Enhancement of chip breakability of aluminium alloys by controlling the solidification during direct chill casting

Barekar, Nilam S.; Skalicky, Ivan; Barbatti, C.; Fan, Z.; Jarrett, Martin

doi:10.1016/j.jallcom.2020.158008

Cited by 5 publications

(3 citation statements)

References 13 publications

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“…These finely dispersed phases particles assist the formation of short, broken chips, regardless of where the tool contacts the article being machined. 6 It should be noted that this bar contains far fewer and finerscale black Mg 2 Si particles as compared to the homogenized material. The Mg 2 Si particles are known for their hardness and brittleness and for acting as stress raisers.…”

Section: Machinability and Tensile Propertiesmentioning

confidence: 97%

“…3 Additionally, during the whole cycle, the shape and uniformity of hard insoluble constituents, such as Si, c-Al 7 Cu 4 Ni, d-Al 3 CuNi, and b-Al 9 Fe 2 Si 2 , should be controlled to provide appropriate machinability upon cutting to a piston-like (or other) shape. [4][5][6] For tuning the above-mentioned structural features, grain refinement is the first procedure applied upon casting the wrought Al alloys. Ideally, a cast billet should have uniform fine grains and cell structure over its cross-section, no coarse intermetallics, minimum surface segregation, or shell zone, and an acceptable surface finish.…”

Section: Introductionmentioning

confidence: 99%

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Comparative Analysis of Structure and Properties of Nb-B Inoculated Direct Chill Cast AA4032 Alloy Extruded from As-Cast and Homogenized Conditions

Barekar

Skalicky

Wang

et al. 2022

JOM

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Al-Si wrought piston alloys can lack properties due to inefficient grain refining. A novel Al-Nb-B grain refiner was introduced some time ago, but has still not been assessed in industry for wrought alloys. This paper describes the first trial of Al-Ni-B addition and its impact on the full-scale manufacturing, structure, and properties of the AA4032 products extruded with and without billet homogenization. It is shown that Nb-B inoculation gives opportunities not only to have a refined as-cast structure but also a more homogenous distribution of the solute. In contrast, homogenization drives nucleation and coarsening of the Mg2Si phase that is retained during further extrusion and heat treatment also affecting the precipitation and properties. It was observed that non-homogenized specimens perform better during machining and tensile testing compared to homogenized specimens. The results are supported by electron microscopy investigations of microstructure formation during different steps in downstream processing.

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Section: Machinability and Tensile Propertiesmentioning

confidence: 97%

Section: Introductionmentioning

confidence: 99%

Comparative Analysis of Structure and Properties of Nb-B Inoculated Direct Chill Cast AA4032 Alloy Extruded from As-Cast and Homogenized Conditions

Barekar

Skalicky

Wang

et al. 2022

JOM

Self Cite

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show abstract

“…Due to the generation of frictional heat during machining, the machined zone can reach temperatures as high as 350 • C or even higher. Consequently, the most crucial attribute of a potential replacement element or a combination thereof is the ability to form low melting point phases or eutectics that liquefy or soften below 350 • C. This not only improves chip breaking but also prevents material buildup on the cutting edge [11][12][13]. Over the last two decades, significant research efforts have been directed towards the development of new lead-free aluminium alloys.…”

Section: Introductionmentioning

confidence: 99%

Thermodynamic and Microstructural Analysis of Lead-Free Machining Aluminium Alloys with Indium and Bismuth Additions

Rečnik,

Vončina,

Nagode

et al. 2023

Materials

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The present study comprises an investigation involving thermodynamic analysis, microstructural characterisation, and a comparative examination of the solidification sequence in two different aluminium alloys: EN AW 6026 and EN AW 1370. These alloys were modified through the addition of pure indium and a master alloy consisting of indium and bismuth. The aim of this experiment was to evaluate the potential suitability of indium, either alone or in combination with bismuth, as a substitute for toxic lead in free-machining aluminium alloys. Thermodynamic analysis was carried out using Thermo-Calc TCAL-6 software, supplemented by differential scanning calorimetry (DSC) experiments. The microstructure of these modified alloys was characterised using SEM–EDS analysis. The results provide valuable insights into the formation of different phases and eutectics within the alloys studied. The results represent an important contribution to the development of innovative, lead-free aluminium alloys suitable for machining processes, especially for use in automatic CNC cutting machines. One of the most important findings of this research is the promising suitability of indium as a viable alternative to lead. This potential stems from indium’s ability to avoid interactions with other alloying elements and its tendency to solidify as homogeneously distributed particles with a low melting point. In contrast, the addition of bismuth does not improve the machinability of magnesium-containing aluminium alloys. This is primarily due to their interaction, which leads to the formation of the Mg3Bi2 phase, which solidifies as a eutectic with a high melting point. Consequently, the presence of bismuth appears to have a detrimental effect on the machining properties of the alloy when magnesium is present in the composition.

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Improved Uniformity of As-Cast Structure, Composition, and Mechanical Properties of 2524 Aluminum Alloy by Intensive Melt Shearing

Zhang,

Liu,

Zhu

et al. 2024

J. of Materi Eng and Perform

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Enhancement of chip breakability of aluminium alloys by controlling the solidification during direct chill casting

Cited by 5 publications

References 13 publications

Comparative Analysis of Structure and Properties of Nb-B Inoculated Direct Chill Cast AA4032 Alloy Extruded from As-Cast and Homogenized Conditions

Comparative Analysis of Structure and Properties of Nb-B Inoculated Direct Chill Cast AA4032 Alloy Extruded from As-Cast and Homogenized Conditions

Thermodynamic and Microstructural Analysis of Lead-Free Machining Aluminium Alloys with Indium and Bismuth Additions

Improved Uniformity of As-Cast Structure, Composition, and Mechanical Properties of 2524 Aluminum Alloy by Intensive Melt Shearing

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