ICAA13: 13th International Conference on Aluminum Alloys

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13th International Conference on Aluminum Alloys
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Proceedings of the
13th International Conference
on Aluminum Alloys
Held
June 3-7, 2012 at Carnegie Mellon University, Pittsburgh, PA
Edited by
Hasso Weiland
Anthony D. Rollett
William A. Cassada
A John Wiley & Sons, Inc., Publication
Copyright © 2012 by The Minerals, Metals, & Materials Society.
All rights reserved.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey.
Published simultaneously in Canada.
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ISBN 978-1-11845-804-4
Printed in the United States of America.
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A John Wiley & Sons, Inc., Publication
TABLE OF CONTENTS
ICAA13: 13th International Conference on Aluminum Alloys
Preface ......................................................................................................................................................................xxiii
About the Editors and Conference Organizers .......................................................................................................... xxv
Technical Program Chairs ....................................................................................................................................... xxvii
ICAA International Committee ................................................................................................................................ xxix
ICAA13: 13th International Conference on Aluminum Alloys
Advanced Analysis
Aberration-Corrected STEM Study of Precipitates in an Al-Mg-Si-Ge-Cu Alloy ........................................................ 3
R. Bjørge, S. Andersen, C. Marioara, J. Etheridge, and R. Holmestad
Diffraction-Amalgamated Grain-Boundary Tracking (DAGT) Technique and Its Application
to an Aluminium Alloy .................................................................................................................................................. 9
D. LeClere, H. Toda, M. Kobayashi, T. Kamiko, Y. Suzuki, A. Takeuchi, K. Uesugi,
and Y. Mizuseki
Effect of Composition and Pre-ageing on the Natural Ageing and Paint-baking Behaviour of Al-Mg-Si Alloys ...... 15
P. Rometsch, S. Gao, and M. Couper
Improvement in the Characterization of the 2099 Al-Li Alloy by Fe-SEM ................................................................ 23
R. Gauvin, N. Brodusch, M. Brochu, M. Trudeau, P. Michaud, L. Rodrigue, and J. Boselli
Towards New Aluminium Alloys through Advances in Atom Probe Microscopy ..................................................... 29
L. Viskari, G. Sha, and S. Ringer
Nano-scale Characterization of Al-Mg Nanocrystalline Alloys .................................................................................. 31
E. Harvey, and L. Ladani
Muon Spin Relaxation and Positron Annihilation Spectroscopy Studies of Natural Aging in Al-Mg-Si Alloys ........ 37
S. Wenner, K. Matsuda, K. Nishimura, J. Banhart, T. Matsuzaki, D. Tomono, F. Pratt, M. Liu,
Y. Yan, C. Marioara, and R. Holmestad
Monitoring Precipitation during Rapid Quenching of Aluminium Alloys by Calorimetric Reheating
Experiments ................................................................................................................................................................. 43
O. Kessler, D. Zohrabyan, B. Milkereit, and C. Schick
Hydrogen Depth-Profiling and Desorption Kinetics in Rapidly Solidified Al-Fe Alloys ........................................... 49
I. Tashlykova-Bushkevich, and G. Itoh
Three-Dimensional Analysis of Microstructure in Cast Aluminium Piston Alloys .................................................... 55
T. Mbuya, I. Sinclair, K. Soady, and P. Reed
Dislocation Density Changes in Ultrafine-Grain Aluminum during Tensile Deformation ......................................... 61
H. Adachi, Y. Miyajima, N. Tsuji, A. Shibata, and D. Terada
v
Casting
Study on DC Casting Process of Three-Layer Composite Ingots of 4045/3004/4045 Aluminum Alloys ................... 69
J. Cui, H. Zhang, H. Jiang, and K. Qin
Study on Electromagnet-Air Knife DC Casting Process of Large-Size AA 7055 Aluminum Alloys ......................... 77
H. Zhang, H. Nagaumi, and J. Cui
Development of Large-size Ultrasonic Sonotrodes for Cavitation Treatment of Molten Metals ................................ 85
S. Komarov, and Y. Ishiwata
Microstructural Evolution in Intensive Melt Sheared Direct-Chill Cast Aluminium Alloys ....................................... 91
S. Jones, A. Prasada Rao, J. Patel, G. Scamans, and Z. Fan
The Grain Refinement of 7050 Alloy Using Al Ti B and Al Ti C Grain Refiners .............................................. 97
-5 -1 -3 -0.15
S. Guo, G. Xue, K. Ma, and H. Nagaumi
Grain Refining Potency of LaB on Aluminum Alloy ............................................................................................... 105
6
P. Li, W. Tian, D. Wang, and X. Liu
The Good Grain Refining Performance of a New Kind of Al-Ti-C-B Master Alloy ................................................ 113
J. Nie, X. Ma, H. Ding, and X. Liu
Assessment of the Al-Ni-Mn-Fe-Si-Zr Phase Diagram for New-Generation Heat-Resistant Casting Aluminum
Alloys ........................................................................................................................................................................ 123
N. Belov, and A. Alabin
The Influence of Heat Treatment Parameters on the Electrical Conductivity of AlSi Mg and AlSi Mg
7 10
Aluminum Cast Alloys .............................................................................................................................................. 129
P. Uliasz, T. Knych, M. Piwowarska, and J. Wiechec
The Effect of Nickel on the Thermal Conductivity of Al-Si Cast Alloys .................................................................. 137
F. Stadler, H. Antrekowitsch, W. Fragner, H. Kaufmann, and P. Uggowitzer
Production of Single Cylinder Engine Piston through Vacuum Die Casting in Sedi Enugu ..................................... 143
E. Nwonye, and C. Nwajagu
Fatigue Behavior in Rheocast Aluminum 357 Suspension Arms Using the SEED Process ...................................... 151
E. Samuel, C. Zheng, A. Bouaicha, and M. Bouazara
Single Roll Caster to Cast Aluminum Alloy Strip ..................................................................................................... 157
T. Haga, S. Kumai, H. Watari, K. Akitsu, and K. Kamakura
Roll Caster to Cast Clad Strip .................................................................................................................................... 163
T. Haga, S. Kumai, H. Watari, H. Tsuge, and T. Ishihar
Tests of Heat Treatment Conditions of AlZr0.22 Alloy Produced using the Continuous Casting Method ............... 169
M. Piwowarska, T. Knych, and P. Uliasz
Investigation on the Evolution of the Microstructure during Homogenization in Thin Al Sheets ............................ 177
I. Peter, and M. Rosso
Investigation of Acoustic Streaming in Aluminum Melts Exposed to High-Intensity Ultrasonic Irradiation ........... 183
S. Komarov, Y. Ishiwata, and Y. Takeda
vi
Fabrication of Aluminum Alloy-Based Diamond Grinding Wheel by the Centrifugal Mixed-Powder Method
For Novel Machining Technology of CFRP .............................................................................................................. 189
T. Kunimine, M. Yamada, H. Sato, and Y. Watanabe
Preparation of Al-Sc Master Alloy by Aluminothermic Reaction with Special Molten Salt .................................... 195
C. Xu, X. Liu, F. Ma, Z. Wang, W. Wang, and C. Ma
In situ Synthesis of Al/TiC Composites by Combustion Reaction in an Al Melt ...................................................... 201
Y. Cho, J. Lee, H. Kim, J. Kim, and S. Kim
Effects of Electroslag Refining on Removal of Iron Impurity and Alumina Inclusions from Aluminum ................. 207
J. Wang, C. Chen, and B. Sun
Aging Behavior of Flexcast® Al-Mg Alloys with Sc and Zr Additions ................................................................... 213
M. Sohi, N. Singh, C. Sinclair, W. Poole, and M. Gallerneault
Electromagnetic Continuous Casting of Free-Shape Aluminum Billet ..................................................................... 219
M. Kim, J. Park, J. Kim, and G. Lee
Effect of Mn on the Interaction between Die Casting Steel and Al Alloy ................................................................. 225
S. Choi, Y. Kim, C. Kim, J. Cho, C. Kang, Y. Kim, and S. Hong
Limitation of Shrinkage Porosity in Aluminum Rotor Die Casting .......................................................................... 231
Y. Kim, S. Choi, C. Kim, J. Cho, S. Lee, and C. Kang
The Effect of Alloying Elements on Thermal Conductivity and Casting Characteristic in High Pressure
Die Casting of Aluminum Alloy ................................................................................................................................ 237
C. Kim, J. Cho, S. Choi, Y. Kim, and C. Kang
Coating and Surfaces
Initial Studies of 6082 Aluminium Thin Films .......................................................................................................... 245
J. Holmestad, Ø. Dahl, S. Andersen, O. Reiso, R. Holmestad, and J. Walmsley
Finite Element Simulation of Shot Peening: Prediction of Residual Stresses and Surface Roughness ..................... 251
A. Gariepy, C. Perron, P. Bocher, and M. Lévesque
The Potential of the Cold Spray Process for the Repair and Manufacture of Aluminium Alloy Parts ...................... 257
T. Marrocco, and D. Harvey
Computational Metallurgy: ICME
Utilisation of Atom Probe Data to Model Precipitation and Strengthening in an Al-Mg-Si-Cu Alloy
During Natural Ageing and Early-Stage Artificial Ageing ....................................................................................... 267
D. Tomus, P. Rometsch, M. Couper, C. Davies, and L. Cao
Ab Initio Simulations of Vacancy-Solute Clusters in Al-Mg-Si and Al-Zn-Mg Alloys ............................................ 273
P. Lang, P. Mohn, A. Falahati, and E. Kozeschnik
The Role of the Si Network to the Stabilization of Hardening Precipitates in the Al-Mg-Si(-Cu) Alloy System ..... 279
F. Ehlers, S. Wenner, S. Andersen, C. Marioara, and R. Holmestad
Residual Stress Analysis in AA7449 As-Quenched Thick Plates Using Neutrons and Fe Modelling ...................... 285
N. Chobaut, J. Repper, T. Pirling, D. Carron, and J. Drezet
vii
A Through Process Model for AA3xxx Aluminum Alloys ....................................................................................... 293
W. Poole, M. Wells, and N. Parson
Modeling the Recrystallization Textures in Particle Containing Al Alloys after Various Rolling Reductions ......... 299
J. Sidor, R. Petrov, L. Kestens, and K. Decroos
TCAL1 and MOBAL2 - The Development and Validation of New Thermodynamic and Mobility Databases for
Aluminium Alloys ..................................................................................................................................................... 305
P. Mason, A. Markstrom, Y. Du, S. Liu, L. Zhang, L. Kjellqvist, J. Bratberg, A. Engstrom,
and Q. Chen
Advances in Aluminium ICME ................................................................................................................................. 311
J. Hirsch
Numerical Simulation of Flat Rolling Practices ........................................................................................................ 319
Y. Shi, P. Wu, and M. Gallerneault
Modelling the Effect of Room Temperature Storage and Deformation on the Age-Hardening Behavior
of Al-Mg-Si Alloys .................................................................................................................................................... 325
C. Schäfer, O. Myhr, Z. Liang, H. Brinkman, O. Engler, J. Hirsch, C. Chang, and J. Banhart
Evaluation of the Quenching Sensitivity of Al-Zn-Mg-Cu-Zr Aluminum Alloys by Mole Fraction
of Equilibrium Phases ................................................................................................................................................ 331
B. Nie, P. Liu, T. Zhou, and Y. Xie
Modelling Grain Deformation during Extrusion of AA3003 using the Finite Element Method ............................... 337
Y. Mahmoodkhani, M. Wells, L. Grajales, W. Poole, and N. Parson
Experience of Developing and Introduction in Industry New Primary and Secondary Al-Alloys with Given
Properties for Shape Casting ..................................................................................................................................... 343
V. Zolotorevskiy
Corrosion
Application of Microelectrochemical Methods for Understanding Localized Corrosion Behavior of Aluminum
Alloys ........................................................................................................................................................................ 351
R. Buchheit, and N. Birbilis
Precipitation of the (cid:533)-phase and Corrosion Behavior of an Al-6.8 wt.% Mg Alloy .................................................. 363
M. Popovic, T. Radetic, and E. Romhanji
Testing the Corrosion Behavior of Plated Aluminum Strips for Heat Exchangers Operating in the Automotive
Industry ...................................................................................................................................................................... 371
M. Nowak, M. Opyrchal, A. Klyszewski, and J. Zelechowski
Corrosion Protection of Light Alloys using Low Pressure Cold Spray ..................................................................... 377
D. Dzhurinskiy, R. Maev, V. Leshchynsky, and E. Strumban
Crystallographic Orientation Dependence of Corrosion Behavior of 5N Purity Aluminum in Different
Concentrations of HCl Aqueous Solutions ................................................................................................................ 391
Y. Takayama, M. Sato, and H. Watanabe
Corrosion Fatigue Mechanism on Hot-Forged AA6082 Aluminum Alloy ............................................................... 397
N. Saleema, P. Gauthier, and X. Chen
viii
Corrosion Inhibition of Stress Corrosion Cracking and Localized Corrosion of Turbo-Expander Materials ........... 405
B. Bavarian, J. Zhang, and L. Reiner
Corrosion Characteristics of an Al-1.78%Si-13.29%Mg Alloy in Chloride Solutions .............................................. 417
M. Pech-Canul, R. Giridharagopal, M. Pech-Canul, and E. Coral-Escobar
Corrosion Performance of New Generation Aluminum-Lithium Alloys for Aerospace Applications ...................... 425
J. Moran, F. Bovard, J. Chrzan, and P. Vandenburgh
Comparison of Corrosion Performance and Mechanisms of Al-Cu Alloys with and without Li Addition ............... 431
C. Henon, and S. Rouault
The Effect of Stress in Age-forming on Corrosion Behavior of High-strength Aluminum Alloy ............................. 437
J. Chen, G. Frankel, C. Xu, G. Li, Z. Lu, and L. Zhen
Corrosion and Potentiostatic Polarization of an Al-Cu-Li Alloy under Tensile Stress .............................................. 443
J. Li, and Z. Zheng
The Effect of Chemical Composition and Structure on the Corrosion Resistance of Plated Aluminium
Alloy Strips ................................................................................................................................................................ 451
A. Klyszewski, J. Zelechowski, M. Opyrchal, M. Nowak, A. Frontczak, and P. Rutecki
Fatigue and Fracture Toughness
Effect of Fatigue and Damage Tolerance Material Properties on the Efficiency of Aircraft Structures................... 461
H. Schmidt, and B. Schmidt-Brandecker
About the Challenge in Determing the Cyclic Material Behaviour of Aluminium Alloys for the Numerical
Fatigue Analyses........................................................................................................................................................ 471
R. Wagener, C. Fischer, A. Frohm, and H. Kaufmann
A Microstructure Based Multi-Site Crack Growth Model ......................................................................................... 479
J. Brockenbrough, H. Weiland, and J. Fridy
Short Fatigue Crack Growth Micromechanisms in a Cast Aluminium Piston Alloy ................................................ 485
T. Mbuya, J. Crump, I. Sinclair, K. Soady, R. Thomson, and P. Reed
Fatigue Life of Ablation Cast 6061-T6 Components................................................................................................. 491
M. Tiryakioglu, J. Campbell, and P. Eason
Mechanical Properties of Heat Exchanger Tube Materials at Elevated Temperatures .............................................. 499
S. Kahl, J. Zajac, and H. Ekström
Fatigue Behavior and Damage Monitoring of Ultrasonic Welded Hybrid Joints ...................................................... 505
F. Balle, S. Huxhold, G. Wagner, and D. Eifler
Fatigue Resistance of Al-Cu-Li and Comparison with 7xxx Aerospace Alloys ........................................................ 511
A. Daniélou, J. Ehrström, J. Ronxin, and C. Nardin
Fatigue Crack Growth Behavior of 2099-T83 Extrusions in Two Different Environments ...................................... 517
F. Tchitembo Goma, D. Larouche, A. Bois-Brochu, C. Blais, J. Boselli, and M. Brochu
Influence of Microstructure on the Fretting Resistance of Al-Cu-Li Alloys ............................................................. 523
J. Delacroix, S. Cazottes, A. Danielou, S. Fouvry, and J. Buffiere
Al-Li-Cu-Mg-(Ag) Products for Lower Wing Skin Applications ............................................................................. 529
L. Karabin, G. Bray, R. Rioja, and G. Venema
ix
Development of High Toughness Sheet and Extruded Products for Airplane Fuselage Structures........................... 535
P. Magnusen, D. Mooy, L. Yocum, and R. Rioja
Expanding the Availability of Lightweight Aluminum Alloy Armor Plate Procured from Detailed Military
Specifications ............................................................................................................................................................ 541
K. Doherty, R. Squillacioti, B. Cheeseman, B. Placzankis, and D. Gallardy
Threshold Stress of A3003 Alloy .............................................................................................................................. 547
M. Ando, Y. Suzuki, and G. Itoh
Ultrasonic Fatigue of SiC Particle Reinforced Aluminum in the VHCF Regime...................................................... 553
G. Wagner, D. Eifler, and M. Wolf
Influence of Strain Hardening on Rheological Properties of AlMgSi Wires ............................................................. 559
B. Smyrak, T. Knych, and K. Korzen
Origin of Ductile Fracture in Aluminum Alloys ........................................................................................................ 565
H. Toda, H. Oogo, H. Tsuruta, K. Horikawa, K. Uesugi, A. Takeuchi, Y. Suzuki, and M. Kobayashi
Damage Tolerance Applied to the Design of Mid-Size Aircraft ............................................................................... 571
C. Chaves
The Metallurgy of High Fracture Toughness Aluminum-Based Plate Products for Aircraft Internal Structure ....... 581
J. Boselli, G. Bray, R. Rioja, D. Mooy, G. Venema, G. Feyen, and W. Wang
The Evolution of Plate and Extruded Products with High Strength and Fracture Toughness ................................... 587
D. Denzer, R. Rioja, G. Bray, G. Venema, and E. Colvin
Lighter and Stiffer Materials for Use in Space Vehicles ........................................................................................... 593
R. Rioja, D. Denzer, D. Mooy, and G. Venema
Research on the High-cycle Fatigue and Crack Initiation Behavior of AA7449 Alloy ............................................. 599
Z. Zheng, S. Zhong, S. Li, and J. Li
Forming and Joining
Vehicle Lightweighting: Challenges and Opportunities with Aluminum .................................................................. 609
A. Sachdev, R. Mishra, A. Mahato, and A. Alpas
Correlation of Fracture Behavior with Microstructure in Friction Stir Welded, and Spin-formed Al-Li
2195 Domes ............................................................................................................................................................... 623
W. Tayon, M. Domack, and S. Hales
Effect of Process Parameters on Microstructure Stability of FSW Butt Joints after Thermal Treatments ................ 629
E. Cerri, and P. Leo
Microhardness Profile and Microstructure Characterization in Friction Stir Processing Zone of the Aged and
Solid Solution Treated 7075 Aluminum Alloys ........................................................................................................ 637
Z. Zhou, S. Chen, and Q. Liu
Microstructure and Mechanical Properties of Dissimilar Friction Stir Welds Using AA6061-T6 and AZ31
Plates ......................................................................................................................................................................... 643
K. Lee, S. Kim, H. Son, and K. Woo
Microstructure and Mechanical Properties of Friction Stir Welded Aluminum Alloy/Stainless Steel Lap Joints .... 647
T. Ogura, T. Nishida, H. Nishida, S. Yoshikawa, T. Yoshida, N. Omichi, M. Fujimoto,
and A. Hirose
x
The Effect of the Variation of Microstructure in the Friction Stir Welded Zone on the Strain and Tensile
Properties of Al2139 .................................................................................................................................................. 653
T. Sano, J. Yu, R. Chen, and C. Yen
Hardening Potential of an Al-Cu-Li Friction Stir Weld ............................................................................................ 659
R. Ivanov, J. Boselli, D. Denzer, R. Gauvin, and M. Brochu
Material Testing and Modeling of Aluminum Alloy Sheet in Support of Forming Simulations ............................... 665
T. Kuwabara, K. Yoshida, and D. Yanaga
Evaluation of the Ring Compression Test for the Parameter Determination of Extended Friction Models .............. 675
D. Horwatitsch, A. Merstallinger, and K. Steinhoff
Finite Element Peen Forming Simulation .................................................................................................................. 681
A. Gariepy, S. Larose, C. Perron, P. Bocher, and M. Lévesque
The Influence of Alloy Composition on the Microstructure, Tensile Ductility and Formability of 6xxx Alloys ...... 687
H. Zhong, P. Rometsch, and Y. Estrin
Accelerated Post-Weld Natural Ageing in Ultrasonic Welding Aluminium 6111-T4 Automotive Sheet ................. 693
P. Prangnell, and Y. Chen
Limitations of M-K Based Forming Limit Diagrams ................................................................................................ 699
M. Mohammadi, K. Inal, and R. Mishra
Influence of Forming Conditions to Springback in V-bending Process Using Servo Press ...................................... 705
S. Abe, and S. Takahashi
Anisotropy and Forming Limit Diagram Comparison of DC and CC 5xxx O Temper Aluminum Alloy Sheets ..... 711
X. Wen, Y. Liu, S. Ningileri, and T. Zhai
Comparison of Localized Deformation in Crystal Plasticity Based Finite Element Simulations between
Experimentally Measured and Statistically Generated Three-Dimensional Microstructures for the Aluminum
Alloy 5754 ................................................................................................................................................................. 717
J. Rossiter, A. Brahme, K. Inal, and R. Mishra
Path Independent Polar Effective Plastic Strain (PEPS) Diagram for Sheet Forming ............................................... 723
J. Yoon, and T. Stoughton
Effect of Impact Compression on the Age-Hardening of Rapidly Solidified Al-Zn-Mg Base Alloys ...................... 731
K. Horikawa, and H. Kobayashi
Fatigue and Creep Properties of Al-Si Brazing Filler Metals .................................................................................... 737
M. Edo, M. Enomoto, and Y. Takayama
Effect of Additional Elements of Al-Si Filler Alloy on Flowability and Clearance Fillability ................................. 743
M. Edo, M. Yoshino, and S. Kuroda
Influence of Erosion Phenomenon on Flow Behavior of Liquid Al-Si Filler Between Brazed Components ............ 749
T. Izumi, and T. Ueda
Effects of Plate Thickness and Projection Shape on the Microstructure and Strength of High-Speed Solid-State
Joined 2024 Alloy Studs and 5052 Alloy Plates ........................................................................................................ 755
S. Kumai, K. Hayashida, and K. Takaya
Interfacial Reaction during Dissimilar Joining of Aluminum Alloy to Magnesium and Titanium Alloys ................ 761
J. Robson, C. Zhang, A. Panteli, D. Baptiste, E. Cai, and P. Prangnell
xi