Microstructural Assessment of a Multiple-Intermetallic-Strengthened Aluminum Alloy Produced from Gas-Atomized Powder by Hot Extrusion and Friction Extrusion

An aluminum (Al) matrix with various transition metal (TM) additions is an effective alloying approach for developing high-specific-strength materials for use at elevated temperatures. Conventional fabrication processes such as casting or fusion-related methods are not capable of producing Al–TM alloys in bulk form. Solid phase processing techniques, such as extrusion, have been shown to maintain the microstructure of Al–TM alloys. In this study, extrusions are fabricated from gas-atomized aluminum powders (≈100–400 µm) that contain 12.4 wt % TM additives and an Al-based matrix reinforced by various Al–Fe–Cr–Ti intermetallic compounds (IMCs). Two different extrusion techniques, conventional hot extrusion and friction extrusion, are compared using fabricating rods. During extrusion, the strengthening IMC phases were extensively refined as a result of severe plastic deformation. Furthermore, the quasicrystal approximant IMC phase (70.4 wt % Al, 20.4 wt % Fe, 8.7 wt % Cr, 0.6 wt % Ti) observed in the powder precursor is replaced by new IMC phases such as Al3.2Fe and Al45Cr7-type IMCs. The Al3Ti-type IMC phase is partially dissolved into the Al matrix during extrusion. The combination of linear and rotational shear in the friction extrusion process caused severe deformation in the powders, which allowed for a higher extrusion ratio, eliminated linear voids, and resulted in higher ductility while maintaining strength comparable to that resulting from hot extrusion. Results from equilibrium thermodynamic calculations show that the strengthening IMC phases are stable at elevated temperatures (up to ≈ 600 °C), thus enhancing the high-temperature strength of the extrudates.

Modification of Mechanical Properties of Aluminum Alloy Rods via Friction-Extrusion Method

The elaboration of a modified friction-extrusion method aimed at obtaining 2017A aluminum rods of gradient microstructure is described. This was achieved by cutting spiral grooves on the face of the stamp used for alloy extrusion. The experiments were carried out at a constant material feed (~10 mm/min) and a range of tool rotation speeds (80 to 315 rpm). The microstructure observations were carried out using light microscopy (LM) and both scanning and transmission electron microscopy (SEM and TEM). The mechanical properties were assessed through hardness measurements and static tensile tests. The performed investigations show that material simultaneous radial and longitudinal flow, enforced by friction of the rotating tool head and extrusion, results in the formation of two zones of very different microstructures. At the perpendicular section, the outer zone stands out from the core due to circumferential elongation of strings of particles, while in the inner zone the particles are arranged in a more uniform way. Simultaneously, the grain size of the outer zone is refined by two to four times as compared with the inner one. The transfer from the outer zone to the core area is of gradient type. The hardness of the outer zone was found to be ~10% to ~20% higher than that of the core.

Use of Friction Extrusion to Fabricate Magnesium Alloy Wires with Rare Earths from Machined Chips

Magnesium alloy wires with rare earth elements were fabricated using friction extrusion by varying tool rotational speed in the range of 400 to 1200 rpm. Microstructure of wires fabricated usin 800 rpm consists finer equiaxed mg grains with finer precipitates homogeneously distributed along the grain boundaries. The strength of the wires fabricated under optimum parametes exhited a strength of 304 MPa which is 45 % higher than the tensile strength of as-cast material. Improper processing conditions results in undesirable microstrucutre and loss of strength values.-

Effect of microhole-textures filled with graphite on tribological properties of WC/TiC/Co carbide tools

To expand the industrial application of cemented carbide, micro-EDM was utilized to machine microhole-textures on the carbide surface; graphite powder was burnished into the textured microholes. The tribological properties of the microhole-textured tool combined with graphite were investigated and compared with the conventional one by carrying out reciprocating sliding friction tests and dry machining tests. Results exhibited that the microhole-textured tool combined with graphite possessed a much lower friction coefficient than that of the conventional one in sliding tests. The cutting forces, average friction coefficient at the tool–chip interface, and rake face wear of the textured tool were reduced, and the workpiece surface quality was also slightly improved. The worn regions of carbide specimen were examined and studied, and the possible effect mechanisms for the enhancement of friction and wear properties mainly consisted of the formation of uneven graphite film by friction extrusion, reduction of actual contact length, entrapment of wear debris and supply of graphite lubricant.