Manufacturing of Nanostructured Blades for a Francis Turbine by Isothermal Forging of AA6063

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
D. Salcedo ◽  
C. J. Luis ◽  
J. León ◽  
I. Puertas ◽  
J. P. Fuertes ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Research Work ◽  
Francis Turbine ◽  
Compression Tests ◽  
Isothermal Forging ◽  
Forging Process ◽  
Different Temperatures ◽  
Traditional Approaches

This research work deals with the manufacturing of blades for a Francis turbine with a submicrometric structure through the isothermal forging of a heat-treatable aluminum alloy that has been previously processed by angular channel extrusion. In addition, mechanical properties and microstructure of these same blades are analyzed. A comparative study is also carried out between the properties obtained in the forged blades from the alloy previously deformed through angular channel extrusion and those obtained by employing two other isothermal forging processes of this alloy which mean utilizing different process stages. Moreover, a modeling by finite element about the isothermal forging process of the blades is performed using flow rules obtained from compression tests on these alloys at different temperatures. In this way, a much higher degree of accuracy is achieved in the results compared with that obtained through traditional approaches. With this present study, it is intended to make some progress in the development of nanostructured mechanical components with the aim of demonstrating the feasibility of their manufacturing and achieving an improvement in their mechanical properties.

Study on Cylindrical Heatsink Forging Process Considering Friction Condition

2019 ◽  
Vol 823 ◽  
pp. 141-144
Author(s):  
Tung Sheng Yang ◽  
Yong Nan Chen
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Friction Factor ◽  
Testing Machine ◽  
Metal Flow ◽  
Compression Tests ◽  
Stress Strain ◽  
Element Analysis ◽  
Forging Process ◽  
Different Temperatures

The feasibility of forging of AL-1050 alloy of cylindrical heatsink under warm conditions is demonstrated in the present work. The stress-strain curves and friction factor play an important role in the cylindrical heatsink forging. The purpose of forging lubrication is to reduce friction between blank and die, and to decrease resistance of metal flow to die. The stress-strain curves at different temperatures are obtained by compressing tests. The friction factor between 1050 aluminum alloy and die material are determined at different temperatures by ring compression tests with graphite lubricants. The compressing and ring compressing tests are carried out by using the computerized screw universal testing machine. The finite element method is used to investigate the forming characters of the forging process. To verify the prediction of FEM simulation in the cylindrical heatsink forging process, the experimental parameters such as stress-strain curves and fiction factor, are as the input data during analysis. Maximum forging load and effective stress distribution are determined of the heatsink forging, using the finite element analysis. Finally, the cylindrical heatsink parts are formed by the forging machine under the conditions using finite element analysis.

Mechanical Properties and Microstructure of Aluminum Alloy Al-6061 Obtained by the Liquid Forging Process

2010 ◽  
Vol 654-656 ◽  
pp. 1420-1423 ◽  
Author(s):  
Chun Wei Su ◽  
Peng Hooi Oon ◽  
Y.H. Bai ◽  
Anders W.E. Jarfors
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Aluminum Alloy ◽  
Treatment Process ◽  
Forging Process ◽  
Al 6061 ◽  
Casting Alloys ◽  
Suitable Heat Treatment ◽  
Structural Applications ◽  
Wrought Aluminum

The liquid forging process has the flexibilities of casting in forming intricate profiles and features while imparting the liquid forged components with superior mechanical strength compared to similar components obtained via casting. Additionally, liquid forging requires significantly lower machine loads compared to solid forming processes. Currently, components that are formed by liquid forging are usually casting alloys of aluminum. This paper investigates the suitability of liquid forging a wrought aluminum alloy Al-6061 and the mechanical properties after forming. The proper handling of the Al-6061 alloy in its molten state is important in minimizing oxidation of its alloying elements. By maintaining the correct alloying composition of Al-6061 after liquid forging, these Al-6061 samples can subsequently undergo a suitable heat treatment process to significantly improve their yield strengths. Results show that the yield strengths of these liquid forged Al-6061 samples can be increased from about 90MPa, when they are in the as-liquid forged state, to about 275MPa after heat treatment. This improved yield strength is comparable to that of Al-6061 samples obtained by solid forming processes. As such, the liquid forging process here has been shown to be capable of forming wrought aluminum alloy components that has the potential for structural applications.

Forging Process Analysis of 6061 Aluminum Alloy Motorcycle Brake Parts

2021 ◽  
Vol 901 ◽  
pp. 176-181
Author(s):  
Tung Sheng Yang ◽  
Chieh Chang ◽  
Ting Fu Zhang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Metal Forming ◽  
Process Analysis ◽  
Surface Hardness ◽  
Dimensional Accuracy ◽  
Die Design ◽  
Element Analysis ◽  
Forging Process

This paper used finite element analysis of metal forming to study the forging process and die design of aluminum alloy brake parts. According to the process parameters and die design, the brake parts were forged by experiment. First, the die design is based on the product size and considering parting line, draft angle, forging tolerance, shrinkage and scrap. Secondly, the finite element analysis of metal forming is used to simulate the forging process of aluminum alloy brake parts. Finally, the aluminum alloy brake levers with dimensional accuracy and surface hardness were forged.

scholarly journals Preparation and Mechanical Properties of ZK61-Y Magnesium Alloy Wheel Hub via Liquid Forging—Isothermal Forging Process

Metals ◽  
2020 ◽  
Vol 10 (3) ◽  
pp. 385
Author(s):  
Yushi Qi ◽  
Heng Wang ◽  
Lili Chen ◽  
Hongming Zhang ◽  
Gang Chen ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Heat Treatments ◽  
Second Phase ◽  
Phase Hardening ◽  
Isothermal Forging ◽  
Forging Process ◽  
Microstructure And Mechanical Properties ◽  
Alloy Wheel

A ZK61-Y magnesium (Mg) alloy wheel hub was prepared via liquid forging—isothermal forging process. The effects of Y-element contents on the microstructure and mechanical properties of liquid forging blanks were investigated. The formation order of the second phase was I-phase (Mg3Zn6Y) → W-phase (Mg3Zn3Y2) → Z-phase (Mg12ZnY) with the increase of the Y-element content. Meanwhile, the I-phase and Z-phase formed in the liquid forging process were beneficial to the grain refinement. The numerical simulation of the isothermal forging process was carried out to analyze the effects of forming temperature on the temperature and stress field in the forming parts using the software Deform-3D. Isothermal forging experiments and post heat treatments were conducted. The influence of isothermal forging temperature, heat treatment temperature and preservation time on the microstructure and mechanical properties of the forming parts were also studied. The dynamic recrystallization (DRX), second-phase hardening, and work hardening account for the improvement of properties after the isothermal forging process. The forming part forged at 380 °C displayed the outstanding properties. The elongation, yield strength, and ultimate tensile strength were 18.5%, 150 MPa and 315 MPa, respectively. The samples displayed an increased elongation and decreased strength after heat treatments. The 520 °C—1 h sample possessed the best mechanical properties, the elongation was 25.5%, the yield stress was 125 MPa and the ultimate tensile strength was 282 MPa. This can be ascribed to the recrystallization and the elimination of working hardening. Meanwhile, the second phase transformation (I-phase → W-phase → Mg2Y + MgZn2), dissolution, and decomposition can be observed, as well.

Fabrication and characterization of friction stir processed Al 6061 reinforced with TiB2-Al2O3

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ch. Mohana Rao ◽  
K. Mallikarjuna Rao
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Friction Stir Processing ◽  
Practical Implication ◽  
Research Work ◽  
Influence Of Process Parameters ◽  
Volume Percentage ◽  
Content Type ◽  
Friction Stir

PurposeThe objective of the paper is to evaluate the fabrication process and to study the influence of process parameters of friction stir processing of 6061-TiB2-Al2O3 Aluminum alloy surface composite on microhardness tensile strength, and microstructure.Design/methodology/approachFriction stir processing method is used for attaining the desired mechanical properties, and selectively processed reinforcements to fabricate the samples. The Taguchi technique was used to optimize rotational speed, travel speed and volume percentage of reinforcement particles to enhance the mechanical properties of 6061-TiB2-Al2O3 Aluminum alloy composite.FindingsThe fabrication of surface composites through FSP allows new inventions in terms of material with enhanced surface layers without changing the base metal.Practical implicationsTo examine the behavior of the surface of the composites in the different zones, the practical implication consists of the use of different characterization techniques like optical microscopy and scanning microscopy for microstructural behavior and the measurement of hardness and tensile tests for mechanical behavior.Originality/valueThe research work consists of tool design and process parameters, which can affect the final product (microstructural changes), and the performance of the modified surface layer behavior was studied and presented.

Effect of UDC Casting on Hot Deformation Behavior and Properties of 2A14 Aluminum Alloy

2019 ◽  
Vol 944 ◽  
pp. 46-51 ◽  
Author(s):  
Yang Qiu ◽  
Zhi Feng Zhang ◽  
Hao Dong Zhao ◽  
Bao Li ◽  
Chun Sheng Chen
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Deformation Behavior ◽  
Direct Chill ◽  
Electromagnetic Stirring ◽  
Ring Rolling ◽  
Compression Tests ◽  
Hot Deformation Behavior ◽  
Dislocation Glide ◽  
Dominant Deformation Mechanism

Uniform direct chill (UDC) casting is coupled annular electromagnetic stirring and intercooling, having been utilized for the preparation of large-sized aluminum alloy billet. In this paper, the UDC casting was applied to 2A14 aluminum alloy billets with a diameter of 584 mm. Hot compression tests, cogging and ring rolling procedures were carried out for the billets, respectively. The results show that during the deformation temperature of 420 °C and the strain rate of 0.01 s−1 to 10 s−1, the flow stresses of different positions are higher and more stable in the UDC casting billet than in the normal direct chill (NDC) casting billet. The dislocation glide is the dominant deformation mechanism of 2A14 aluminum alloy. Meanwhile, the UDC casting significantly improves the mechanical properties of the rolled rings in tangential and axial directions compared with the NDC casting.

Predicting the Impact of Quenching on Mechanical Properties of Complex-Shaped Aluminum Alloy Parts

1995 ◽  
Vol 117 (2) ◽  
pp. 479-488 ◽  
Author(s):  
D. D. Hall ◽  
I. Mudawar
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Boundary Conditions ◽  
Finite Element Program ◽  
Part Geometry ◽  
Heat Treated ◽  
Element Program ◽  
Nozzle Configuration ◽  
The Impact

The mechanical properties of age-hardenable aluminum alloy extrusions are critically dependent on the rate at which the part is cooled (quenched) after the forming operation. The present study continues the development of an intelligent spray quenching system, which selects the optimal nozzle configuration based on part geometry and composition such that the magnitude and uniformity of hardness (or yield strength) is maximized while residual stresses are minimized. The quenching of a complex-shaped part with multiple, overlapping sprays was successfully modeled using spray heat transfer correlations as boundary conditions within a finite element program. The hardness distribution of the heat-treated part was accurately predicted using the quench factor technique; that is, the metallurgical transformations that occur within the part were linked to the cooling history predicted by the finite element program. This study represents the first successful attempt at systematically predicting the mechanical properties of a quenched metallic part from knowledge of only the spray boundary conditions.

Consolidation and Mechanical Properties of Mechanically Alloyed Al-Mg Powders

2008 ◽  
Vol 1128 ◽  
Author(s):  
Mira Sakaliyska ◽  
Sergio Scudino ◽  
Hoang Viet Nguyen ◽  
Kumar Babu Surreddi ◽  
Birgit Bartusch ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Sintering Temperature ◽  
Nanocrystalline Structure ◽  
Hot Extrusion ◽  
High Strength ◽  
Processing Route ◽  
Compression Tests ◽  
Mechanically Alloyed ◽  
Different Temperatures ◽  
Microstructure Density

AbstractNanostructured Al-Mg bulk samples with compositions in the range of 10 – 40 at.% Mg have been produced by consolidation of mechanical alloyed powders. Powders with composition Al90Mg10 and Al80Mg20 were consolidated into highly dense specimens by hot extrusion. Room temperature compression tests for the Al90Mg10 specimen reveal interesting mechanical properties, namely, a high strength of 630 MPa combined with a plastic strain of about 4 %. The increase of the Mg content to 20 at.% increases the strength by about 100 MPa but it suppresses plastic deformation. The Al60Mg40 powder was consolidated at different temperatures by spark plasma sintering and the effect of the sintering temperature on microstructure, density and hardness have been studied. The results reveal that both density and hardness of the consolidated samples increase with increasing sintering temperature, while retaining a nanocrystalline structure. These results indicate that powder metallurgy is a suitable processing route for the production of nanocrystalline Al-Mg alloys with promising mechanical properties.

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