Recent trends in processing and degradation of aluminium alloys

528 Pages·2011·15.01 MB·English

by  Zaki Ahmad (editor)

RECENT TRENDS IN
PROCESSING AND
DEGRADATION OF
ALUMINIUM ALLOYS
Edited by Zaki Ahmad
RECENT TRENDS IN
PROCESSING AND
DEGRADATION OF
ALUMINIUM ALLOYS

Edited by Zaki Ahmad
Recent Trends in Processing and Degradation of Aluminium Alloys
Edited by Zaki Ahmad

Published by InTech
Janeza Trdine 9, 51000 Rijeka, Croatia

Copyright © 2011 InTech
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Image Copyright McIek, 2011. Used under license from Shutterstock.com

First published November, 2011
Printed in Croatia

A free online edition of this book is available at www.intechopen.com
Additional hard copies can be obtained from [email protected]

Recent Trends in Processing and Degradation of Aluminium Alloys, Edited by Zaki Ahmad
p. cm.
ISBN 978-953-307-734-5

Contents

Preface IX
Part 1 Casting and Forming of Aluminium Alloys 1
Chapter 1 Aluminium Countergravity
Casting – Potentials and Challenges 3
Bolaji Aremo and Mosobalaje O. Adeoye
Chapter 2 Intermetallic Phases Examination in
Cast AlSi5Cu1Mg and AlCu4Ni2Mg2
Aluminium Alloys in As-Cast and T6 Condition 19
Grazyna Mrówka-Nowotnik
Chapter 3 Rotary-Die Equal Channel Angular Pressing Method 41
Akira Watazu
Part 2 Welding of Aluminium Alloys 61
Chapter 4 Welding of Aluminum Alloys 63
R.R. Ambriz and V. Mayagoitia
Chapter 5 Prediction of Tensile and Deep Drawing
Behaviour of Aluminium Tailor-Welded Blanks 87
R. Ganesh Narayanan and G. Saravana Kumar
Part 3 Surface Treatment of Aluminium Alloys 113
Chapter 6 Laser Surface Treatments of Aluminum Alloys 115
Reza Shoja Razavi and Gholam Reza Gordani
Chapter 7 Microstructural Changes of Al-Cu Alloys After
Prolonged Annealing at Elevated Temperature 155
Malgorzata Wierzbinska and Jan Sieniawski
VI Contents

Chapter 8 PIII for Aluminium Surface Modification 175
Régulo López-Callejas, Raúl Valencia-Alvarado,
Arturo Eduardo Muñoz-Castro, Rosendo Pena-Eguiluz,
Antonio Mercado-Cabrera, Samuel R. Barocio,
Benjamín Gonzalo Rodríguez-Méndez and
Anibal de la Piedad-Beneitez
Chapter 9 Optimizing the Heat Treatment
Process of Cast Aluminium Alloys 197
Andrea Manente and Giulio Timelli
Part 4 Mechanical Behavior of
Aluminium Alloys and Composites 221
Chapter 10 High Strength Al-Alloys:
Microstructure, Corrosion and Principles of Protection 223
Anthony E. Hughes, Nick Birbilis, Johannes M.C. Mol,
Santiago J. Garcia, Xiaorong Zhou and George E. Thompson
Chapter 11 Mechanical Behavior and Plastic Instabilities of
Compressed Al Metals and Alloys Investigated with
Intensive Strain and Acoustic Emission Methods 263
Andrzej Pawelek
Chapter 12 Aluminum Alloys for Al/SiC Composites 299
Martin I. Pech-Canul
Part 5 Corrosion and Mechanical
Damage of Aluminium Alloys 315
Chapter 13 Effects of Dry Sliding Wear of Wrought
Al-Alloys on Mechanical Mixed Layers (MML) 317
Mariyam Jameelah Ghazali
Chapter 14 Comparison of Energy-Based and
Damage-Related Fatigue Life Models for
Aluminium Components Under TMF Loading 329
Eichlseder Wilfried, Winter Gerhard,
Minichmayr Robert and Riedler Martin
Chapter 15 Deformation Characteristics of
Aluminium Composites for Structural Applications 347
Theodore E. Matikas and Syed T. Hasan
Chapter 16 Corrosion Behavior of
Aluminium Metal Matrix Composite 385
Zaki Ahmad, Amir Farzaneh and B. J. Abdul Aleem
Contents VII

Chapter 17 Interrelation Between Failure and Damage Accumulation
in the Pre-Fracture Zone Under Low-Cycle Loading 407
Vladimir Kornev, Evgeniy Karpov and Alexander Demeshkin
Part 6 Microstructures, Nanostructures and Image Analysis 423
Chapter 18 Nanostructure, Texture Evolution and
Mechanical Properties of Aluminum Alloys
Processed by Severe Plastic Deformation 425
Abbas Akbarzadeh
Chapter 19 Statistical Tests Based on the
Geometry of Second Phase Particles 459
Viktor Beneš, Lev Klebanov, Radka Lechnerová and Peter Sláma
Chapter 20 Microstructural Evolution During the
Homogenization of Al-Zn-Mg Aluminum Alloys 477
Ali Reza Eivani, Jie Zhou and Jurek Duszczyk

Preface

Aluminum is the second most plentiful element on the earth and it became a
competition in 19th century. The huge demand of aluminum is projected to get 70
million tons, over 30 millions being obtained from recycled scrap. The scope of
aluminum ranges from household to space vehicles. Dramatic advances in
casting,welding,forming and eco friendly methods of production have made
aluminum and aluminum alloys highly attractive candidate for automotive and
aerospace industry, because of their wide range of attributes such as high strength,
resistance to corrosion, low density, high reflectively, high ductility and proven
reliability. The developments in the last two decades have been revolutionary and well
documented both for wrought, heat treatable and non-heat treatable alloys. New
developments in methods of casting, forming, welding, environmental degradation,
grain refinement and particle size at nano and micro scale have made big impact on
their demand for space and automotive industry.
Despite serious competition from composites, aluminum alloys are still the king in
these industries, as exemplified by 777 Airbus. Aluminium is a very versatile metal
and can be cast in any form, stamped, forged, machine, brazed and resin bonded.
Substantial evidence has been gathered on formability which affects the structural
integrity of the components. The demand on quality and integrity of welding is
increasing on military and commercial aircraft. This includes improved toughness,
lower weight and increased resistance to corrosion fatigue. The progress made in
welding, analysis of different techniques and their impact on micro structural
characteristics has been discussed in several chapters in the hinder the section
“welding, casting and forming”. Ambriz Richardo has discussed this topic whereas
Saravana Kumar has provided valued information on tailored blanks and deep
drawing behavior of aluminum alloys. Because of high plastic strain, levels, rigid
strength requirements and high quality controls are required for forming processes
ranging from single to multiple stage because of increasingly dynamic and
competitive market demands which includes outstanding toughness and a high
resistance to corrosion fatigue. Various casting process such as direct chill casting,
rotary die equal channel angular processing, counter gravity casting and centrifugal
casting is described by Aremo Bolaji, Watazu Akira and others have shown new
X Preface

dimensions in the field of casting. Dramatic changes in surface treatment have
proved highly effective in the life cycle of aluminum alloys as shown by Shoja Razavi
Reza, Wierzbinska Malgorzata, Lopez-Cellajas Regulo, Metikas Theodore and
Morwka-Nowotnik Grazyna have added new data to new information.
Improvements in surface topography and stability are only achieved successfully by
combining electrochemistry, microstructures and the role of micro/nano particles new
methods of surface modifications are described by Akbarzadeh Abbas, Timelli Giulio
and Kornev Vladimir. Corrosion is a serious thread to aluminum alloys and
aluminum based metal matrix composites reinforced by silicon carbide. A brief
mechanism of corrosion of composited is given by Zaki Ahmad. Environmental
damages such as corrosion fatigue in aluminum alloys and their mechanism have
been described by Ghazali Mariam and Eichlseder Wilfried. The principle behind the
chapters in book was an analysis of the procedures such as casting, forming, welding
and environmental degradation which have a strong bearing on the integrity of
aerospace structures and automotive. The authors have addressed the problems of
grain refinement, micro segragation, casting defects, crack growth, weld defects to
show to what levels the aluminum alloys have been technically elevated. The
chapters were selected on a rigid criteria of which novelty and new approaches were
the main pillars.
I hope the book would be very useful for practicing engineers, technicians, senior
students and all those interested in aluminum alloys in particular the technical staff of
aerospace, automotive and defense industry. Chapters on casting, welding and others
could be used to support their textbook at a graduate level. This book is profusely
illustrated to make the concepts clear to the readers.
While editing the book I had the problems of shifting from one country other which
prolonged my editing work for which I apologize.
I thank Mr. Mishaal Ahmed (my grandson), Manzar Ahmed, Intesar Ahmed,
Shamsujehan, Huma Sabir and Abida Sultana, they provided me with the mental
support for the work not the least, the spirit of my beloved dead son Intekhab Ahmed
drove me through very hard times while reviewing the chapters.
I am very grateful to KFUPM who gave me the moral support. I am specially indebted
to Dr Faleh Al Sulaiman vice rector of technology at KFUPM, Dr Nasir Aqeeli, Mr
Faheemuddin and Mr Abdul Aleem of M.E department of KFUPM. I also thanks Dr
M. Budair rector of Al-Jouf University for his moral support.
In the end I thank the Al Mighty to give me the moral courage to undertake the
responsibility. I am grateful to InTech publisher for giving me the honor of being the
chief editor of this book.