Squeeze casting of aluminium alloys for higher formability in cold forging

Abstract

This research project investigated the process conditions of using squeeze casting process to produce aluminium alloy preforms or billets for subsequent cold forging process. The comparative effects of heat treatments, their microstructures and mechanical properties were evaluated. Through these studies and experiments, the main emphasis is on the study of commercial material Al 6061, Al 2014 and Al 356 alloys. The formability of the alloys was carried out using forward and backward extrusion test at 50% area reduction at room temperature (cold extrusion). It was found that when wrought aluminium 6061, 2014 and 356 alloys were squeeze cast to form the preforms, the preform microstructures revealed very fine microstructures that are feasible to be cold extruded. In addition, after thermal annealing treatment of 6061 squeeze cast preforms, the samples showed a similar value of work hardening exponent value of 0˙20 as compared to the wrought aluminium alloy 6061, with a workhardening exponent value of 0˙21 obtained from the static compression test. Wrought aluminium alloys generally cost twice the amount as compared with casting ingots. The microstructures of the squeeze cast 6061 alloy showed no visible cracks or inclusions after the deformation by extrusion. The results of the studies showed that Al 6061 preforms via squeeze cast technique may be cold extruded or formed, which provide an alternative means for the production of billets for the cold extrusion or forging process.     

Recycling of aluminium alloy turning scrap via cold pressing and melting with salt flux

Among the various steps of aluminium production from liquid metal, a lot of scrap is generated due to machining operations. Therefore, recycling of aluminium scrap is an interesting subject because of the broad applications of this metal and low efficiency of processes used to recycle metal scrap. In this paper, the recyclability of aluminium alloy AA 336 turnings with different cold compacting pressures and a protective salt flux (NaCl–KCl–KF) has been experimentally studied. Various categories of compacted samples were melted at 750 °C in molten aluminium alloy AA 336 and also in the protective salt flux to recover aluminium alloy. In order to understand the amount of recycling of different samples, weight loss measurement was applied. From recyclability stand point it is shown that using protective salt flux is the best route, from the point of view of recyclability. Mechanical properties and chemical analysis of samples were approximately the same as the primary material produced by conventional casting process.     

非贯通内齿轮冷挤压成形工艺研究

针对目前内齿轮主要靠机械加工成形,齿件强度不足、材料利用率低和加工成本高等问题,提出采用冷挤压技术成形非贯通内齿轮的工艺方案.根据初始坯料形状将工艺方案分为两种,即实心坯料冷挤压和带中心孔坯料冷挤压,指出各自的加工工序,并提出齿形凸模设计的具体要求;通过数值模拟方法,从成形载荷、有效齿高、齿件精度及模具强度等方面对两种挤压工艺方案进行系统研究,得到这两种工艺方案各自的适用条件.研究结果对实际生产有一定的指导作用.     

自行车辐条条母用超高强铝合金工艺研究

对超高强铝合金熔铸、挤压、热处理制度和冷变形量进行试验研究，选择较佳的工艺条件，生产出强度高和尺寸精度好的冷拉线材，满足了用户的使用要求。     

固溶处理对7B04铝合金冷轧板组织性能的影响

在实验室中制备了试验用7B04铝合金,经铸造-均质化退火-热轧-中间退火-冷轧后制得7B04铝合金板材,并对合金板材进行了后续固溶时效处理,研究了固溶处理对其组织和性能的影响。结果表明,470 ℃×1 h固溶+120 ℃×21 h时效处理铝合金冷轧板材再结晶明显,有少量晶粒处于伸长状态,除粗大第二相粒子外,未发现细小第二相粒子,综合力学性能较好,抗拉强度为596 MPa,屈服强度为537 MPa,伸长率为14.88%。固溶温度达到480 ℃时,合金再结晶明显,但保温时间不能超过0.5 h,否则合金强度和塑性下降。     

固相再生AZ31B镁合金的组织与力学性能

在不同的挤压温度和挤压比下,将AZ31B镁合金机加屑冷压后热挤压固结而再生镁合金。与铸锭挤压合金对比,从动态再结晶组织与屑间结合情况两个主要方面分析了加工工艺对再生合金力学性能的影响。随着挤压温度升高,再生合金的极限抗拉强度和延伸率先增加而后降低。随挤压温度升高,晶粒长大与屑间结合增强的相反作用共同导致了再生合金力学性能的变化。当挤压比从4:1 增加到 44:1,晶粒细化且屑间结合增强,使再生合金的抗拉强度增加。而当挤压比高于25:1时,由于显著的形变强化作用导致延伸率下降。     

深冷处理对冷轧铜合金组织与性能的影响

采用扫描电子显微镜、透射电子显微镜、X射线衍射仪、万能试验机及电阻率测试仪等研究了深冷处理(DCT)对冷轧Cu-1.34Ni-1.02Co-0.61Si合金组织和性能的影响。深冷处理使30%压下率冷轧合金显微组织细化和均匀化,并且随着深冷处理时间增加,细化和均匀化程度不断提高。深冷处理促使固溶Ni、Co和Si等原子不断从铜基体中析出,在合金晶粒内和晶界处形成尺寸为0.1～1μm之间的细小弥散球形和长条形第二相颗粒。冷轧前后合金的抗拉强度、电导率和延伸率均随着深冷处理时间延长而增加,并在约36 h后趋于稳定。深冷处理48 h后,冷轧前后合金的抗拉强度、电导率和延伸率分别增加了5.4%和4.4%、6.7%和8.0%、及13.2%和18.7%。冷轧后合金的抗拉强度高于冷轧前;而冷轧后的电导率和延伸率低于冷轧前,但差距均随着深冷处理时间增加而缩小。经深冷处理合金的拉伸断口韧窝的数量和深度比未经深冷处理合金大,且分布更加均匀。     

Recycling of AZ91 Mg alloy through consolidation of machined chips by extrusion and ECAP

AZ91 Mg alloy recycled by a solid state process and equal channel angular pressing (ECAP) exhibited a superior strength. The mechanical properties of AZ91 Mg alloy recycled from machined chips by extrusion at 623 K and ECAP at 573 K and 623 K were compared with those of the reference alloy which was produced from an as-received AZ91 Mg alloy block under the same conditions as the recycled alloy. The recycled specimens show a higher strength at room temperature than the reference alloy. The improvement of the tensile properties is attributed not only to the small grain size, but also to the dispersed oxide contaminants.     

1 200 MPa级冷轧先进高强钢轧制稳定性的分析及控制

针对1 200 MPa级冷轧先进高强钢轧制不稳定问题,对热轧原料组织性能均匀性、冷轧压缩比、冷连轧机组轧制策略等进行了分析。结果表明,热轧工序投入边部加热器,采用分段冷却等手段,可有效降低热轧原料头尾部组织性能差异,保证通卷性能均匀,进而保证通卷轧制过程稳定;通过优化冷连轧机组压缩比,可有效降低材料本身的加工硬化强度,进而避免连轧机组后面机架的轧制超负荷情况;通过优化冷连轧机组轧制策略,可保证轧制过程中各机架均匀变形,避免出现轧制力差异较大的情况,进而保证轧制过程稳定。采用上述措施,1 200 MPa级冷轧先进高强钢轧制力控制在约15 000 kN,厚度精度控制在±0.06 mm以内,可保证该级别高强钢的稳定轧制。     

2024 aluminium alloy wettability and superficial cleaning improvement by air cold plasma treatment

2024 aluminium alloy is used for parts and structures which demand high-strength/weight ratio. In particular, Al2024 is, for its high specific strength and good chemical stability, a suitable material for aerospace application. Aluminium alloys are involved in corrosive phenomena when they are used in critical applications, such as the aeronautic ones. The solution commonly adopted to solve corrosive problems is to paint aluminium alloy surface including 2024 aluminium alloy which is the subject of this study. The applied paint film protects the aluminium alloy from corrosion. In order to improve the adhesion of the paint film it is necessary to pre-treat the manufactured surface. The objective of the pre-treatment is to develop a cleaned, uniform, wettable surface. Cold plasma is an efficient, economic and environmentally attractive alternative to the use of the traditional pre-treatment. This work aims to study the relationship between cold plasma and 2024 aluminium alloy wettability and cleaning. Surface samples have been analysed by: (i) standard procedure to measure the quantitative wettability; (ii) Energy Dispersive X-ray Spectroscopy or EDS to determine a quantitative measure of organic contaminant.This work demonstrates that air cold plasma treatment improves significantly wettability and cleaning of 2024 aluminium alloy surfaces both associated with pre-cleaning by MEK^® and without pre-cleaning by MEK^®: the wettability reducing has been greater than 70% and the contaminants reducing greater than 65%.     

Microstructure and mechanical properties of AZ31B magnesium alloy prepared by solid-state recycling process from chips

AZ31B magnesium alloy chips were recycled by three solid-state recycling processes including cold-pressing, hot-pressing followed by hot extrusion and double extrusion. Microstructure and mechanical properties of the recycled specimens and reference specimens were compared. For the recycled specimen by cold-pressing, the grains are refined to a large extent during hot extrusion due to the presence of twins and high density dislocation. The recycled specimens by hot-pressing and double extrusion do not exhibit finer grain than that the recycled specimen by cold-pressing. Consequently, higher ultimate tensile strength of the recycled specimen by hot-pressing and double extrusion is not achieved. For hot pressing process, more compact billet lowers the porosity in recycled material, so elongation to failure of the recycled specimen increases. The recycled specimen fabricated by double extrusion process shows slightly higher elongation than the reference specimen. The second extrusion makes the oxides further crush and distribute more dispersedly, and minimizes porosity, which is responsible for the improved ductility.     

Plasticity improvement of amorphous alloy via skim cold rolling

This study reports the plasticity improvement of amorphous alloy associated with skim cold rolling. It was found that, with an increasing reduction in thickness of up to 6 %, the plastic strain increased considerably from 1.5 % to 9.6% while the yield strength deceased slightly from 1.75 GPa to 1.68 GPa. With further rolling beyond 6 %, the changes in the plasticity and yield strength were observed to be insignificant. In this study, we discussed the principle underlying the improved plasticity of amorphous alloy in view of the creation of excess free volume during skim cold rolling.     

Effect of extrusion ratio on microstructure and mechanical properties of AZ91D magnesium alloy recycled from scraps by hot extrusion

A method for recycling AZ91D magnesium alloy scraps directly by hot extrusion was studied. Various microstructural analyses were performed using the techniques of optical microscopy, scanning electron microscopy (SEM) and energy dispersive spectroscopy(EDS). Microstructural observations revealed that all the recycled specimens consisted of fine grains due to the dynamic recrystallization. The main strengthening mechanism of the recycled specimen was grain refinement strengthening and homogeneous distribution of oxide precipitates. The interfaces of individual scraps of extruded materials were not identified when the scraps were extruded with the extrusion ratio of 40:1. Oxidation layers of the scraps were broken into pieces by high compressive and shear forces under the extrusion ratio of 40:1. The ultimate tensile strength and elongation to failure increased with increasing the extrusion ratio. Recycled specimens with the extrusion ratio of 40:1 showed higher ultimate tensile strength of 342.61 MPa and higher elongation to failure of 11.32%, compared with those of the cast specimen.     

Extrusion of spray-formed Al–25Si–X composites and their evaluation

A comprehensive methodology to fabricate an Al–25Si–X composite via spray-forming and extrusion was investigated to judge the potential of this alloy for applications requiring high strength as well as high wear resistance and/or high elastic modulus. Billets were spray-formed with a low gas/metal ratio of about 0.8 m³/kg to reduce the consumption of nitrogen gas. The billets, having considerable porosity, were then extruded into sub-scale bars using various extrusion parameters, such as extrusion ratio, die temperature, and die configuration to optimize the extrusion conditions and eliminate the pores in the preform. Based on results obtained from the preliminary sub-scale extrusion tests, the spray-formed billets were then hot extruded into a tubular shape with outer and inner diameters of 97 mm × 77 mm, respectively, at an extrusion temperature of 500 °C. Various material properties of the extruded tubes were measured and compared with other candidate materials for these applications.     

双辊快速凝固0.1～0.5mm铝合金薄带的冷轧性

介绍了AlSi12.5共晶合金和AlMn1.2(3A21)合金用双辊快速凝固法，制得0.28mm和0.45mm薄带，经退火后具有优良的冷轧性；AlSi12.5合金第一道压缩率30％冷轧时薄带边缘无裂缝，冷轧后强度较快凝态薄带提高11％，塑性也有提高。AlMn1.2合金第一道次压缩率50％，边缘无裂缝，冷轧后的强度较常规方法制得的3A21合金Y1硬化态提高40％。     

Effect of cold flakes on mechanical properties of aluminium alloy die casts

Abstract

The cold flake was detected in aluminium alloy die casts ADC12 by using the scanning acoustic microscope, and was visualised in the acoustic image as bright and dark regions, which were corresponding to the oxide layer and the body of the cold flake respectively. By using the specimen which contains the cold flake, the tensile testing and the fatigue testing were carried out. The in process ultrasonic measurement was also carried out with a water bag in the fatigue testing to detect detachment of the cold flake from the matrix in the fatigue process. From these results, it was found that the cold flake was detached from the matrix in the fatigue process to form a crack, and cold flakes, especially exposed cold flakes, reduce the tensile strength and the fatigue life of die casts. The effect of the cold flake on the strengths was discussed from the point of crack propagation.     

2014、2024铝合金挤压棒材的组织与性能研究

对2014、2024铝合金挤压棒材分别进行淬火、时效等工艺处理后,采用电子万能试验机及金相显微镜分析比较了2014、2024铝合金挤压棒材的组织和性能。结果表明:2014合金相对于2024合金具有更好的高温强度,当测试温度达到200℃时,合金强度才会明显的降低。     

柱塞泵滑靴冷挤压成形工艺分析及数值模拟

采用机加工生产的柱塞泵滑靴零件,材料浪费严重、废品率高、抗拉强度及耐磨性较低,而改用冷挤压成形工艺可显著解决上述问题。但由于滑靴零件具有薄壁内凹球面结构,挤压过程中产生的残余应力、内球面及柱面的回弹,将使其产生裂纹及变形。通过QFORM-3D软件的模拟结果,改进实验工艺方案,有效降低实际成形的平均应力、成形力及回弹量,保证了内凹球面的尺寸精度和模具结构设计的合理性。     

冷轧变形量及再结晶对TC4合金组织与性能的影响

通过XRD、OM、EDS、SEM和万能试验机等方法,研究了不同冷变形量对TC4合金微观组织及力学性能的影响以及相同再结晶处理对不同冷变形量合金再结晶程度的影响。结果表明,冷轧制使得TC4合金产生加工硬化,相较固溶试样,35%和48%冷变形量试样的抗拉强度分别提高451 MPa和228 MPa。再结晶工艺相同时,随着变形量的增大,合金的抗拉强度逐渐降低。     

冷轧法提高Mg-3Gd-1Zn合金的强度(英文)

利用大应变冷轧提高Mg3Gd1Zn(质量分数)合金的强度。通过单道次23%压下量的冷轧处理,可在Mg3GdZn合金热轧板材的组织中引入大量位错,使其形成基面织构,进而使其屈服强度提高150%。与Mg3GdZn合金热轧板材相比,将冷轧板材在350°C下退火30min,可以提高其强度,同时具有较高的塑性。由于剪切带的软化作用,多道次冷轧的Mg3Gd1Zn合金板材没有获得预期的强度;但是,利用多道次冷轧来制备厚度小于1mm的薄板或箔材,可以尽可能减少道次间的回炉退火,从而提高生产效率,降低能耗。