Laser forming of open-cell aluminium foams

Open-cell aluminium foams cannot be formed by conventional mechanical processes because of the occurrence of failure during deformation. In this study, open cell-aluminium foams with different densities were laser bent by means of a diode laser. Laser bending tests were performed with different values of laser power and scan velocity, and were compared with mechanical bending tests. High bending angles were reached for proper combinations of process parameters: 90° bending was obtained by sharing out the total angle among many parallel bending lines. The process efficiency was measured in terms of bending increase per single laser pass: similar efficiencies were observed for the foams with different density at low number of scans, but higher efficiencies were measured for the low density foam at high number of scans because of the lower pre-heating during the process.     

Deformation behaviour of closed-cell aluminium foams in tension

The mechanical behaviour of commercially available ALPORAS aluminium foam with two different densities was studied under tension loading. In addition to the common stress–strain measurements, local deformation, notch-opening displacement and damage evolution were determined. The deformation characteristics deviated from those observed in aluminium foams under compression. No deformation bands or plastic instabilities could be observed in tension, which are very frequent in compression of metallic foams. Four regimes were evident in the stress–strain curves and deformation maps: the linear elastic regime, the plastic regime with no significant crack initiation and propagation, the regime of formation of a fracture process zone and, finally, the regime of fracture, where a main crack propagates through the specimen and leads to failure. The fracture strain was only a few per cent, with the higher-density foam showing a larger fracture strain, and the plastic Poisson's ratio was about 0.35. The notched specimens showed increasing fracture strengths in terms of the net section stress with increasing notch depth. It is suggested that a change in stress state, caused by a non-vanishing Poisson's ratio, in front of the notch tip creates an increase of the fracture strength similar to the behaviour in ductile bulk metals.     

浸渍法制备泡沫铝的显微组织和力学性能(英文)

利用聚合物泡沫采用压力浸渗铸造工艺制备开孔泡沫铝。所制备的泡沫铝能够很好地复制聚合物泡沫的几何尺寸。开孔泡沫铝的强度比闭孔泡沫铝的低很多,从而得到更多的应用。添加陶瓷颗粒可以改善泡沫铝的力学性能。本研究中,向 AC3A 铝合金中添加 SiC 颗粒得到复合材料泡沫。在复合材料泡沫中,SiC 颗粒嵌入在合金基体中及孔筋表面。高体积分数的陶瓷颗粒使合金泡沫铝的压缩强度、能量吸收、显微硬度增大。这些性能的改善归结为于泡沫铝的结构改变以及 SiC 颗粒存在于结点和孔筋处而引起的强度增加。     

Weld structure of joined aluminium foams with concentrated solar energy

Concentrated solar energy was applied to welded foam plates in non-protective atmosphere. The filler was a pore-generating aluminium–silicon alloy placed between two commercial aluminium foam plates. The heating device provided enough energy to melt and foam the filler. The heat affected surfaces on foam plates and welding mechanisms were correlated with heating conditions. Test plate thickness controlled filler foaming, and two runs were necessary to complete foaming. Weld characterization through tensile tests and microstructural study was performed. The role of the oxide layer on the weld was analyzed and the main welding mechanisms identified: a mechanical form-fit and a metallurgical connection.     

Fibre laser welding of aluminium alloy

The objectives of this research are to investigate the effects of various welding conditions on penetration and defect formation, to clarify their welding phenomena and to develop the procedure of reduction of the defect. Fibre laser bead-on-plate welding was performed on several aluminium alloys, in particular A5083, at the power of 6 or 10 kW and several power densities from 0.4 kW/mm². It was found that the weld beads were narrower and deeper with an increase in the laser power density. For example, fully penetrated weld beads in 10 mm thick plates were produced at the laser power density of 640 kW/mm² and the welding speed of 10 m/min. However, convex–concave bead surfaces were formed. Moreover, in the case of the high power density, no porosity and many pores were present at high and low welding speeds, respectively. On the other hand, in the case of the ultra-high power density, few pores were generated in high speed welding. These reasons were interpreted by observing keyhole behaviour, bubble formation and the molten pool geometry during high power fibre laser welding with a high-speed video camera and microfocused X-ray transmission in situ observation method. Moreover, the porosity in the weld bead was reduced and prevented by the utilization of nitrogen gas instead of Ar gas, or the forward inclination angle of 40° (50° from the right angle) in Ar shielding gas.     

铝合金的搅拌摩擦焊

在详细介绍搅拌摩擦焊原理，特点的基础上，针对铝合金的搅拌摩擦焊特点，性能以及工业应用进行了阐述，并且对搅拌摩擦焊在中国市场的发展和应用作了简略介绍和预测。     

闭孔泡沫铝的电磁屏蔽性能

采用粉末冶金发泡法制备闭孔泡沫铝,通过调整发泡剂含量、发泡温度、粘度、保温时间等手段,制得孔隙率可调、孔洞分布均匀的闭孔泡沫铝样品,并测试了不同孔隙率、孔径泡沫铝样品的电磁屏蔽性能.结果表明:在100～1000MHz内,泡沫铝的电磁屏蔽性能在60～90dB之间,且随着孔隙率、孔径的增加,泡沫铝的电磁屏蔽性能下降.     

Fluidity of aluminium die castings alloy

Abstract

The aim of the present work was to investigate the fluidity of four different high pressure die cast Al–Si alloys at different pouring temperatures. A vacuum fluidity test apparatus was employed to measure fluidity. The analysed alloys showed different flow sensitivities to casting temperatures. Furthermore, it is showed that among the considered alloying elements, magnesium and silicon affected the fluidity of the melt. One alloy was then contaminated with 50% scrap addition, increasing the amount of oxide inclusions. The fluidity of the contaminated melt has then been measured and compared with the fluidity of the clean melt. The results show that the fluidity of the alloy with scrap addition is lower than that of the clean melt. Further the fluidity linearly increases at increasing temperatures within the range between 580 and 680°C until it reaches a plateau at the highest pouring temperatures.     

用于铝合金生产的高硅含量铝-硅中间合金的试制

用户需求w(Si)=55%~60%的高硅含量铝-硅中间合金,通过理论分析,确定了试制工艺,试制出了w(Si)=57.36%~58.12%的高硅含量铝-硅中间合金,通过在实验室的使用和工业生产中试用,验证了所制得的铝-硅中间合金的应用效果良好,为其在工业生产中应用奠定了基础。     

Fabrication of aluminium foams from powder by hot extrusion and foaming

In order to produce aluminium foams for light-weight and energy absorbing structures of automobiles, a method for fabricating aluminium foam from powder mixed with a foaming agent by using a mould is proposed. The method consists of four sequential processes: powder compacting, extruding, foaming and moulding. In the experiment for fabricating aluminium foam from powder, the conditions of powder extrusion and foaming by the heated die are determined from the density of the aluminium foams made without a mould. The experimental results show that the relative density of the aluminium foam made under appropriate conditions is 0.22. In moulding of aluminium foam, a stainless steel pipe is used as a mould and the cylindrical aluminium foam is produced by filling into the pipe mould. The distribution of relative density within the aluminium foam bar is in a range of 0.2–0.3 by rapid cooling of the pipe. To examine the ratio of deformation energy to weight of the pipe including the aluminium foam, a compression test using a press is carried out. The deformation energy of the pipe can be increased with aluminium foam filled by the proposed method.     

491铝合金光电光谱分析法

针对491铝合金成分波动大的特点,选取制备适宜的国家标样和标准化控样,对分析条件进行最佳选择及工作曲线校正、样品激发部位的确定,从而制定DV-4光电光谱分析方法,可满足生产需要。     

Size effects in aluminium alloy castings

A finding by Benzerga et al. (Acta Mater 2001; 49:3071) that the yield strength of Al–7Si–0.3Mg castings is smaller for castings with a fine secondary dendrite arm spacing (SDAS) than for those with a coarse SDAS is revisited. Previous experimental data for Al–Si–Mg castings are reviewed, and new experiments carried out, both on the original castings used in Benzerga et al. and on Al–Si binary alloy castings whose microstructures more closely conform to the theoretical model of Benzerga et al. The experimental results show that the inverse size effect reported by Benzerga et al. was a consequence of different heat-treatments applied to the original castings, rather than to any intrinsic size effect. The present results confirm that there is a negligibly small size effect in both heat-treatable (Al–Si–Mg) and non-heat-treatable (Al–Si) castings.     

Macro-segregation in aluminium alloy sprayformed billets

It is generally assumed that during sprayforming the amount of micro- and macro-segregation in the sprayforms will be limited or absent because of low liquid fractions, small grain size and high cooling rate. This paper shows that macro-segregation can occur in sprayforms of Al, even when small liquid fractions are present during growth of the sprayform. This segregation occurs by an inverse mechanism, with solute-rich liquid sucked back through a solid network by solidification shrinkage. Liquid flow outwards is further enhanced by the centrifugal force produced by sprayform rotation. The liquid sucked outwards is enriched in solute (with partition coefficients <1), resulting in solute depletion at the centre and enrichment at the surface. Elements that form dispersoid particles in the spray do not segregate because they are locked into the solid network. The segregation profile can be modelled using equations similar to those used to describe inverse segregation.     

7055铝合金的三级时效处理

采用透射电镜、电导率和维氏硬度测定法,研究了7055铝合金三级时效过程中一级时效时间和二级时效条件对合金组织和性能的影响。结果表明,第一级120℃时效0．5 h即可对第二级190℃时效起预形核处理作用,但继续延长第一级时效时间对三级时效后合金的电导率和硬度影响不大,第二级时效时快速加热有利于同时提高合金的硬度和电导率,第三级120℃ 24 h时效具有同时提高合金硬度和电导率的作用,使合金晶界和基体析出相粗化,但对基体析出相的密度影响不大。经合适的三级时效处理（如120℃ 0．5 h～24 h＋盐浴190℃ 10 min,W,Q＋120℃ 24h）．7055合金获得的硬度和电导率比116状念的更高。     

Diode laser brazing of aluminium alloy to steels with aluminium filler metal

Abstract

Diode laser brazing of aluminium alloy (A5052) to interstitial free steel (IF steel) or type 304 stainless steel (SUS304) was conducted using aluminium filler metal (BA4047) with Nocolock flux. The processing parameters of laser power, wire feed rate and travel speed were varied. The strength of lap joints of A5052 on steels was evaluated by tensile shear test. The joint strength of A5052/steels was increased with increasing laser power and reached the maximum strength, more than approximately 80% of the A5052 base metal strength, at a laser power of 1300 W. Voids and incomplete penetration of filler metal were observed at the A5052/braze layer interface when the laser power was below 1100 W. The Fe–Al intermetallic compounds were formed at the steel/braze layer interfaces and grew drastically when the laser power exceeded 1300 W. Superior brazability of A5052/steels was found at brazing conditions corresponding to a temperature of filler metal droplet of 1050–1250 K.     

含钪铝合金的钎焊工艺

探讨了Al-Zn-Mg-Sc-Zr铝合金采用炉中钎焊的可行性。结果表明，通过选用合理的钎料和钎剂组合以及优化试验条件下的钎焊工艺参数，可获得焊缝表面成形良好的钎焊接头。对获得的接头进行力学性能测试，结果表明，文中试验条件下获得的钎焊接头具有相对较高的抗剪强度；金相组织观察显示，钎缝金属组织致密，未发现有气孔、夹渣和微裂纹等焊接缺陷；扫描电镜观察显示接头拉伸断口大部呈韧性断裂机制。钎缝微区成分分析表明钎料与母材之间存在明显的合金元素互扩散，钎缝与母材之间结合良好；X射线衍射相结构分析表明，接头钎缝金属中含有Al，Sc、Al，Zb等组成相，对提高接头抗翦强度具有重要作用。     

'Quench sensitivity' of 7075 aluminium alloy plates

Abstract

7075 aluminium alloy is widely used especially in those applications for which high mechanical performances are required. In the technical literature it is well known that the corrosion resistance and the mechanical properties of this material strongly depend on the cooling rate during quenching. This phenomenon is known as 'quench sensitivity'. The main aim of this paper is to investigate the influence of the cooling rate during quenching of samples taken from plates by varying the parameters of the heat treatment and the rolling direction (L, LT and ST). All the samples were heat treated in laboratory equipment to reach T6, T76 and T73 tempers. The samples were prisms (13 × 13 × 100 mm) and were quenched in water; the cooling rate was imposed by changing the water temperature or changing the polymer amount in a water agitated bath at 20°C. In each of the experimented condition, the cooling rate was measured by a thermocouple placed in the sample. Moreover, a finite element method (FEM) simulation was carried out in order to estimate the heat transfer coefficient during the cooling in all the experimented conditions. Tensile and intergranular corrosion tests were performed to point out the influence of the investigated cooling rates.