Search Results (90)

This research systematically investigates the influence of multi-microalloying with Sn, Mn, Er, and Zr on the homogenized microstructure, aging behavior, and mechanical properties of a 6082 Al-Mg-Si alloy. The optimization of the homogenization treatment for the alloy was based on isochronal aging curves and conductivity measurements. The results show that the addition of Mn, Er, and Zr can precipitate thermally stable Al(Fe,Mn)Si dispersoids and Al(Er,Zr) dispersoids. The three-stage homogenization treatment resulted in the precipitation of more heat-resistant dispersoids, thereby achieving the best thermal stability. During direct artificial aging, the initial hardening rate of the Mn-containing alloy was slightly delayed, but its peak hardness was significantly increased. This is due to the dispersoids offering additional heterogeneous nucleation sites for the strengthening precipitates. Meanwhile, the Sn atoms release their trapped vacancies at the aging temperature, thereby promoting atomic diffusion. However, short-term natural aging before artificial aging accelerated the early-stage aging response of the Sn-containing alloy but resulted in a reduced peak hardness. Notably, the co-microalloying with Mn and Sn led to a higher peak hardness during direct artificial aging, while it caused a more significant hardness loss when a natural aging preceded artificial aging, revealing a distinct synergistic negative effect. The reason for the negative synergy effect might be related to the weakened ability of Sn to release vacancies after natural aging. This study clarifies the process dependence of microalloying effects, providing a theoretical basis for optimizing aluminum alloy properties through the synergistic design of composition and processing routes. Full article

Although low-silicon Al-Si alloys have been extensively studied, further improvement in their mechanical performance remains a critical challenge. This study examines the synergistic effects of scandium (Sc) and zirconium (Zr) additions on the solidification behavior, microstructural evolution, and mechanical properties of Al-5Si-Cu-Mg alloys. The Sc/Zr additions refine the α-Al grains and modify the eutectic Si morphology, with the most uniform microstructure obtained at 0.5 wt.% due to the formation of coherent Al₃(Sc,Zr) dispersoids. These additions also suppress the formation of needle-like β-Al₅FeSi phases and promote the transformation to compact α-Al₁₅(Fe,Mn)₃(Si,Zr,Sc)₂ intermetallics, optimizing the solidification process. The yield strength increases with Sc/Zr content owing to grain-boundary and precipitation strengthening. However, the alloy without Sc/Zr exhibits the highest ultimate tensile strength and elongation, likely due to its finer secondary dendrite arm spacing and the absence of casting-induced cracks in this investigation. Although Sc/Zr additions of 0.25–0.5 wt.% contribute to microstructural refinement, the concurrent formation of porosity and coarse intermetallic compounds leads to a deterioration in ductility. Excessive Sc/Zr additions further coarsen grains and degrade the overall mechanical integrity. Full article

This study reported the development of a novel Al-Si-Mg-based composite reinforced by micron-sized Cu-Mn binary solid solution phases and submicron-sized α-Al(Mn,Fe)Si dispersoids. The Cu-Mn binary solid solution phases were added to the melt in the form of an Al-3%CuMn master alloy, whereas α-Al(Mn,Fe)Si dispersoids were obtained via heat treatment. The microstructure analysis confirmed the presence of micron-sized Cu-Mn binary, eutectic Mg₂Si, and Al₁₅(FeMn)₃Si₂ intermetallic phases, submicron-sized α-Al(Mn,Fe)Si dispersoids, and nano-sized precipitates in the Al-based composite. At room temperature, tensile results represented a yield strength of 287 MPa and a tensile strength of 306 MPa, with an elongation of 17%. Moreover, the Al-based composite maintained a yield strength of 277 MPa up to 250 °C, with a slight increase in elongation. The composite also exhibited excellent high-temperature high-cycle fatigue properties and showed a high-cycle fatigue limit of 140 MPa at 130 °C, which is ~2.3 times higher than that of the commercial A319 alloy. A fractography study revealed that the secondary particles hindered the movement of dislocations, thus delaying crack initiation under cyclic loading at high temperatures. Additionally, Cu-Mn binary solid solutions and Al₁₅(FeMn)₃Si₂ phases were found to be effective in reducing the crack propagation rate by hindering the movement of the propagated crack. Full article

To investigate the movement law of top coal and the influencing factors of coal caving ratio in fully mechanized top coal caving faces, this study adopts the theory of dispersoid mechanics. First, a top coal flow model was established without considering the influence of the support. Then, the effect of the support was analyzed, and it was found that the sliding resistance of the top coal body increases with the square of both the support width and the top coal thickness. Furthermore, the positive stress on the coal particles was derived through a microelement force analysis, and a theoretical formula for arching probability was proposed. The mobility of top coal was evaluated using a flow factor, and the influence of lump size on arching tendency was quantitatively analyzed. Based on these insights, several measures to improve top coal flowability and recovery rate were proposed, including increasing mining height, enlarging the coal caving opening, enhancing the initial support force, extending the caving step, and applying multiple alternating loads to pre-break top coal. These strategies provide a theoretical basis and practical guidance for enhancing top coal caving efficiency. Full article

We simulate the dispersoid distribution within the Al matrix grains of an aluminum 6082 alloy by combining finite difference cell modeling with mean-field precipitation simulations. The results demonstrate that the initial as-cast microstructure and the heating rate during the ramp-up to the isothermal homogenization temperature are the most important factors governing the dispersoid particle distribution. The simulation results are validated by Electron Probe Microanalysis (EPMA) and Optical Microscopy on experimental run products. The results indicate that dispersoids can only achieve uniform distribution throughout the grain when the heating rate to the homogenization temperature is sufficiently slow. Full article

Understanding the development of an asphalt binder’s internal network structure is essential when interacting asphalt and crumb rubber. Thus, the focus of this study was to reveal the development of asphalt–rubber binders’ (A-RBs) network structures at different interaction times and their correlation with performance. Atomic force microscopy (AFM) was utilized to image the morphologies of the binders, and the binders’ performances were explored rheologically with a dynamic shear rheometer. Extending the interaction time to 8 h and utilizing a soft binder altered the network structures from agglomerated dispersoids—minuscule distributed phase zones embedded in the continuous matrix of the asphalt binder—to well-organized lamellar structures. At 8 h, using a softer binder increased stiffness by 25% and elasticity by 15%, accelerating early rubber dissolution. Extending the interaction time from 4 to 8 h increased rubber dissolution by 5–23%, depending on the binder type. The 150% increase in stress overshoot for A-RBs with the soft binder versus those with the stiff one reflects the development of the network structure. At 8 h, the soft binder reduced the AFM mean phase angle by 10% and the standard deviation by 64%, indicating a more homogeneous and stable network than that obtained with the stiff binder. Thus, the 8 h interaction time and soft binder facilitated rubber swelling and enhanced component diffusion, aiding in the formation of a homogeneous network. Full article

There is a demand for a 6005A series extrusion alloy with improved strength that maintains good extrudability. Replacing Mn and Cr dispersoid formers with Sc and Zr is expected to increase the room temperature mechanical properties while not affecting extrudability. Al₃X dispersoids with a Sc core surrounded by a Zr shell are stable at higher temperatures and enhance recrystallization resistance and precipitation strengthening. However, there is little information on how the Sc and Zr additions affect the properties of an extrudate as a function of extrusion geometry and ratio. A 6005A series alloy with Cr and Mn additions is compared to an alloy with Sc and Zr additions with rod and flat cross-sections at extrusion ratios of 25 and 92. The results show that Sc and Zr additions increased yield strength and ultimate tensile strength while maintaining ductility compared to Cr and Mn additions. Rod shapes performed significantly better than flat shapes, but there was no significant effect of extrusion ratio. Full article

Application of rare earths (RE) as grain refiners is well-known in the technology of aluminum alloys for the automotive industry. In the current study, Al-2.4%Cu-0.4%Mg alloy (coded 220) and Al-7.5%Si-0.35%Mg alloy (coded 356.1), were prepared by melting each alloy in a resistance furnace. Strontium (Sr) was used as a modifier, while titanium boride (TiB₂) was added as a grain refiner. Measured amounts of Ce and La were added to both alloys (max. 1 wt.%). The alloy melts were poured in a preheated metallic mold. The main part of the study was conducted on tensile testing at room temperature. The results show that although RE would cause grain refining to be about 30–40% through the constitutional undercooling mechanism, grain refining with TiB₂ would lead to approximately 90% refining (heterogenous nucleation mechanism). The addition of high purity Ce or La (99.9% purity) has no modification effect regardless of the alloy composition or the concentration of RE. Depending on the alloy ductility, the addition of 0.2 wt.%RE has a hardening effect that causes precipitation of RE in the form of dispersoids (300–700 nm). However, this increase vanishes with the decrease in alloy ductility, i.e., with T6 treatment, due to intensive precipitation of ultra-fine coherent Mg₂Si-phase particles. There is no definite distinction in the behavior of Ce or La in terms of their high affinity to interact with other transition elements in the matrix, particularly Ti, Fe, Cu, and Sr. When the melt was properly degassed using high-purity argon and filtered using a 20 ppi ceramic foam filter, prior to pouring the liquid metal into the mold sprue, no measurable number of RE oxides was observed. In conclusion, the application of RE to aluminum castings would only lead to formation of a significant volume fraction of brittle intermetallics. In Ti-free alloys, identification of Ce- or La-intermetallics is doubtful due to the fairly thin thickness of the precipitated platelets (about 1 µm) and the possibility that most of the reported Al, Si, and other elements make the reported values for RE rather ambiguous. Full article

This study investigates the effects of nano-oxide dispersoids on microstructural evolution, phase formation, and mechanical properties of W-Mo-Ti alloys reinforced with AlCoCrFeNi_2.1 during mechanical alloying. An EBSD/EDS analysis confirmed the formation of different phases, including the tungsten matrix, FCC reinforcement phase, Al₂O₃, and (Al,Cr) oxide. Y₂O₃ particles played a crucial role in refining the microstructure, promoting a uniform dispersion of the reinforcement phase and oxide particles in the tungsten model alloys. Mechanical testing demonstrates that the Y₂O₃-containing alloy exhibits improved hardness with prolonged milling, attributed to the refinement in the microstructure. In contrast, the Y₂O₃-free alloy shows reduced hardness due to the agglomeration of reinforcement phases surrounded by an (Al,Cr) oxide layer. The model tungsten alloys exhibit brittle behavior in compression tests, which can be attributed to the presence of (Al,Cr) oxide layers weakening the interfacial bonding and limiting plastic deformation. Full article

The long-term corrosion resistance of commercially pure aluminum (AA1050) processed by equal channel angular pressing (ECAP) was evaluated in a saline environment. The study compared the microstructure and corrosion behavior of ECAP-processed samples in route A with 1X, 4X, and 8X passes to an annealed sample using a 3.5% NaCl solution. Characterization techniques, including optical microscopy (OM), scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), transmission electron microscopy (TEM), and electrochemical impedance spectroscopy (EIS), were employed. Results indicate that ECAP processing enhances the passive corrosion resistance compared to the undeformed sample. However, the improvement in corrosion resistance did not consistently increase with the number of ECAP passes. Factors such as the distribution of high- and low-angle grain boundaries, dislocation density, and fragmentation and redistribution of coarse dispersoid particles play a significant role in the corrosion behavior post-ECAP. Additionally, findings suggest that long-term immersion tests are required to obtain a more reliable electrochemical response. Full article

This study examined the effects of heat treatment on the microstructure and dynamic deformation characteristics of AA2519 aluminum alloy in T4, T6, and T8 tempers under high strain rates of 1000–4000 s⁻¹. A Split Hopkinson pressure bar (SHPB) was utilized to characterize the mechanical response, and microstructural analysis was performed to examine the material’s microstructure. The findings indicated varied deformation across all three temper conditions. The dynamic behavior of each temper is influenced by its strength properties, which are determined by the aging type and the subsequent transformation of strengthening precipitates, along with the initial microstructure. At a strain rate of 1500 s⁻¹, AA2519-T6 demonstrated a peak dynamic yield strength of 509 MPa and a flow stress of 667 MPa. These values are comparable to those recorded for AA2519-T8 at a strain rate of 3500 s⁻¹. AA2519-T4 exhibited the lowest strength and flow stress characteristics. The T6 temper demonstrated initial stress collapse, dynamic strain aging, and an increased tendency for shear band formation and fracture within the defined strain rate range. The strain rates all showed similar trends in terms of strain hardening rate. The damage evolution of the alloy primarily involved the nucleation, shearing, and cracking of dispersoid particles. Full article

This study presents the results of research on the influence of different contents of copper in aluminium alloys based on the 6xxx series on mechanical and structural properties. The investigation started with the alloying, and casting four billet variants with different copper content—0.8% Cu; 2B—1% Cu; 3A—1.2% Cu; and 3B—1.4% Cu. The prepared materials were homogenised and extruded on a 500T horizontal press with two different process temperatures and ram speeds ranging from 1 mm/s to 9 mm/s. After heat treating to the T6 and T5 tempers, their mechanical properties were tested. On this basis, the two most promising alloys 2A and 3B were selected and subjected to further tests. After extrusion and heat treatment of the profiles (to F, T1, T2, T5, and T5510), their mechanical properties were determined to select the preferred process parameters. Finally, a structural test based on crystallographic orientation based on the EBSD technique and TEM observations allowed for the characterisation of grain size, dispersoids, and phase analysis. Bright-field (BF) analysis allowed us to compare the deformed areas for T1, T5, and T5510 temperatures. The results showed significant growth in the mechanical properties of all the subjected alloys, and the best properties were shown for a Cu content of 1.4% with a tensile strength of 460 MPa and an elongation of 16% (T5510 tempering). The structural test showed an average grain size of 18 µm to 23 µm and solid solution decomposition differences for different heat-treating parameters. Full article

The impact of annealing on the recrystallized grain structure and superplastic behavior of two Al-Mg 5xxx alloys used for high-speed blow forming (HSBF) was studied. The results revealed that both alloys demonstrated rapid static recrystallization after only a few minutes of annealing at 520 °C, forming fine and equiaxed grain structures. After four min of annealing, Alloy 2 (Al-4.0Mg-1.18Mn) exhibited a higher fraction of small grains (<10 µm) compared to Alloy 1 (Al-4.5Mg-0.74Mn). Moreover, Alloy 2 displayed enhanced resistance to grain coarsening with increasing annealing times, which was attributed to its higher amount of Al₆(Mn,Fe) intermetallic particles and a higher number density of Mn dispersoids. Optimizing the annealing time can effectively develop a fine and stable grain structure in Al-Mg 5xxx alloys. During tensile deformation, Alloy 2 consistently showed higher ductility compared to Alloy 1 at low strain rates (170% vs. 138% at 0.001 s⁻¹ and 163% vs. 134% at 0.01 s⁻¹), whereas at a high strain rate of 1 s⁻¹, both alloys displayed comparable tensile elongation. The high superplastic response of Alloy 2 at low strain rates renders it a superior superplastic alloy for HSBF applications. Full article

Al-Mg alloys are characterized by permanent solid solution hardening and can additionally be work-hardened. The high mechanical properties of Al-Mg alloys with above-standard Mg content obtained after plastic deformation processes decrease over time. The addition of minor alloying elements like Er or Zr is an alternative method to improve the durability of mechanical properties and increase the strength of Al-Mg alloys due to densely and evenly distributed dispersoids being formed. In this paper, Al-Mg alloys with above-standard Mg content (7 wt.%) and Zr and Er micro-alloying elements and their influence on the microstructure and durability of the mechanical properties were examined. The cast ingots of AlMg7 alloys were characterized by a smooth surface without cracks. The plastic deformation process in a static compression test resulted in an about 60 HBW increase in the Brinell hardness of all the deformed alloys relative to casting. It was revealed that the addition of Er and Zr significantly improved the mechanical properties and durability of the mechanical properties of the Al-Mg after annealing. The addition of Er or Zr slightly restrained the decrease in the Brinell hardness after annealing but did not inhibit it. Full article

The friction stir welding (FSW) process is a unique combination of deformation and high temperature, which provides opportunities to modify microstructures through the adjustment of the processing parameters and is an ideal way to join non-weldable aluminum alloys by avoiding the formation of a molten pool. The 7xxx series heat-treatable aluminum alloys are widely used in the aerospace field as high-performance structural materials. The microstructure evolution and mechanical performance of these alloys are affected by the effects of thermomechanical processing, which provides opportunities to optimize the material properties by controlling microstructural features such as intermetallic constituent particles, dispersoids and nanoscale precipitates. This paper focuses on the basic principles of the thermal and mechanical effects generated during FSW on the evolution of second-phase particles in different zones of the weld. Full article