Direct Chill Casting of CLAD Ingot

Wagstaff, Robert B.; Lloyd, D. J.; Bischoff, Todd F.

doi:10.4028/www.scientific.net/msf.519-521.1809

Cited by 43 publications

(21 citation statements)

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“…A commercial Al-Si clad brazing sheet (denoted as Al(Si)) was selected to test the concept of using an Al-Si alloy coating interlayer to improve the joint performance in Al-Mg dissimilar welds. This material (designated Al(Si)) was manufactured by the 'Novelis Fusion ä ' dual-launder DC co-casting process [22] and had an AA6016 core with an AA4045 (10 pct Si) cladding layer. A further unclad 6XXX series Al alloy, AA6111 (in a T4 temper), was used to prepare Al-Mg baseline samples for comparison purposes.…”

Section: Methodsmentioning

confidence: 99%

The Effectiveness of Al-Si Coatings for Preventing Interfacial Reaction in Al-Mg Dissimilar Metal Welding

Wang

Al-Zubaidy

Prangnell

2017

Metall Mater Trans A

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The dissimilar welding of aluminum to magnesium is challenging because of the rapid formation of brittle intermetallic compounds (IMC) at the weld interface. An Al-Si coating interlayer was selected to address this problem, based on thermodynamic calculations which predicted that silicon would change the reaction path to avoid formation of the normally observed binary Al-Mg IMC phases (b-Al 3 Mg 2 and c-Al 12 Mg 17 ). Long-term static heat treatments confirmed that a Si-rich coating will preferentially produce the Mg 2 Si phase in competition with the less stable, b-Al 3 Mg 2 and c-Al 12 Mg 17 binary IMC phases, and this reduced the overall reaction layer thickness. However, when an Al-Si clad sheet was tested in a real welding scenario, using the Refill ä friction stir spot welding (FSSW) technique, Mg 2 Si was only produced in very small amounts owing to the much shorter reaction time. Surprisingly, the coating still led to a significant reduction in the IMC reaction layer thickness and the welds exhibited enhanced mechanical performance, with improved strength and fracture energy. This beneficial behavior has been attributed to the softer coating material both reducing the welding temperature and giving rise to the incorporation of Si particles into the reaction layer, which toughened the brittle interfacial IMC phases during crack propagation.

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Section: Methodsmentioning

confidence: 99%

The Effectiveness of Al-Si Coatings for Preventing Interfacial Reaction in Al-Mg Dissimilar Metal Welding

Wang

Al-Zubaidy

Prangnell

2017

Metall Mater Trans A

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“…Many high-strength alloys, such as the high Mg AA5000 series, are not easily bondable mainly because of their susceptibility to oxidation during the bonding process, which is carried out at elevated temperatures. Recently, a new technology referred to as ''Fusion Technology'' (Novelis-Solatens Technology Center, Spokane Valley, WA) [1,2] has been developed that produces clad material by direct chill (DC) casting. This process has few restrictions with regard to the combination of alloys that can be cast, and it allows clad sheet to be produced by essentially the same hot and cold rolling routes used for conventional, monolithic alloys.…”

Section: Introductionmentioning

confidence: 99%

The Deformation of Clad Aluminum Sheet Produced By Direct Chill Casting

Lloyd

Gallerneault

Wagstaff

2010

Metall Mater Trans A

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The tensile and bending response of AA3003/AA6111 sheet produced by direct chill casting has been investigated. It is shown that the interface strength of the clad sheet has a minimum value of 175 MPa, and failure does not occur in the interface. The yield strength of the clad sheet obeys the rule of mixtures, and up to a cladding thickness of 100 lm-which was the thickest investigated-the work hardening behavior and tensile response are essentially unaffected by the presence of the cladding. The bending response of the sheet is improved greatly by the presence of ductile cladding, which was the case for prestrained and aged sheet. Under bending, failure is initiated in the lower bendability core and then eventually propagates through the more ductile cladding, which yields the final bend failure.

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“…[18] In order to illustrate the motivation for the development of structural materials with graded structure, the example of functionally graded steel (FGS) is presented. The graded microstructure is obtained by a decarburization thermal treatment.…”

Section: Gradient In Propertiesmentioning

confidence: 99%

“…An alternative approach is to consider modification of processing techniques such as co-casting where more than one material is solidified simultaneously such as in the Wagstaffe casting operation to produce composite plates and tubes. [18] In the area of deformation processing the traditional approach has been to use a unique strain path e.g rolling or wire drawing but changes in strain path permit the development of much more complex architectures for combinations of phases as illustrated in Figure 15 by twisting-rolling methods which proposes to roll twisted multi-materials wires. [33] This use of a complex processing path may also be of value in tailoring the degree of kinematic hardening exhibited by the final product due to the manner in which the internal stresses carried by the embedded phases depend on the detailed nonmonotonic strain path.…”

Section: Reviewsmentioning

confidence: 99%

Heterogeneous and Architectured Materials: A Possible Strategy for Design of Structural Materials

Bouaziz¹,

Bréchet²,

Embury³

2008

Adv Eng Mater

128

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One of the main driving force for the development of advanced structural materials is weight saving especially in the transportation industry in order to reduce CO 2 emission. These new demands provide strong requirements for an optimal choiceof materials (inducing a very fierce competition between materials such as aluminium, magnesium and steels in the automotive industry, aluminium, titanium and composite materials in the aeronautical industry). They also lead the engineer to consider solutions where the structural component also provide a functional property (such as thermal insulation, magnetic properties, acoustic damping or energy absorption)Facing these increasing demands for multifunctional solutions, the classical strategy of the metallurgist to improve properties, using microstructural refinement, reaches its limits: very often the function is not provided by the property only, but by the interplay between the shape, the properties, and possible association of materials. The purpose of the present paper is to outline the new strategies for structural materials development offered by these new degrees of freedom and by their combination: not only playing with the microstructure or with the macroscopic shape, but allowing a new scale for materials organization, the "architecture" , and controlling a new degree of freedom, the "spatial heterogeneity". For these ideas to be effective, the question of processing such "heterogeneous architectured materials" in an afford- 24Facing increasing demands for multifunctional solutions, the classical strategy of the metallurgist to improve properties, using microstructural refinement, reaches its limits: very often the function is not provided by the property only, but by the interplay between the shape, the properties, and possible association of materials. The purpose of the present paper is to outline new strategies for structural materials development offered by new degrees of freedom and by their combination: not only playing with the microstructure or with the macroscopic shape, but allowing a new scale for materials organization, the "architecture", and controlling a new degree of freedom, the "spatial heterogeneity". For these ideas to be effective, the question of processing such "heterogeneous architectured materials" in an affordable manner has to be kept in mind. Very often the development of architectured materials will require new processing methods.

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Direct Chill Casting of CLAD Ingot

Cited by 43 publications

References 0 publications

The Effectiveness of Al-Si Coatings for Preventing Interfacial Reaction in Al-Mg Dissimilar Metal Welding

The Effectiveness of Al-Si Coatings for Preventing Interfacial Reaction in Al-Mg Dissimilar Metal Welding

The Deformation of Clad Aluminum Sheet Produced By Direct Chill Casting

Heterogeneous and Architectured Materials: A Possible Strategy for Design of Structural Materials

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