An excellent physical and mechanical property makes Aluminium (Al) alloy suitable alternative lightweight materials against steel and cast iron in automotive components. ICME is a computational tool, which integrates the materials information to engineering product performance analysis. MatCalc is ICME tool, which follows the chain rule of process, microstructure, property and performance relationship in materials development. This paper reports the development of Al 6061-T6 propeller shaft through forging process and the materials and process model of the Al yoke is simulated using MatCalc simulation software. Finite element analysis method is used for designing of Al 6061-T6 propeller shaft. The forged Al yoke is solutionized at temperature 550°C for 1 hr followed by artificial ageing at temperature 180°C for 16 hrs to improve the hardness and strength of the yoke. The strengthening mechanisms involved in improvement of mechanical properties of yoke are precipitation, grain boundary, dislocation, solid solution strengthening mechanism respectively. The experimental values are correlated with the simulated data and good correlation is achieved.
The microstructural characterization reveals the presence of Mg2Si and Mg5Si6 precipitate at the grain boundary. The average grain size of primary α-Al grain and precipitates are also reduced after forging and heat treatment. The hardness and yield strength of yoke component is enhanced to 108 HV and 270 MPa as compared to as-received materials 60 HV and 200 MPa.
The Al based propeller shaft has significantly reduced the weight by 30% as compared to steel part and with the same performance.