the final report. The final report was prepared by Robert Naranjo, Lee Schultz, Rajita Majumdar, Bill Choate, Ellen Glover, and Krista Jones of BCS, Incorporated. The cover was designed by Borys Mararytsya of BCS, Incorporated. We also gratefully acknowledge the support of the U.S. Department of Energy, the Advanced Technology Institute, and the Cast Metals Coalition in conducting this project. Disclaimer This report was prepared as an account of work sponsored by an Agency of the United States Government. Neither the United States Government nor any Agency thereof, nor any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any Agency thereof. The views and opinions expressed by the authors herein do not necessarily state or reflect those of the United States Government or any Agency thereof.
  • Cast Irons from Les Forges Du Saint- Maurice, Quebec a Metallurgical Study

    Cast Irons from Les Forges Du Saint- Maurice, Quebec a Metallurgical Study

    Cast Irons from Les Forges du Saint- Maurice, Quebec A Metallurgical Study Henry Unglik Environment Canada Environnement Canada Parks Service Service des pares Cast Irons from Les Forges du Saint- Maurice, Quebec A Metallurgical Study Henry Unglik Studies in Archaeology Architecture and History National Historic Parks and Sites Parks Service Environment Canada ©Minister of Supply and Services Canada 1990. Available in Canada through authorized bookstore agents and other bookstores, or by mail from the Canadian Government Publishing Centre, Supply and Services Canada, Hull, Que­ bec, Canada Kl A 0S9. Published under the authority of the Minister of the Environment, Ottawa, 1990 Editing and design: Jean Brathwaite Production: Lucie Forget and Rod Won Parks publishes the results of its research in archaeology, architecture, and history. A list of publications is available from Research Publications, Parks Service, Environment Can­ ada, 1600 Liverpool Court, Ottawa, Ontario K1A 0H3. Canadian Cataloguing in Publication Data Unglik, Henry Cast irons from les Forges du Saint-Maurice, Quebec: a met­ allurgical study (Studies in archaeology, architecture and history, ISSN 0821-1027) Issued also in French under title: Fontes provenant des Forges du Saint-Maurice. Includes bibliographical references. ISBN 0-660-13598-1 DSS cat. no. R61-2/9-48E 1. Forges du Saint-Maurice (Quebec) — Antiquities. 2. Iron­ works — Quebec (Province) — Saint Maurice River Valley — History. 3. Cast-iron — Analysis. I. Canadian Parks Service. National Historic Parks and
  • Heat Treating of Aluminum Alloys

    Heat Treating of Aluminum Alloys

    ASM Handbook, Volume 4: Heat Treating Copyright © 1991 ASM International® ASM Handbook Committee, p 841-879 All rights reserved. DOI: 10.1361/asmhba0001205 www.asminternational.org Heat Treating of Aluminum Alloys HEAT TREATING in its broadest sense, • Aluminum-copper-magnesium systems The mechanism of strengthening from refers to any of the heating and cooling (magnesium intensifies precipitation) precipitation involves the formation of co- operations that are performed for the pur- • Aluminum-magnesium-silicon systems herent clusters of solute atoms (that is, the pose of changing the mechanical properties, with strengthening from Mg2Si solute atoms have collected into a cluster the metallurgical structure, or the residual • Aluminum-zinc-magnesium systems with but still have the same crystal structure as stress state of a metal product. When the strengthening from MgZn2 the solvent phase). This causes a great deal term is applied to aluminum alloys, howev- • Aluminum-zinc-magnesium-copper sys- of strain because of mismatch in size be- er, its use frequently is restricted to the tems tween the solvent and solute atoms. Conse- specific operations' employed to increase quently, the presence of the precipitate par- strength and hardness of the precipitation- The general requirement for precipitation ticles, and even more importantly the strain hardenable wrought and cast alloys. These strengthening of supersaturated solid solu- fields in the matrix surrounding the coher- usually are referred to as the "heat-treat- tions involves the formation of finely dis- ent particles, provide higher strength by able" alloys to distinguish them from those persed precipitates during aging heat treat- obstructing and retarding the movement of alloys in which no significant strengthening ments (which may include either natural aging dislocations.
  • Bifilm Inclusions in High Alloyed Cast Iron

    Bifilm Inclusions in High Alloyed Cast Iron

    materials Article Bifilm Inclusions in High Alloyed Cast Iron Marcin Stawarz * and Malwina Dojka Department of Foundry Engineering, Silesian University of Technology, 7 Towarowa Street, 44-100 Gliwice, Poland; [email protected] * Correspondence: [email protected]; Tel.: +48-32-338-5532 Abstract: Continuous improvement in the quality of castings is especially important since a cast without defects is a more competitive product due to its longer lifecycle and cheaper operation. Producing quality castings requires comprehensive knowledge of their production, crystallization process, and chemical composition. The crystallization of alloyed ductile iron (without the addition of magnesium) with oxide bifilm inclusions is discussed. These inclusions reduce the quality of the castings, but they are a catalyst for the growth of spheroidal graphite that crystallizes in their vicinity. The research was carried out for cast iron with a highly hyper-eutectic composition. Scanning electron microscopy and EDS analysis were used in the research. A detailed analysis of the chemical composition was also carried out based on the spectrometric method, weight method, etc. Based on the obtained results, a model of spheroidal graphite crystallization near bifilm inclusions was proposed. The surface of the analyzed graphite particles was smooth, which suggests a primary crystallization process. The phenomenon of simple graphite and bifilm segregation towards the heat center of the castings was also documented. Keywords: bifilms; spheroidal graphite; alloyed cast iron; crystallization Citation: Stawarz, M.; Dojka, M. Bifilm Inclusions in High Alloyed Cast Iron. Materials 2021, 14, 3067. 1. Introduction https://doi.org/10.3390/ Foundry engineering processes are prone to many issues during casting manufactur- ma14113067 ing that may influence the final casting quality.