Casting and Forming of Advanced Aluminum Alloys

Puga, Hélder

doi:10.3390/met10040494

Cited by 9 publications

(6 citation statements)

References 10 publications

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“…While cast alloys are responsible for most of the surplus, the improvement of casting technologies enhancing properties of cast alloys could help reducing this waste. By improving the casting process and better controlling the microstructure of aluminum alloys (Puga, 2020), cast alloys could be used for new applications that would lead to a greater demand of cast alloys limiting the surplus problem.…”

Section: Discussionmentioning

confidence: 99%

How much sorting is required for a circular low carbon aluminum economy?

Pedneault

Majeau‐Bettez

Margni

2023

J of Industrial Ecology

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Aluminum recycling follows a downcycling dynamic where wrought alloys are transformed into cast alloys, accumulating tramp elements at every cycle. With the saturation of stocks of aluminum and the reduction of the demand for cast alloy due to electrification of transport, improvement in the recycling system must be made to avoid a surplus of unused recycled aluminum, reduce the overall environmental impacts of the industry, and move toward a circular economy. We aim to evaluate the potential environmental benefits of improving sorting efforts by combining operations research, prospective material flow analysis, and life cycle assessment. An optimization defines the optimal sorting to minimize climate change impacts according to different sorting efforts, dismantling conditions, and collection rates. Results show how the improvement of sorting can reduce by around 30% the greenhouse gas emissions of the industry, notably by reducing unused scrap generation and increasing the recycled content of the flows that supply the demand of aluminum. The best performance is achievable with four different sorting pathways. Further improvements occur with a better dismantling and an increase of collection rates, but it requires more sorting pathways. Results point to different closed‐loop recycling initiatives that should be promoted on priority in specific sectors, like the building and construction sector and the aluminum cans industry. To implement a better material circularity, the mobilization of different stakeholders is needed. From a wider perspective, the article shows how operations research can be used to project a circular future in a specific industry. This article met the requirements for a Gold–Gold JIE data openness badge described at http://jie.click/badges.

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Section: Discussionmentioning

confidence: 99%

How much sorting is required for a circular low carbon aluminum economy?

Pedneault

Majeau‐Bettez

Margni

2023

J of Industrial Ecology

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“…Wrought alloys typically contain up to 5% alloying elements and are used in a hardened and heat-treated condition. In special conditions, cast aluminium alloys can also be processed by plastic working [ 3 ]. However, aluminium-based alloys generally have relatively low fatigue strength [ 4 ].…”

Section: Introductionmentioning

confidence: 99%

Friction Behaviour of 6082-T6 Aluminium Alloy Sheets in a Strip Draw Tribological Test

et al. 2023

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Aluminium alloy sheets cause many problems in sheet metal forming processes owing to their tendency to gall the surface of the tool. The paper presents a method for the determination of the kinematic friction coefficient of friction pairs. The determination of coefficient of friction (COF) in sheet metal forming requires specialised devices that ‘simulate’ friction conditions in specific areas of the formed sheet. In this article, the friction behaviour of aluminium alloy sheets was determined using the strip drawing test. The 1-mm-thick 6082 aluminium alloy sheets in T6 temper were used as test material. Different values for nominal pressures (4.38, 6.53, 8.13, 9.47, 10.63, and 11.69 MPa) and different sliding speeds (10 and 20 mm/min.) were considered. The change of friction conditions was also realised with several typical oils (hydraulic oil LHL 32, machine oil LAN 46 and engine oil SAE 5W-40 C3) commonly used in sheet metal forming operations. Friction tests were conducted at room temperature (24 °C). The main tribological mechanisms accompanying friction (adhesion, flattening, ploughing) were identified using a scanning electron microscope (SEM). The influence of the parameters of the friction process on the value of the COF was determined using artificial neural networks. The lowest value of the COF was recorded when lubricating the sheet metal surface with SAE 5W40 C3 engine oil, which is characterised as the most viscous of all tested lubricants. In dry friction conditions, a decreasing trend of the COF with increasing contact pressure was observed. In the whole range of applied contact pressures (4.38–11.69 MPa), the value of the COF during lubrication with SAE 5W40 C3 engine oil was between 0.14 and 0.17 for a sliding speed of 10 mm/min and between 0.13 and 0.16 for a sliding speed of 20 mm/min. The value of the COF during dry friction was between 0.23 and 0.28 for a sliding speed of 10 mm/min and between 0.22 and 0.26 for a sliding speed of 20 mm/min. SEM micrographs revealed that the main friction mechanism of 6082-T6 aluminium alloys sheet in contact with cold-work tool steel flattens surface asperities. The sensitivity analysis of the input parameters on the value of COF revealed that oil viscosity has the greatest impact on the value of the COF, followed by contact pressure and sliding speed.

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“…Also, high-quality Al-based alloy and MMC can be produced by proper mixing of alloying elements and reinforcement material, respectively. Casting of Al alloys and Al MMC can be divided into two types: batch and continuous casting (Puga, 2020). The batch process normally holds the molten metal in a large furnace, followed by mechanical mixing or stirring of new constituents before casting.…”

Section: Introductionmentioning

confidence: 99%

Concept development, design and validation of a novel continuous casting equipment

Biswas¹,

Patel²,

Mallik

et al. 2023

WJE

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Purpose The purpose of this paper is to develop a concept and design to cast Al alloys/metal matrix composites (MMCs) by continuous casting process. The various steps involved in the evolution of the design have been reported and discussed in this study. Design/methodology/approach On the basis of developed design concept, initial prototype design has been prepared in this study. The casting process's melt flow pattern was studied via computer simulation, and the resulting changes were implemented in the original design. The single-phase fluid flow pattern through bottom feeding technique is studied. The equipment was fabricated based on computer simulation and water modelling studies. Finally, validation was performed for the preparation of Al alloys/ MMCs after parameter optimisation. The results were observed in the optical metallography to confirm the alloying and Al MMC preparation. Findings The developed continuous casting process with bottom feeding technique for the addition of constituent particles shows more efficiency in comparison to the existing batch processes. The final manufactured setup demonstrates effective Al alloy/MMC production as the basis for final fabrication has been accomplished by both computer simulation and water model test. In addition, the microstructure exhibits homogeneous distribution, validating the reliability of the setup. Originality/value Integrating continuous casting with continuous reinforcement or master alloy addition is novel in this area. The constraints that batch production had that have been rectified will also lower the contemporary cost of production.

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Casting and Forming of Advanced Aluminum Alloys

Abstract: The automotive and aeronautical industry´s response to the environmental impact provoked by gas emissions and consumer expectations has driven aluminum alloy casting changes in recent years [...]

Cited by 9 publications

References 10 publications

How much sorting is required for a circular low carbon aluminum economy?

How much sorting is required for a circular low carbon aluminum economy?

Friction Behaviour of 6082-T6 Aluminium Alloy Sheets in a Strip Draw Tribological Test

Concept development, design and validation of a novel continuous casting equipment

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