Browse Topic: Metallurgy

Items (16,036)
Nowadays, more than in the recent decades, the design process for the body in white for passenger cars is driven by efficiency. This results in the enhanced usage of large-scale cast components made of aluminum, for the battery compartment, the front or rear body and other components. While the automotive industry is striving towards even larger structures made with so-called “Giga-Casting”, challenges in the casting and supply chain processes, but also maintenance and repair processes of these large structures, arise. Other tasks to solve might follow from controlling local microstructures, and thus the strength of the parts, when the flow length of the molten metal increases with component size, especially in relation to an increased fraction of recycled aluminum. Within the Fraunhofer-internal project “FutureCarProduction”, focus is directed towards understanding what drives efficiency, availability and sustainability of modern processes for the production of a car body. Moreover
Bleicher, ChristophQaralleh, AhmadLehmhus, DirkHaesche, MarcoFernandes Gomes, LeonardoPintore, ManuelKleinhans, RobertSommer, SilkeTlatlik, Johannes
Solid state joining processes are attractive for magnesium alloys as they can offer robust joints without the porosity issue typically associated with welding of magnesium and dissimilar materials. Among these techniques, Self-Piercing Riveting (SPR) is a clean, fast and cost-effective method widely employed in automotive industry for aluminum alloys. While SPR has been proven effective for joining aluminum and steel, it has yet to be successfully adapted for magnesium alloy castings. The primary challenge in developing magnesium SPR technology is the cracking of the magnesium button, which occurs due to magnesium's low formability at room temperature. Researchers and engineers approached this issue with several techniques, such as pre-heating, applying rotation to rivets, using a sacrificial layer and padded SPR. However, all these methods involve the employment of new equipment or introduction of extra processing steps. The aim of this work is to develop a SPR technique which adapts
Tabatabaei, YousefWang, GerryWeiler, Jonathan
The significant mechanical features of aluminum alloy, including cost-effectiveness, lightweight, durability, high reliability, and easy maintenance, have made it an essential component of the automobile industry. Automobile parts including fuel tanks, cylinder heads, intake manifolds, brake elements, and engine blocks are made of aluminum alloy. The primary causes of its engineering failure are fatigue and fracture. Aluminum alloys' fatigue resistance is frequently increased by surface strengthening methods like ultrasonic shot peening (USP). This article discusses the shot peening dynamics analysis and the influence of ultrasonic shot peening parameters on material surface modification using the DEM-FEM coupling method. Firstly, the projectile motion characteristics under different processes are simulated and analyzed by EDEM. The projectile dynamics characteristics are imported into Ansys software to realize DEM-FEM coupling analysis, and the surface modification characteristics of
Adeel, MuhammadAzeem, NaqashXue, HongqianHussain, Muzammil
Image-based machine learning (ML) methods are increasingly transforming the field of materials science, offering powerful tools for automatic analysis of microstructures and failure mechanisms. This paper provides an overview of the latest advancements in ML techniques applied to materials microstructure and failure analysis, with a particular focus on the automatic detection of porosity and oxide defects and microstructure features such as dendritic arms and eutectic phase in aluminum casting. By leveraging image-based data, such as metallographic and fractographic images, ML models can identify patterns that are difficult to detect through conventional methods. The integration of convolutional neural networks (CNNs) and advanced image processing algorithms not only accelerates the analysis process but also improves accuracy by reducing subjectivity in interpretation. Key studies and applications are further reviewed to highlight the benefits, challenges, and future directions of
Akbari, MeysamWang, AndyWang, QiguiYan, Cuifen
This paper focuses on the basic principle of measuring viscosity and density with U-shaped tungsten wire sensor, and develops a model for measuring liquid viscosity and density with the help of oscillating ball model. Firstly, the working mechanism of the wire resonator is deeply analyzed. Then, by reducing the order of the fluid dynamic function, a simplified model is established for measuring the viscosity and density of liquid with U-shaped tungsten resonator. The experimental results show that the maximum error of viscosity is 7.22% and the average error is 2.81% when the viscosity ranges from 4.526mPa.s to 62.01mPa.s. In the range of 0.8486g/cm3 to 0.8711g/cm3, the maximum density error is 7.00% and the average density error is 1.89%. In summary, the simplified model proposed in this paper can accurately measure the viscosity and density of liquids.
Shan, BaoquanShen, YitaoYang, JianguoZhang, ZhaoyingWu, DehongZhao, Yingke
The initial powder used for the manufacturing of NdFeB permanent magnets is usually prepared through rapid cooling, either by melt spinning or strip casting. The powders produced by these two methods are suitable for different applications: while melt-spun powder is a good initial material for bonded and hot-deformed magnets, strip-cast powder is normally used for sintered magnets. To investigate the suitability of using strip-cast powder to manufacture hot-deformed magnets, NdFeB powder prepared by strip casting was hot pressed (without particle alignment) and compared with melt-spun powder prepared under the same conditions (700 °C, 45 MPa, 90 min). Although the processing parameters are the same (pressed in the same mold), the magnetic properties of the magnets made from the two powders are significantly different. Surprisingly, the magnet made from the strip-cast powder (after ball milling) shows comparable magnetic properties to those of isotropic magnets, with coercivity (HcJ) of
He, YouliangSong, ShaochangWalsh, DanBernier, FabriceMozharivskyj, YurijPeng, Philip
Given the strategic importance of aluminum cast materials in producing lightweight, high-performance products across industries, it is fundamental to assess their mechanical and cyclic fatigue properties thoroughly. This investigation is primarily for optimizing material utilization and enhancing the efficiency and reliability of aluminum cast components, contributing to significant conservation of raw materials and energy throughout both the manufacturing process and the product's lifecycle. In this study, a systematic material investigation was conducted to establish a reliable estimation of the fatigue behavior of different aluminum cast materials under different loading ratios and elevated temperatures. This paper presents an analysis of the statistical and geometrical influences on various aluminum alloys, including AlSi10MnMg, AlSi7Mg0.3, and AlSi8Cu3Fe, produced via pressure die casting and gravity die casting (permanent mold casting), and subjected to different heat treatment
Qaralleh, AhmadNiewiadomski, JanBleicher, Christoph
Blistering in aesthetic parts poses a significant challenge, affecting overall appearance and eroding brand image from the customer's perspective and blister defects disrupt painting line efficiency, resulting in increased rework and rejection rates. This paper investigates the causes and effects of blistering, particularly in the context of internal soundness of Aluminum castings, emphasizing the crucial role of Computed Tomography in defect analysis. Computed Tomography is an advanced Non-Destructive Testing technique used to examine the internal soundness of a material. This study follows a structured 7-step QC story approach, from problem identification to standardization, to accurately identify the root Cause and implement corrective actions to eliminate blister defect. The findings reveal a strong link between internal soundness and surface quality. Based on the root cause, changes in the casting process and die design were made to improve internal soundness, leading to reduced
D, BalachandarNataraj, Naveenkumar
The current ASTM A653 standard for determining the bake hardening index (BHI) of sheet metals can lead to premature fracture at the transition radius of the tensile specimen in high strength steel grades. In this study, a new test procedure to characterize the BHI was developed and applied to 980 and 1180 MPa third generation advanced high strength steels (3G-AHSS). The so-called KS-1B methodology involves pre-straining over-sized tensile specimens followed by the extraction of an ASTM E8 sample, paint baking and re-testing to determine the BHI. Various pre-strain levels in the range of 2 to 10% were considered to evaluate the KS-1B procedure with select comparisons with the ASTM A653 methodology for pre-strain levels of 2 and 8%. Finally, to characterize the influence of paint baking at large strain levels, sheared edge conical hole expansion tests were conducted. The tensile mechanical properties of the 3G steels after paint baking were observed to be sensitive to the pre-strain with
Northcote, RhysBerry, AvalonNarayanan, AdvaithTolton, CameronLee, HaeaSmith, JonathanMcCarty, EricButcher, Cliff
The advance of regulatory emission standards for light-duty vehicles, trucks and motorcycles, coupled with rising sustainability concerns, particularly United Nations' Sustainable Development Goal 12 (responsible consumption and production), has created an urgent need for lighter, stronger, and more ecological materials. Polylactic acid (PLA), a biodegradable polymer derived from plant sources, offers promising mechanical tensile strength and processability. Nanocomposites, a solution that combines a base matrix with a nanoreinforcing filler, provides a path toward developing sustainable materials with new properties. Cellulose nanofibrils (CNF) are a valuable nanofiller obtained through industrial waste or vegetal fibers, offer a promising avenue for strengthening PLA-based materials. Additive manufacturing (AM) has gained popularity due to its ability to create complex parts, prototyping designs, and to evaluate new nanocomposite materials such as PLA/CNF, showing significant
de Oliveira, ViníciusHoriuchi, Lucas NaoGoncalves, Ana PaulaDe Andrade, MarinaPolkowski, Rodrigo
Gray cast iron (GJL) is one of the oldest cast iron materials and is still in use in many applications in the automotive industry due to its good characteristics, in relation to lubrication, heat conductivity and damping. Engine parts particularly benefit from these parameters. Nevertheless, the design of these components has always been challenging, in terms of maximizing material utilization for lightweight designs for components under cyclic loading. In particular, with regard to the influence of the statistical (component size), geometrical (notches) and technological (microstructural) size effects, the existing guidelines and literature lack the necessary information to provide a comprehensive understanding of the cyclic material behavior of GJL materials. Within a comprehensive study, different GJL materials have been investigated at Fraunhofer LBF to provide more detailed information regarding the influence of size effects on fatigue strength. Accordingly, a variety of specimen
Bleicher, ChristophKansy, Axel
This specification covers the requirements of uncoated aluminum alloy foil for core materials required for structural sandwich construction.
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing produced with cross-sectional area of 32 square inches (206 cm2), maximum (see 8.6).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of hand forgings 11.000 inches (280 mm) and under in nominal thickness and of forging stock of any size (see 8.6).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of bars and rods 0.750 to 3.500 inches (19.05 to 88.90 mm), inclusive, in nominal diameter or least distance between parallel sides (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers a low-carbon steel in the form of seamless tubing up to 5.50 inches (139.7 mm), nominal OD, inclusive.
AMS E Carbon and Low Alloy Steels Committee
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing produced with cross-sectional area of 32 square inches (206 cm2), maximum (see 8.6).
AMS D Nonferrous Alloys Committee
This specification covers a titanium alloy in the form of bars, wire, forgings, flash-welded rings 4.000 inches (101.60 mm) and under in nominal diameter or least distance between parallel sides, and stock for forging and flash-welded rings of any size (see 8.6).
AMS G Titanium and Refractory Metals Committee
This specification covers an aluminum alloy in the form of plate 4.001 to 7.000 inches (101.62 to 177.80 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers two types of free-machining, corrosion- and heat-resistant steel in the form of bars, wire, forgings, and forging stock.
AMS F Corrosion and Heat Resistant Alloys Committee
This specification covers an aluminum alloy in the form of plate 1.000 to 6.000 inches (25.40 to 152.40 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of die and hand forgings 4 inches (102 mm) and under in thickness, rolled or forged rings 2.50 inches (63.5 mm) and under in radial thickness, and stock of any size for forging or rings (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy procured in the form of extruded profiles (shapes) with nominal thickness of over 0.040 to 0.375 inch (over 1.00 to 9.5 mm), inclusive, and cross sections up to 7.75 square inches (5000 mm2) and circle sizes as indicated (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of seamless, drawn tubing having a nominal wall thickness of 0.120 to 0.400 inch (3.00 to 10.00 mm), inclusive (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of sheet 0.011 to 0.126 inch (0.28 to 3.20 mm), inclusive, in nominal thickness, with a grain size of ASTM No. 6 or finer (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of plate 3.000 to 7.000 inches (76.20 to 177.80 mm) in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy procured in the form of extruded profiles (shapes) with cross sections up to 0.750 inch (19.05 mm) (see 8.6).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, shapes, and tubing produced with cross-sectional area of 32 square inches (206 cm2), maximum (see 8.6).
AMS D Nonferrous Alloys Committee
This specification covers a titanium alloy in the form of sheet, strip, and plate up through 4.000 inches (101.60 mm), inclusive (see 8.6).
AMS G Titanium and Refractory Metals Committee
This specification covers a cast tin bronze in the form of sealing rings (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of die forgings and hand forgings up to 6.000 inches (152.40 mm) in nominal thickness at the time of heat treatment (see 8.6).
AMS D Nonferrous Alloys Committee
This specification covers the requirements for electrodeposited zinc-nickel on metal parts, including fasteners and other standard parts.
AMS B Finishes Processes and Fluids Committee
This specification covers an aluminum alloy in the form of hand forgings 12 inches (305 mm), inclusive, and under in nominal thickness and forging stock of any size (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers a titanium alloy in the form of forgings 4.00 inches (101.6 mm) and under in nominal cross-sectional thickness and of forging stock of any size (see 8.6).
AMS G Titanium and Refractory Metals Committee
This specification covers one grade of commercially pure titanium in the form of sheet, strip, and plate up through 1.000 inch (25.40 mm), inclusive (see 8.6).
AMS G Titanium and Refractory Metals Committee
This specification covers a corrosion- and heat-resistant nickel alloy in the form of bars, forgings, flash-welded rings, and stock for forging or flash-welded rings.
AMS F Corrosion and Heat Resistant Alloys Committee
This specification covers an aluminum alloy procured in the form of extruded bars, rods, and profiles (shapes) with nominal thickness up to 3.000 inches (76.20 mm), inclusive, and having a cross-sectional area of 26.3 square inches (170 cm2) maximum and circle size of 15.3 inches (389 mm) maximum (see 8.6).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of extruded bars, rods, and profiles (shapes) produced with nominal thickness up to 3.000 inches (76.20 mm), inclusive, and having a cross-sectional area of 42 square inches (271 cm2) maximum and a circumscribing circle diameter (circle size) of 15 inches (38 cm) maximum (see 2.4.1 and 8.8).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of plate 0.250 to 3.000 inches (6.35 to 76.20 mm), inclusive, in nominal thickness (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers a premium aircraft-quality, corrosion-resistant steel in the form of bars, wire, forgings, mechanical tubing, and forging stock.
AMS F Corrosion and Heat Resistant Alloys Committee
This specification covers an aluminum alloy in the form of hand forgings 17 inches (432 mm) and under in nominal thickness and rolled rings up to 6 inches (152 mm), inclusive, in nominal thickness at the time of heat treatment (see 8.6).
AMS D Nonferrous Alloys Committee
This specification covers an aluminum alloy in the form of seamless drawn tubing having nominal wall thickness of 0.018 to 0.500 inch (0.46 to 12.70 mm), inclusive (see 8.4).
AMS D Nonferrous Alloys Committee
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