Effect of Friction Stir Processing on Microstructure and Tensile Properties of an Investment Cast Al-7Si-0.6Mg Alloy

Friction stir processing (FSP) is emerging as a promising tool for microstructural modification. The current study assesses the effects of FSP on the microstructure and mechanical properties of an investment cast Al-7Si-Mg alloy. FSP eliminates porosity and significantly refines eutectic Si particles. The extent of particle refinement varied with changes in processing conditions. A high tool rotation rate and a low-to-intermediate tool traverse speed generated a higher volume fraction of finer particles. Tensile ductility changed significantly as a result of FSP, whereas ultimate tensile strength improved only marginally. Yield strength was similar in both cast and FSP samples under various heat-treated conditions, with the highest value obtained after a T6 heat treatment. Furthermore, FSP caused significant grain refinement in the stir zone, subsequently transforming into very coarse grains as abnormal grain growth occurred during solution treatment at high temperature.     

Interface- and diffusion-limited capillary rise of reactive melts with a transient contact angle

The kinetics of unidirectional capillary penetration by a reactive fluid under the limiting cases of diffusion control and interface control has been derived for the reactive infiltration phenomenon characterized by a shrinking capillary radius due to interphase formation and an exponentially decaying contact angle. The computational outcomes for the reactive penetration of Si₃N₄ capillaries by AgCuTi brazes and of carbon capillaries by Si show that greater lengths are attained at lower values of the parabolic rate constant (under diffusion control), and the limiting length is reached earlier at larger values of the linear rate constant (under interface control). A capillary-driven flow analysis (Washburn equation) overestimates the infiltration kinetics, whereas an analysis that considers pore shrinkage but assumes the contact angle and the capillary pressure to be constant during flow underestimates the kinetics. The penetration lengths predicted by the analysis at pore closure due to reaction choking exhibit a slightly better agreement with the recent measurements in the Si/C system than the models of reactive flows currently in vogue.     

Particle distribution control in cast aluminium alloy-mica composites

A suspension of mica particles (40m diameter and 3.7 thick) obtained in a mechanically stirred Al-4 wt % Cu-1.5 wt % Mg melt was poured and solidified in a variety of moulds under different heat flow configurations. The resulting cast structure showed a non-uniform distribution of dispersed mica particles with mica-depleted and segregated zones due to their flotation before and during solidification. The experimentally observed profiles of mica-free regions deviate significantly from those computed on the basis of Stokes's law and freezing-time computations. In relatively thick castings, segregation of mica could be minimized by using low pouring temperatures and/or side as well as bottom chilling. It was found, however, that thin castings (12.5 mm) could easily be produced with a homogeneous distribution of mica particles.     

Rolling contact fatigue behavior of sintered and hardened steels

Powder-metal-processed bearings and gears are finding increasing application because of their economical and technical advantages. The residual pores from the sintering operatives act as lubricant pockets and dampen sound and vibration. However, porosity also decreases the mechanical strength and reduces the life of components fabricated by powder processing relative to similar wrought components. The rolling contact fatigue behavior of sintered and heat treated steel rollers was investigated using a fatigue test machine designed and fabricated for that purpose. The powder-metal-processed and the wrought steel rollers that were tested had similar composition and hardness and were mated against wrought steel rollers of high hardness. The contact stress versus number of cycles to failure data showed that the wrought steel had a very high endurance limit under rolling contact fatigue compared to the sintered steels investigated. Rolling contact fatigue behavior was found to depend on the porosity present in the material. Large surface peeling failures and pitting type fatigue failures were observed in the sintered and hardened steels, while only pitting type failures were observed in the wrought steels     

Need of Alcohol Reference Materials and Reliable Measurement of Alcohol Content by Breath Alcohol Analyzer in India: An Overview

Breath alcohol analyser is used to detect alcohol content in end-expiratory breaths in order to enforce driving regulations under the influence of alcohol legislation. The accuracy and reliability of the routine measurements of alcohol content performed with breath alcohol analyser can be achieved by the calibration of the breath alcohol analyser using standards traceable to SI reference material. Proper calibration is essential for transparency in legal verification for which reference material is needed. At international level, a number of NMIs are active to address this important measurement issue of providing accurate measurements. Several international key comparison programs have been organized so far for the determination of ethanol content in aqueous and in nitrogen/air matrix. NIST, USA; BAM, Germany; IRMM, Belgium, Portugal, INMETRO, Brazil, LGC, UK etc. have developed certain reference materials of ethanol in water solution/air with different concentration ranges. However, no such reference material is introduced in India as an indigenous standard, rather, being procured from abroad or using high purity alcohol for calibration purposes. CSIR-NPL, India, being the NMI is now focusing on establishing the calibration facility and development of SI traceable aqueous alcohol standard to provide test reliability for the testing in breath alcohol analyser. This program has a societal impact which contributes to human health and regulatory needs for the nation.     

Single point incremental forming: state-of-the-art and prospects

Incremental sheet metal forming in general and Single Point Incremental Forming (SPIF) specifically have gone through a period of intensive development with growing attention from research institutes worldwide. The result of these efforts is significant progress in the understanding of the underlying forming mechanisms and opportunities as well as limitations associated with this category of flexible forming processes. Furthermore, creative process design efforts have enhanced the process capabilities and process planning methods. Also, simulation capabilities have evolved substantially. This review paper aims to provide an overview of the body of knowledge with respect to Single Point Incremental Forming. Without claiming to be exhaustive, each section aims for an up-to-date state-of-the-art review with corresponding conclusions on scientific progress and outlook on expected further developments.     

Superplastic behavior and microstructural stability of friction stir processed AZ91C alloy

Superplastic behavior of a solution treated and friction stir processed (FSP) AZ91C alloy is studied. These studies are conducted in the temperature range of 300–375 °C and strain rates (SRs) in the range of 1 × 10^?4–3 × 10^?3 s^?1. Microstructural stability of the FSP alloy is also studied in comparison to the AZ31, AZ61, and AZ91 alloys processed by various routes. High SR sensitivity in the range of 0.33–0.39 and grain size stability till 350 °C is observed for the FSP alloy. The FSP AZ91C alloy showed better thermal stability in comparison to AZ31 and AZ61 alloys. Kinetics of superplastic deformation of the FSP alloy is found to be slower as compared to AZ31 and AZ61 alloys processed by various routes, which is due to the presence of significant amount of second phase precipitates, such as, β-Mg₁₇(Al,Zn)₁₂, Mg₂Si, and Al₈Mn₅ in the FSP alloy. However, these precipitates contributed for better thermal stability of the microstructure of FSP AZ91C alloy.     

Mathematical modelling and numerical simulation of ordered porosity metal materials formation

Ordered porosity metal materials belong to a relatively new class of porous materials named gasars. This paper presents a mathematical model of the complex physical phenomena in the production of gasars. Analyses for heat transfer, solidification kinetics and gas diffusion were coupled to describe the formation of unique gasar structure. Several criterial functions were introduced to provide significant quantitative information about the relationship between the operating technological parameters and the final structure. The computational outcomes of the numerical simulation were compared with the characteristics of real gasar ingots. The model was applied to determine the boundary conditions that would provide approximately constant physical conditions on the solidification front. The structure sensitiveness of gasars with respect to the different technological parameters is discussed.