Journal articles: 'Aluminum alloys – Cracking'

1

Jawan, Hosen Ali. "Some Thoughts on Stress Corrosion Cracking of (7xxx) Aluminum Alloys." International Journal of Materials Science and Engineering 7, no. 2 (June 2019): 40–51. http://dx.doi.org/10.17706/ijmse.2019.7.2.40-51.

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2

Field, D. P., H. Weiland, and K. Kunze. "Intergranular Cracking in Aluminum Alloys." Canadian Metallurgical Quarterly 34, no. 3 (July 1995): 203–10. http://dx.doi.org/10.1179/cmq.1995.34.3.203.

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3

Zhang, Fan, Songmao Liang, Chuan Zhang, Shuanglin Chen, Duchao Lv, Weisheng Cao, and Sindo Kou. "Prediction of Cracking Susceptibility of Commercial Aluminum Alloys during Solidification." Metals 11, no. 9 (September 17, 2021): 1479. http://dx.doi.org/10.3390/met11091479.

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Cracking during solidification is a complex phenomenon which has been investigated from various angles for decades using both experimental and theoretical methods. In this paper, cracking susceptibility was investigated by a simulation method for three series of aluminum alloys: AA2xxx, AA6xxx, and AA7xxx alloys. The simulation tool was developed using the CALPHAD method and is readily applicable to multicomponent alloy systems. For each series of alloys, cracking susceptible index values were calculated for more than 1000 alloy compositions by high-throughput calculation. Cracking susceptible maps were then constructed for these three series of aluminum alloys using the simulated results. The effects of major and minor alloying elements were clearly demonstrated by these index maps. The cooling rate effect was also studied, and it was concluded that back diffusion in the solid can significantly improve the cracking susceptibility.

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4

Yang, Xiao, Xianfeng Zhang, Yan Liu, Xuefeng Li, Jieming Chen, Xinyao Zhang, and Lingqing Gao. "Environmental Failure Behavior Analysis of 7085 High Strength Aluminum Alloy under High Temperature and High Humidity." Metals 12, no. 6 (June 5, 2022): 968. http://dx.doi.org/10.3390/met12060968.

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High-strength aluminum alloys are exposed to more and more environmentally-induced cracking failure behaviors during service. However, due to the hard to detect nature of hydrogen, and the special working conditions, failure research has obvious hysteresis and complexity, and it is impossible to truly reflect the material failure phenomenon and mechanism. In this paper, 7085 high-strength aluminum alloy is selected as the research material to simulate and reproduce the environmental failure phenomenon of aircraft under extreme working conditions (temperature 70 °C, humidity 85%). The results proved that high-strength aluminum alloy has environmental cracking failure behavior under extreme working conditions. The failure mode that was determined was due to environment-induced hydrogen and hydrogen-induced cracking, which is the result of the combined action of hydrogen and stress. Meanwhile, we demonstrate that high-strength aluminum alloy’s environmental failure behavior in an environment of high temperature and high humidity is different from traditional stress corrosion cracking behavior.

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5

OHSAKI, Shuhei. "Stress corrosion cracking of aluminum alloys." Journal of Japan Institute of Light Metals 46, no. 9 (1996): 456–66. http://dx.doi.org/10.2464/jilm.46.456.

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6

Yang, Xiao, Yan Liu, Xian-feng Zhang, Xue-feng Li, Xin-yao Zhang, and Ling-qing Gao. "Characterization of hydrogen assisted corrosion cracking of a high strength aluminum alloy." Materials Testing 64, no. 10 (October 1, 2022): 1527–31. http://dx.doi.org/10.1515/mt-2022-0079.

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Abstract Environmentally and hydrogen assisted cracking can occur during application of high-strength aluminum alloys. However, there are only few suitable laboratory procedures to characterize and evaluate the environmentally and hydrogen assisted cracking behavior of materials. By optimizing the hydrogen charging parameters and slow strain rate, a multidimensional test procedure was established, which could simulate the actual working environment and could realize the test and evaluation of hydrogen assisted cracking susceptibility in the laboratory. Moreover, it provides a new environmental adaptability evaluation method for the high-strength aluminum alloy materials.

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7

Kyogoku, Hideki, Kohei Yamamoto, Toshi Taka Ikeshoji, Kazuya Nakamura, and Makiko Yonehara. "Melting and Solidification Behavior of High-Strength Aluminum Alloy during Selective Laser Melting." Materials Science Forum 941 (December 2018): 1300–1305. http://dx.doi.org/10.4028/www.scientific.net/msf.941.1300.

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Additive manufacturing (AM) technology has been dramatically attracted attention because of advantages in building free-shaped parts and simplification of manufacturing process. Recently the most relevant alloys, such as TiAl6V4, Inconel 718, AlSi10Mg and so on, are able to manufacture the parts using metal AM technology. However high-strength 2024, 6061 and 7075 aluminum alloys are difficult to fabricate using selective laser melting (SLM) owing to solidification cracking during solidification. In this research, the melting and solidification behaviors of AlSi10Mg alloy during SLM process were observed under various fabrication conditions of laser power and scan speed using a high-speed camera. It was found that the melting and solidification behavior of the alloy is greatly different by the fabrication conditions. And also the mechanism of solidification cracking in 2024 and 6061 aluminum alloys is investigated by the observation of the surface morphology and microstructure of the alloys using OM, SEM and EDS, comparing with Al10SiMg alloy. As a result, crack-free 2024 and 6061 aluminum alloy parts can be obtained by fabrication at the higer enrgy density.

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Lalpoor, Mehdi, Dmitry G. Eskin, Hallvard Gustav Fjær, Andreas Ten Cate, Nick Ontijt, and Laurens Katgerman. "Application of a Criterion for Cold Cracking to Casting High Strength Aluminium Alloys." Materials Science Forum 654-656 (June 2010): 1432–35. http://dx.doi.org/10.4028/www.scientific.net/msf.654-656.1432.

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Direct chill (DC) casting of high strength 7xxx series aluminum alloys is difficult mainly due to solidification cracking (hot cracks) and solid state cracking (cold cracks). Poor thermal properties along with extreme brittleness in the as-cast condition make DC-casting of such alloys a challenging process. Therefore, a criterion that can predict the catastrophic failure and cold cracking of the ingots would be highly beneficial to the aluminum industry. The already established criteria are dealing with the maximum principal stress component in the ingot and the plane strain fracture toughness (KIc) of the alloy under discussion. In this research work such a criterion was applied to a typical 7xxx series alloy which is highly prone to cold cracking. The mechanical properties, constitutive parameters, as well as the KIc values of the alloy were determined experimentally in the genuine as-cast condition and used as input data for the finite element package ALSIM5. Thermomechanical simulations were run for billets of various diameters and the state of residual thermal stresses was determined. Following the contour maps of the critical crack size gained from the model, the casting conditions were optimized to produce a crack-free billet.

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9

OHNISHI, Tadakazu, Hiroyuki KOJIMA, Nobuya SEKO, and Kenji HIGASHI. "Stress corrosion cracking of 7075 series aluminum alloys." Journal of Japan Institute of Light Metals 35, no. 6 (1985): 344–52. http://dx.doi.org/10.2464/jilm.35.344.

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10

Abbaschian, Lara, and Milton Sergio Fernandes de Lima. "Cracking susceptibility of aluminum alloys during laser welding." Materials Research 6, no. 2 (June 2003): 273–78. http://dx.doi.org/10.1590/s1516-14392003000200024.

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11

Balasubramaniam, R., D. J. Duquette, and K. Rajan. "On stress corrosion cracking in aluminum-lithium alloys." Acta Metallurgica et Materialia 39, no. 11 (November 1991): 2597–605. http://dx.doi.org/10.1016/0956-7151(91)90075-c.

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12

Zielinski, A. "Hydrogen-enhanced stress-corrosion cracking of aluminum alloys." Materials Science 34, no. 4 (July 1998): 469–75. http://dx.doi.org/10.1007/bf02360698.

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13

Zhang, Di, Xin Zhao, Yanlin Pan, Hongxiang Li, Li Zhou, Jishan Zhang, and Linzhong Zhuang. "Liquation Cracking Tendency of Novel Al-Mg-Zn Alloys with a Zn/Mg Ratio below 1.0 during Fusion Welding." Metals 10, no. 2 (February 6, 2020): 222. http://dx.doi.org/10.3390/met10020222.

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The main obstacle for the application of high strength 7××× series aluminum alloys is that these alloys are susceptible to hot cracking during fusion welding. This study presents the liquation cracking susceptibility of the novel T-Mg32(AlZn)49 phase strengthened Al-Mg-Zn alloy with a Zn/Mg ratio below 1.0 by a circular-patch welding test, and compared the liquation cracking tendency with η-MgZn2 phase strengthened 7××× series alloys whose Zn/Mg ratios are above 1.0. It was found that all these novel Al-Mg-Zn alloys still have as low a liquation cracking susceptibility as traditional 5××× series alloys, surpassing that of traditional 7××× series alloys substantially. It was noticed that the increase of the Zn/Mg ratio will result in a larger difference between the fraction solids of the fusion zone and the partially melted zone during the terminal solidification stage, which can lead to a wider crack healing disparity between these two areas and thus result in different liquation cracking susceptibilities in different alloys.

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14

Yoon, Jong Hoon, Joon Tae Yoo, Kyung Ju Min, and Ho Sung Lee. "A Study on Post Weld Heat Treatment of Friction Stir Welded Al2195 Blank for Spin Forming." Advanced Materials Research 1125 (October 2015): 190–94. http://dx.doi.org/10.4028/www.scientific.net/amr.1125.190.

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It is well known that the significant weight reduction and increased strength have placed advanced aluminum-lithium alloys at the forefront of aerospace materials research. For example the use of aluminum-lithium based alloys for rocket fuel tank domes can reduce weight because aluminum-lithium alloys have lower density and higher strength than Al-Cu alloy 2219. However, Al-Li alloys have been shown the inherent low formability characteristic that make them susceptible to cracking during the spinning operations. In this study a novel heat treatment process on the formability of friction stir welded Al-Li alloy blanks are presented. It is shown that the successful heat treatment process has been developed with superior mechanical properties and currently the patent is applied.

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15

Chen, Mien-Chung, Ming-Che Wen, Yang-Chun Chiu, Tse-An Pan, Yu-Chih Tzeng, and Sheng-Long Lee. "Effect of Natural Aging on the Stress Corrosion Cracking Behavior of A201-T7 Aluminum Alloy." Materials 13, no. 24 (December 10, 2020): 5631. http://dx.doi.org/10.3390/ma13245631.

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The effect of natural aging on the stress corrosion cracking (SCC) of A201-T7 alloy was investigated by the slow strain rate testing (SSRT), transmission electron microscopy (TEM), scanning electron microscopy (SEM), differential scanning calorimetry (DSC), conductivity, and polarization testing. The results indicated that natural aging could significantly improve the resistance of the alloys to SCC. The ductility loss rate of the unaged alloy was 28%, while the rates for the 24 h and 96 h aged alloys were both 5%. The conductivity of the as-quenched alloy was 30.54 (%IACS), and the conductivity of the 24 h and 96 h aged alloys were decreased to 28.85 and 28.65. After T7 tempering, the conductivity of the unaged, 24 h, and 96 h aged alloys were increased to 32.54 (%IACS), 32.52 and 32.45. Besides, the enthalpy change of the 24 h and 96 h aged alloys increased by 36% and 37% compared to the unaged alloy. The clustering of the solute atoms would evidently be enhanced with the increasing time of natural aging. Natural aging after quenching is essential to improve the alloy’s resistance to SCC. It might be due to the prevention of the formation of the precipitation free zone (PFZ) after T7 tempering.

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16

Wang, Xi-Shu, Xu-Dong Li, Hui-Hui Yang, Norio Kawagoishi, and Pan Pan. "Environment-induced fatigue cracking behavior of aluminum alloys and modification methods." Corrosion Reviews 33, no. 3-4 (July 1, 2015): 119–37. http://dx.doi.org/10.1515/corrrev-2014-0057.

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AbstractThis paper reviews the current corrosion fatigue strength issues of light metals, which include the corrosion fatigue cracking behaviors, such as the prior-corrosion pit deformation mechanism, the synergistic interaction between prior-corrosion pits and local stress/strain, the coupling damage behavior under mechanical fatigue loading, and the surrounding environmental factors such as a high humidity and a current 3.5 wt.% or 5.0 wt.% NaCl aqueous solution. The characterization of corrosion fatigue crack growth rate based on simple and measurable parameters (crack propagation length and applied stress amplitude or stress intensity factor) is also of great concern in engineering application. In addition, an empirical model to predict S-N curves of aluminum alloys at the environmental conditions was proposed in this paper. One of the main aims was to outline the corrosion fatigue cracking mechanism, which favors the corrosion fatigue residual life prediction of aluminum alloys subjected to the different environmental media that are often encountered in engineering services. Subsequently, this paper explores recently various surface modification technologies to enhance corrosion fatigue resistance and to improve fatigue strength. For example, the fatigue strength of 2024-T4 aluminum alloy has been modified using plasma electrolytic oxidation coating with the impregnation of epoxy resin modification method to compare with other oxide coating or uncoated substrate alloy.

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17

Huang, C., G. Cao, and S. Kou. "Liquation Cracking in Aluminum Welds." Materials Science Forum 539-543 (March 2007): 4036–41. http://dx.doi.org/10.4028/www.scientific.net/msf.539-543.4036.

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Liquation cracking in the partially melted zone (PMZ) of aluminum welds was studied. The PMZ is the region immediately outside the fusion zone where the material is heated above the eutectic temperature. Highly crack-susceptible alloys 2024 and 7075 were welded using gas-metal arc welding (GMAW) with filler metals 1100 and 4043, respectively. Circular-patch welds were made on 3.2 mm thick workpiece with full penetration, and single-pass welds were made on 9.5 mm thick workpiece with partial penetration. Liquation cracking was observed in all welds. Dualpass welds were also made on 9.5 mm thick workpiece, with overlapping between the penetration tips of the two partial-penetration passes made on the opposite sides of the workpiece. Liquation cracking was found in the first pass but not in the second pass. The results were explained using TfS (temperature vs. fraction solid) curves of the weld metal (WM) and the PMZ based on the following criterion proposed recently: liquation cracking can occur if WM fS > PMZ fS during PMZ solidification.

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18

Langelandsvik, Geir, Odd M. Akselsen, Trond Furu, and Hans J. Roven. "Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing." Materials 14, no. 18 (September 17, 2021): 5370. http://dx.doi.org/10.3390/ma14185370.

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Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

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19

Novák, Pavel, Nguyen Hong Vu, Lucie Šulcová, Jaromír Kopeček, František Laufek, Alisa Tsepeleva, Petr Dvořák, and Alena Michalcová. "Structure and Properties of Alloys Obtained by Aluminothermic Reduction of Deep-Sea Nodules." Materials 14, no. 3 (January 25, 2021): 561. http://dx.doi.org/10.3390/ma14030561.

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This paper brings an innovative processing route of manganese deep-sea nodules, which results in completely new grades of alloys. Deep-sea nodules were processed by aluminothermic method without the extraction of individual elements, producing complexly alloyed manganese-based “natural alloys”. Three levels of the amount of aluminum were used for the aluminothermic reduction, and hence the alloys differ strongly in the amount of aluminum, which has a significant effect on their phase composition. The alloys have very high wear resistance, comparable with tool steel. The disadvantage of low-aluminum alloy is the susceptibility to local thermal cracking during friction, which occurs especially in the case of a dry sliding wear against the static partner with low thermal conductivity.

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20

Kwak, Z., S. Rzadkosz, A. Garbacz-Klempka, M. Perek-Nowak, and W. Krok. "The Properties of 7xxx Series Alloys Formed by Alloying Additions." Archives of Foundry Engineering 15, no. 2 (June 1, 2015): 59–64. http://dx.doi.org/10.1515/afe-2015-0039.

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Abstract Currently there is a constant development in the field of aluminium alloys engineering. This results from, i.a., better understanding of the mechanisms that direct strengthening of these alloys and the role of microalloying. Now it is microalloying in aluminum alloys that is receiving a lot of attention. It affects substantially the macro- and microstructure and kinetics of phase transformation influencing the properties during production and its exploitation. 7xxx series aluminum alloys, based on the Al-Zn-Mg-Cu system, are high-strength alloys, moreover, the presence of Zr and Sr further increases their strength and improves resistance to cracking. This study aims to present the changes of the properties, depending on the alloy chemical composition and the macro- and microstructure. Therefore, the characteristics in the field of hardness, tensile strength, yield strength and elongation are shown on selected examples. Observations were made on ingot samples obtained by semi-continuous casting, in the homogenized state. Samples were prepared from aluminum alloys in accordance with PN-EN 573-3: 2013. The advantage of Al-Zn-Mg-Cu alloys are undoubtedly good strength, Light-weight and resistance to corrosion. As widening of the already published studies it is sought to demonstrate the repeatability of the physical parameters in the whole volume of the sample.

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21

TAKAHASHI, Akihiro, Toshiro KOBAYASHI, and Hiroyuki TODA. "Stress criterion of delamination cracking in 2091 aluminum alloys." Journal of Japan Institute of Light Metals 49, no. 6 (1999): 249–52. http://dx.doi.org/10.2464/jilm.49.249.

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22

Makar, G. L., J. Kruger, and K. Sieradzki. "Stress corrosion cracking of rapidly solidified magnesium-aluminum alloys." Corrosion Science 34, no. 8 (August 1993): 1311–42. http://dx.doi.org/10.1016/0010-938x(93)90090-4.

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23

Olik, A. P. "Cyclic cracking resistance of ship hull plate aluminum alloys." Soviet Materials Science 26, no. 4 (1991): 431–34. http://dx.doi.org/10.1007/bf00727058.

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24

Liu, Jiangwei, and Sindo Kou. "Susceptibility of ternary aluminum alloys to cracking during solidification." Acta Materialia 125 (February 2017): 513–23. http://dx.doi.org/10.1016/j.actamat.2016.12.028.

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25

Burapa, R., S. Rawangwong, J. Chatthong, and Worapong Boonchouytan. "Effects of Mold Temperature and Casting Temperature on Hot Cracking in Al-4.5 wt.% Cu Alloy." Advanced Materials Research 747 (August 2013): 623–26. http://dx.doi.org/10.4028/www.scientific.net/amr.747.623.

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Hot cracking is an important defect that occurs during solidification of aluminum-copper alloys. In this present work, the effects of mold temperature and casting temperature on hot cracking in the Al-4.5 wt.% Cu alloy has been studied using a ring mold for hot cracking assessment. For the experimental conditions, three mold temperatures between 150 and 350°C and three casting temperatures between 670 and 770°C were studied and Al-7 wt.% Si alloy was used as reference for comparison. The results showed Al-7 wt.% Si alloy has high resistance to hot cracking and no hot cracking forms under three different mold temperatures, while Al-4.5 wt.% Cu alloy shows significant hot cracking tendency under the same casting conditions. The severity of hot cracking in Al-4.5 wt.% Cu alloy decreased significantly with increasing the mold temperature and decreasing the casting temperature. On the other hand, an increasing casting temperature resulted in severer hot cracking in Al-4.5 wt.% Cu alloy.

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26

Kim, Seong Jong, and Seok Ki Jang. "A Slow Strain Rate Test Experiment to Evaluate the Characteristics of High-Strength Al-Mg Alloy for Application in Ships." Materials Science Forum 510-511 (March 2006): 162–65. http://dx.doi.org/10.4028/www.scientific.net/msf.510-511.162.

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Recently, there has been increased interest in using aluminum alloys in ship construction instead of fiber-reinforced plastic (FRP). This is because aluminum alloy ships are faster, have a greater load capacity, and are easier to recycle than FRP ships. In this study, we investigated the mechanical and electrochemical properties of aluminum alloys using the slow strain rate and potentiostatic tests under various potential conditions. The optimum protection potential range with regards to hydrogen embrittlement and stress corrosion cracking was determined to lie between -1.5 and -0.7 V (SSCE). These results can be used as reference data for ship design.

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27

Walsh, D. W., and D. B. Gibbs. "Weldability Study of Aluminum Alloys Using Weld Simulation and Complimentary Variable Restraint Testing." Materials Science Forum 638-642 (January 2010): 3799–804. http://dx.doi.org/10.4028/www.scientific.net/msf.638-642.3799.

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Aluminum alloys containing lithium are attractive to the aerospace industry. The high specific strength and stiffness of these alloys improves lift efficiency, fuel economy and performance and increases payload capability. The objective of this study was to compare the fabricability of six different aluminum base alloys. Three were Li containing alloys, two variants of AL 2195 (Al-4Cu-1Li) and a lithium enhanced analog of AL 5083 (Al-4Mg-2Li). Three were materials in common usage, Al 2219, Al 2014 and Al 5083. Fabricability was assessed using Gleeble thermomechanical testing, Varestraint testing and differential scanning calorimetry (DSC). Results indicate that Alloy 2195 is more susceptible to hot cracking than both Al 2219 and Al 2014. Cracking sensitivity is a strong function of chemical composition within specification ranges for Al 2195. Results also indicate that the lithium containing analog of Al 5083 is more hot crack susceptible than its parent material. Fabricability was correlated to material microstructure using optical microscopy, scanning electron microscopy and microprobe analysis. Hot cracking in all materials was associated with persistent, continuous liquid films produced by weld thermal cycling, aggravated by base material structure. Measures of several characteristic temperatures using the Gleeble simulator were fully consistent with Varestraint results. The maximum crack length in the Varestraint test correlates well to the liquidus temperature for the alloy less the nil ductility temperature. The temperature difference is equivalent to the thermal gradient associated with welding times the maximum crack length.

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Y, Tilahun, and Mesfin G. "A Review on Role of Aluminum Matrix Materials, Failure Causes and Optimization Techniques." International Innovative Research Journal of Engineering and Technology 6, no. 3 (March 31, 2021): 1–11. http://dx.doi.org/10.32595/iirjet.org/v6i3.2021.143.

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Aluminum is a metal matrix material which is widely used in different industrial as well as engineering applications.it has a great advantage due to its remarkable properties like less density, formability, and light in weight, recyclability and other properties. but, failure of aluminum matrix materials are the main problems in aluminum industries now a days.in this review role of aluminum and its alloys as matrix materials, their failure modes, causes of failure and optimization techniques to minimize this failure modes and causes of failure are discussed. Sources are reviewed which are from 2005 to recent one. Consequently, most modes of failure, causes of failure and most optimization techniques of aluminum and its alloy matrix materials are found. most modes of failure are mechanical related like fatigue failure, surface cracking, ductile failure, porosity formation, and stress related like stress corrosion cracking, surface weakness due to repeated stresses and other factors are summarized.in causes of failure mostly like corrosion formation, wear formation and poor mechanical properties are discussed.

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Y, Tilahun, and Mesfin G. "A Review on Role of Aluminum Matrix Materials, Failure Causes and Optimization Techniques." International Innovative Research Journal of Engineering and Technology 6, no. 3 (March 31, 2021): 1–11. http://dx.doi.org/10.32595/iirjet.org/v6i.2021.143.

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Aluminum is a metal matrix material which is widely used in different industrial as well as engineering applications.it has a great advantage due to its remarkable properties like less density, formability, and light in weight, recyclability and other properties. but, failure of aluminum matrix materials are the main problems in aluminum industries now a days.in this review role of aluminum and its alloys as matrix materials, their failure modes, causes of failure and optimization techniques to minimize this failure modes and causes of failure are discussed. Sources are reviewed which are from 2005 to recent one. Consequently, most modes of failure, causes of failure and most optimization techniques of aluminum and its alloy matrix materials are found. most modes of failure are mechanical related like fatigue failure, surface cracking, ductile failure, porosity formation, and stress related like stress corrosion cracking, surface weakness due to repeated stresses and other factors are summarized.in causes of failure mostly like corrosion formation, wear formation and poor mechanical properties are discussed.

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30

Jaiganesh, V., D. Srinivasan, and P. Sevvel. "Optimization of process parameters on friction stir welding of 2014 aluminum alloy plates." International Journal of Engineering & Technology 7, no. 1.1 (December 21, 2017): 9. http://dx.doi.org/10.14419/ijet.v7i1.1.8906.

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Aluminum Alloy 2014 is a light weight high strength alloy used widely in the aerospace and also in other industries. 2014 is the second most popular of the 2000-series aluminium alloys, after 2024 aluminium alloy. However, it is difficult to weld, as it is subject to cracking. Joining of 2014 aluminium alloy in friction stir welding which is based on frictional heat generated through contact between a rotating tool and the work piece. Determination of the welding parameters such as spindle speed, transverse feed , tilt angle plays an important role in weld strength. The whole optimization process is carried out using Taguchi technique. The SEM analysis is done to check the micro structure of the material after welding by electron interaction with the atoms in the sample. Tensile test have been conducted and the s-n ratio curve is generated. The test is conducted and analysed on the basis of ASTM standards.

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31

Lee, Ho Sung, Jong Hoon Yoon, Joon Tae Yoo, and Kyung Ju Min. "Microstructure and Mechanical Properties of Friction Stir Welded AA2195-T0." Materials Science Forum 857 (May 2016): 266–70. http://dx.doi.org/10.4028/www.scientific.net/msf.857.266.

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Aluminum-copper-lithium alloy is a light weight metal that has been used as substitute for conventional aerospace aluminum alloys. With addition of Li element, it has lower density but higher strength. However these aluminum alloys are hard to weld by conventional fusion welding, since they often produce porosities and cracking in the weld zone. It is known that solid state welding like friction stir welding is appropriate for joining of this alloy. In this study, friction stir welding was performed on AA2195 sheets, in butt joint configuration in order to understand effects of process parameters on microstructure and mechanical properties in the weld zone. The results include the microstructural change after friction stir welding with electron microscopic analysis of precipitates.

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32

Cross, Carl E. "Applying Solidification Theory to Aluminum Weldability and Consumable Development." Welding Journal 101, no. 8 (August 1, 2022): 209–23. http://dx.doi.org/10.29391/2022.101.016.

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One defect encountered in the fusion zone when welding aluminum alloys involves solidification cracking (i.e., the tearing apart of grain boundary liquid films at the trailing edge of the weld pool). This problem can often be mitigated by the proper selection of filler metal. Two key engineering examples, one aerospace and one maritime, where this has occurred were examined in terms of alloy development to achieve optimum mechanical properties while maintaining weldability. Specifically, base metal/filler metal systems susceptible to cracking were examined in terms of filler metal dilution. A mechanism for crack growth was presented based upon critical strain rate. Conditions needed for improved weldability through grain refinement were defined based upon the columnar-to-equiaxed solidification theory.

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El-Batahgy, A., and M. Kutsuna. "Laser Beam Welding of AA5052, AA5083, and AA6061 Aluminum Alloys." Advances in Materials Science and Engineering 2009 (2009): 1–9. http://dx.doi.org/10.1155/2009/974182.

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The present investigation was mainly concerned with characteristics of autogeneous laser butt welding of 2 mm thickness nonheat treatableAA5052-H12,AA5083-H12 and 2 mm, 3 mm thickness heat treatableAA6061-T6aluminum alloys. The effect of laser welding parameters, surface cleaning, filler wire addition, and backing strip on quality of laser welded joints was clarified using 5 kW laser machine. It was found that all the investigated alloys showed tendencies for porosity and solidification cracking, particularly, at high welding speed (4 m/min). Porosity was prevented by accurate cleaning of the base metal prior to welding and optimizing the flow rate of argon shielding gas. Solidification cracking was avoided through two different approaches. The first one is based on the addition of filler metal as reported in other research works. The other new approach is concerned with autogeneous welding using a backing strip from the same base metal, and this could be applicable in production. Preventing solidification cracking in both cases was related mainly to a considerable decrease in the stress concentration at the weld metal center as a result of improving the fusion zone profile. The implementation of the new approach could help in producing weldments with a better quality due to the absence of the filler metal, which is known as a source for hydrogen-related porosity. It can also have a positive economic aspect concerning the manufacturing cost since welding is done without the addition of filler metal. Not only quality and economic positive aspects could be achieved, but also high productivity is another feature since high quality autogeneous weldments were produced with high welding speed, 6 m/min. Hardness measurements and tensile test of AA6061 alloy welds indicated a remarkable softening of the fusion zone due to dissolution of the strengthening precipitates, and this was recovered by aging treatment after welding. For alloys AA5052 and AA5083, softening of the fusion zone due to the loss of its work-hardened condition was much less in comparison with AA6061 alloy.

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Kapp, J. A., D. Duquette, and M. H. Kamdar. "Crack Growth Behavior of Aluminum Alloys Tested in Liquid Mercury." Journal of Engineering Materials and Technology 108, no. 1 (January 1, 1986): 37–43. http://dx.doi.org/10.1115/1.3225839.

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Crack growth rate measurements have been made in three mercury embrittled aluminum alloys each under three loading conditions. The alloys were 1100-0, 6061-T651, and 7075-T651. The loading conditions were fixed displacement static loading, fixed load static loading, and fatigue loading at two frequencies. The results showed that mercury cracking of aluminum was not unlike other types of embrittlement (i.e. hydrogen cracking of steels). Under fixed load static conditions no crack growth was observed below a threshold stress intensity factor (KILME). At K levels greater than KILME cracks grew on the order of cm/s, while under fixed displacement loading, the crack growth rate was strongly dependent upon the strength of the alloy tested. This was attributed to crack closure. In the fatigue tests, no enhanced crack growth occurred until a critical range of stress intensity factor (ΔKth) was achieved. The ΔKth agreed well with the KILME obtained from the static tests, but the magnitude of the fatigue growth rate was substantially less than was expected based on the static loading results. Observations of the fracture surfaces in the SEM suggested a brittle intergranular fracture mode for the 6061-T651 and the 7075-T651 alloys under all loading conditions. The fractographic features of the 1100-0 alloy under fixed load and fatigue loading conditions were also brittle intergranular. Under fixed displacement loading the cracks grew via a ductile intergranular mode.

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Song, Sang-Woo, Sang-Hoon Lee, Byung-Chul Kim, Tae-Jin Yoon, Nam-Kyu Kim, In-Bae Kim, and Chung-Yun Kang. "Liquation Cracking of Dissimilar Aluminum Alloys during Friction Stir Welding." MATERIALS TRANSACTIONS 52, no. 2 (2011): 254–57. http://dx.doi.org/10.2320/matertrans.m2010343.

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AOSHIMA, Shohei, Fang YANG, Kengo MOCHIDZUKI, Goroh ITOH, Akira KURUMADA, and Junya KOBAYASHI. "421 Sustained-load cracking in some 6000 series aluminum alloys." Proceedings of Ibaraki District Conference 2015.23 (2015): 125–26. http://dx.doi.org/10.1299/jsmeibaraki.2015.23.125.

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Chang, Keh‐Minn, and Bruce Kang. "Cracking control in DC casting of high‐strength aluminum alloys." Journal of the Chinese Institute of Engineers 22, no. 1 (January 1999): 27–42. http://dx.doi.org/10.1080/02533839.1999.9670439.

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Ali, N. Ben, D. Tanguy, and R. Estevez. "Effects of microstructure on hydrogen-induced cracking in aluminum alloys." Scripta Materialia 65, no. 3 (August 2011): 210–13. http://dx.doi.org/10.1016/j.scriptamat.2011.04.008.

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Han, Jiaqiang, Junsheng Wang, Mingshan Zhang, and Kangmin Niu. "Susceptibility of lithium containing aluminum alloys to cracking during solidification." Materialia 5 (March 2019): 100203. http://dx.doi.org/10.1016/j.mtla.2018.100203.

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R. Caballero and A. Quintero. "Application of SEM, TEM and CBED Techniques for Compound Identification in Stress Corrosion Cracking Failure." Microscopy and Microanalysis 4, S2 (July 1998): 518–19. http://dx.doi.org/10.1017/s1431927600022716.

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Stress corrosion cracking has been a problem in aluminum alloys exposed to an aggressive environment under high static residual tensile stress. This work is concerned with the application of electron microscopy to investigate possible causes that led to failure through stress corrosion cracking in the aluminum alloy 5182. This alloy is commonly used for making carbonated beverage containers. The containers in this study did not experience any problem at the time of the filling. However, after humid storage periods going from a few days to a few weeks, leakage at the can ends was reported in many of them. These leaks developed from a failure referred to as aluminum can end blow out.Figure la shows an SEM micrograph of a cross section of the score imposed on the top of the can during manufacturing. The unscored metal below the score is broken when the ring or tab is pulled out during opening.

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Chen, K. H., H. C. Fang, Z. Zhang, and L. P. Huang. "Effect of Yb Additions on Microstructures and Properties of High Strength Al-Zn-Mg-Cu-Zr Alloys." Materials Science Forum 546-549 (May 2007): 1021–26. http://dx.doi.org/10.4028/www.scientific.net/msf.546-549.1021.

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The effect of 0.30 Yb (mass fraction,%) additions on the microstructure and properties of high strength Al-Zn-Mg-Cu-Zr aluminum alloys has been investigated by TEM, optical microscopy, hardness and electric conductivity measurement, tensile test, stress corrosion cracking test. The results show that the ytterbium additions to high strength Al-Zn-Mg-Cu-Zr aluminum alloys significantly inhibited recrystallization during solution treatment. The tensile and yield strengths, elongation, hardness, electric conductivity and stress corrosion cracking resistance of the Yb-containing alloys are improved compared to the alloys without Yb additions. By Yb additions, the critical stress intensity (KISCC) is enhanced from 7 MPa·m1/2 up to 14.5 MPa·m1/2 with the improvement of the strength and ductility. The mechanism for the property improvement from Yb additions has been discussed.

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Wang, Xiaoguo, Jian Qin, Hiromi Nagaumi, Ruirui Wu, and Qiushu Li. "The Effect of α-Al(MnCr)Si Dispersoids on Activation Energy and Workability of Al-Mg-Si-Cu Alloys during Hot Deformation." Advances in Materials Science and Engineering 2020 (May 20, 2020): 1–12. http://dx.doi.org/10.1155/2020/3471410.

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The hot deformation behaviors of homogenized direct-chill (DC) casting 6061 aluminum alloys and Mn/Cr-containing aluminum alloys denoted as WQ1 were studied systematically by uniaxial compression tests at various deformation temperatures and strain rates. Hot deformation behavior of WQ1 alloy was remarkably changed compared to that of 6061 alloy with the presence of α-Al(MnCr)Si dispersoids. The hyperbolic-sine constitutive equation was employed to determine the materials constants and activation energies of both studied alloys. The evolution of the activation energies of two alloys was investigated on a revised Sellars’ constitutive equation. The processing maps and activation energy maps of both alloys were also constructed to reveal deformation stable domains and optimize deformation parameters, respectively. Under the influence of α dispersoids, WQ1 alloy presented a higher activation energy, around 40 kJ/mol greater than 6061 alloy’s at the same deformation conditions. Dynamic recrystallization (DRX) is main dynamic softening mechanism in safe processing domain of 6061 alloy, while dynamic recovery (DRV) was main dynamic softening mechanism in WQ1 alloy due to pinning effect of α-Al(MnCr)Si dispersoids. α dispersoids can not only resist DRX but also increase power required for deformation of WQ1 alloy. The microstructure analysis revealed that the flow instability was attributed to the void formation and intermetallic cracking during hot deformation of both alloys.

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Heiland, Steffen, Benjamin Milkereit, Kay-Peter Hoyer, Evgeny Zhuravlev, Olaf Kessler, and Mirko Schaper. "Requirements for Processing High-Strength AlZnMgCu Alloys with PBF-LB/M to Achieve Crack-Free and Dense Parts." Materials 14, no. 23 (November 25, 2021): 7190. http://dx.doi.org/10.3390/ma14237190.

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Processing aluminum alloys employing powder bed fusion of metals (PBF-LB/M) is becoming more attractive for the industry, especially if lightweight applications are needed. Unfortunately, high-strength aluminum alloys such as AA7075 are prone to hot cracking during PBF-LB/M, as well as welding. Both a large solidification range promoted by the alloying elements zinc and copper and a high thermal gradient accompanied with the manufacturing process conditions lead to or favor hot cracking. In the present study, a simple method for modifying the powder surface with titanium carbide nanoparticles (NPs) as a nucleating agent is aimed. The effect on the microstructure with different amounts of the nucleating agent is shown. For the aluminum alloy 7075 with 2.5 ma% titanium carbide nanoparticles, manufactured via PBF-LB/M, crack-free samples with a refined microstructure having no discernible melt pool boundaries and columnar grains are observed. After using a two-step ageing heat treatment, ultimate tensile strengths up to 465 MPa and an 8.9% elongation at break are achieved. Furthermore, it is demonstrated that not all nanoparticles used remain in the melt pool during PBF-LB/M.

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Kim, Seong Jong, Jae Cheul Park, and Seok Ki Jang. "Evaluation of Electrochemical Characteristics for Casted AC7AV Aluminum Alloy." Advanced Materials Research 811 (September 2013): 54–60. http://dx.doi.org/10.4028/www.scientific.net/amr.811.54.

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The Al alloy is environmental friendly, easy to recycle, and provides a high added value to fishing boats. Aluminum alloy do not corrode due to the formation of an anticorrosive passive film, such as Al2O3or Al2O33H2O, which resists corrosion in neutral solution. In seawater, however, Cl-ions destroy this passive film. We investigated on several electrochemical tests undertaken to determine the optimum conditions in seawater for corrosion protection of casted AC7AV aluminum alloy. The components of casted AC7AV aluminum alloy are similar with Al-Mg alloys (5xxx series) which are used for ship. Result of electochemical experiment, the optimum protection potential range with regards to hydrogen embrittlement and stress corrosion cracking was determined to lie between-1.3 and-0.7 V(vs Ag/AgCl).

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G. Mousavi, Mehdi. "Grain Refinement and Elimination of Hot Cracks due to Application of Electromagnetic Stirring in Commercial Aluminum Alloy Welds." Advanced Materials Research 875-877 (February 2014): 1306–11. http://dx.doi.org/10.4028/www.scientific.net/amr.875-877.1306.

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. In this work the physical effects of electromagnetic stirring (EMS) during welding on the microstructure of some commercial 6xxx and 7xxx series of aluminum alloys are investigated. Experiments are carried out with standard GTA equipment in combination with a current carrying coil providing an axial magnetic field. In order to achieve the maximum grain refining effect, a range of optimal stirring parameters is established. It is then demonstrated that the optimal parameters are in the frequency range of 2 to 15 Hz and the corresponding magnetic field intensities of 10 to 25 mT. These parameters are then applied to reduce susceptibility of these alloys to hot cracking. This paper concludes that by application of EMS to GTA welding of aluminum alloys it is possible to refine the grain structure and reduce the hot cracking susceptibility of these alloys, especially those employed in the aerospace and automotive industries.

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Zhai, Ziyu, Wei Pan, Bo Liang, Yantao Liu, and Yongzhong Zhang. "Cracking Behavior, Microstructure and Properties of Selective Laser Melted Al-Mn-Mg-Sc-Zr Alloy." Crystals 12, no. 4 (April 18, 2022): 565. http://dx.doi.org/10.3390/cryst12040565.

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In this paper, the cracking of Al-Mn-Mg-Sc-Zr alloys prepared by selective laser melting (SLM) was comprehensively explored and the influence of process parameters on the generation and propagation of cracks was deeply studied. It was found that the higher laser power and volume energy density will lead to a decrease in the relative density of the material. The lower laser power or volume energy density will lead to cracking of the alloy. The microstructure analysis indicated that plenty of manganese-rich second phases precipitated at the bottom of the melt pool, which increased the tendency of cracking occurred at the bottom of the melt pool. Through the optimization of the process parameters, the SLM forming process parameters of the Al-5.22Mn-1.16Mg-0.81Sc-0.46Zr alloy are successfully obtained, and the crack-free tensile samples are prepared. The microstructure and mechanical properties of the as-deposited aluminum-manganese alloy is analyzed. The bottom and inside of the melt pool are equiaxed grains. The size of the equiaxial grains at the bottom of the melt pool is less than 2 μm, and the coarse equiaxial grains inside the melt pool are approximately 5 μm. As-deposited alloy has a room temperature tensile strength of 455.2 ± 0.7 MPa and elongation of 15.4 ± 0.3%. This study provides guidance for selective laser melting forming of high-strength aluminum-manganese alloy parts, and promotes the industrial production of high-strength aluminum alloy near net forming complex parts.

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Zaid, H. R., A. M. Hatab, and A. M. A. Ibrahim. "Properties enhancement of Al-Zn-Mg alloy by retrogression and re-aging heat treatment." Journal of Mining and Metallurgy, Section B: Metallurgy 47, no. 1 (2011): 31–35. http://dx.doi.org/10.2298/jmmb1101031z.

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The higher strength 7xxx aluminum alloys exhibited low resistance to stress corrosion cracking (SCC) when aged to the peak hardness (T6 temper). The overaged alloys (T7 temper) developed to enhance the SCC with loss in the strength of the alloy. Recently, retrogression and re-aging (RRA) heat treatments are used for improving the SCC behavior for alloys in T6 tempers such as 7075, 7475 and 8090. In this study, an application of retrogression and re-aging heat treatment processes are carried out to enhance toughness properties of the 7079-T651 aluminum alloy, while maintaining the higher strength of T651-temper. The results of charpy impact energy and electrical conductivity tests show a significantly increases in absorbed energy and electrical conductivity values, when the alloys are exposed to various retrogression temperatures (190, 200, 210?C) and times (20, 40, 60 minutes), and then re-aged at 160?C for 18 hours.

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Eperješi, Š., M. Matvija, ľ. Eperješi, and M. Vojtko. "Evaluation of Cracking Causes of AlSi5Cu3 Alloy Castings." Archives of Metallurgy and Materials 59, no. 3 (October 28, 2014): 1089–92. http://dx.doi.org/10.2478/amm-2014-0187.

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Abstract Recently, the castings made from aluminum-silicon alloys by pressure die casting are increasingly used in the automotive industry. In practice, on these castings are high demands, mainly demands on quality of their structure, operating life and safety ensuring of their utilization. The AlSi5Cu3 alloy castings are widely used for production of car components. After the prescribed tests, the cracks and low mechanical properties have been identified for several castings of this alloy, which were produced by low pressure casting into a metal mould and subsequent they were heat treated. Therefore, analyses of the castings were realized to determine the causes of these defects. Evaluation of structure of the AlSi5Cu3 alloy and causes of failure were the subjects of investigation presented in this article.

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Dixit, Som, and Shunyu Liu. "Laser Additive Manufacturing of High-Strength Aluminum Alloys: Challenges and Strategies." Journal of Manufacturing and Materials Processing 6, no. 6 (December 8, 2022): 156. http://dx.doi.org/10.3390/jmmp6060156.

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Metal additive manufacturing (AM)-fabricated high-strength aluminum (HS-Al) alloys (2xxx, 6xxx, and 7xxx) tend to produce fatal metallurgical defects such as porosity and cracks. Since Al is the most important lightweight structural material in automotive and aviation industries, successful printing of HS-Al alloys is in high demand. Therefore, this review focuses on the formation mechanisms and research advancements to address these metallurgical defects. Firstly, the process optimization strategies, including AM parameter optimization, hybrid AM processes, and post-processing treatment, and their effectiveness and limitations have been reviewed thoroughly. However, process optimization can address defects such as porosity, surface roughness, and residual stresses but has limited effectiveness on cracking alleviation. Secondly, the research efforts on composition modification to address cracking in AM of HS-Al alloys are critically discussed. Different from process optimization, composition modification alters the solidification dynamics in AM of HS-Al alloys and hence is considered the most promising route for crack-free printing.

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Ohnishi, Tadakazu. "Contribution of hydrogen embrittlement on stress corrosion cracking of aluminum alloys." Bulletin of the Japan Institute of Metals 26, no. 5 (1987): 389–95. http://dx.doi.org/10.2320/materia1962.26.389.

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Journal articles on the topic 'Aluminum alloys – Cracking'

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