Cast Materials Task Force Update/Deliverables Status
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Transcript of Cast Materials Task Force Update/Deliverables Status
Cast Materials Task Force Update/Deliverables Status
NADCA R&D Committee Meeting
Oak Ridge National Laboratory
Oak Ridge, TN
June 14, 2007
#137 Innovative Semi-#137 Innovative Semi-Solid Metal (SSM) Solid Metal (SSM)
ProcessingProcessing
Q. Y. Pan, P. Hogan, B. DewhirstQ. Y. Pan, P. Hogan, B. Dewhirst
D. Apelian, M.M. Makhlouf D. Apelian, M.M. Makhlouf
Project Period: 06/1/04 through Project Period: 06/1/04 through 6/30/076/30/07
Major TasksMajor Tasks
Task 1: Optimize the Continuous Rheoconversion Process (CRP)
for commercial applications
Task 2: SSM alloy development
Task 3: Optimize heat treatment processes for SSM castings
Task 1 Achievements to DateTask 1 Achievements to Date CRP can retrofit most die casting facilities
(both vertical & horizontal machines)
CRP has been successfully scaled up for commercial applications; successful Beta trials conducted with numerous industrial partners (Buhler, THT Presses, Hayes-Lemmerz, Rheinfelden etc.)
Sound SSM castings were produced using a variety of commercial alloys (A356, 319, A206, Silafont-36 etc)
Some data for CRP operational window generated
More data for the operational window will be generated through additional industrial trials with ACRC Consortium members
CRP Processed Castings: CRP Processed Castings: Tensile Tensile DataData
SSM vs. Squeeze • Similar UTS & YS• SSM: Slightly higher EL
SSM: T5 vs. T6
• Excellent data under T6• A slight ductility loss under T5 (!!!)
Sr: no significant effect
Observations:
Established Criteria for SSM alloy optimization/design
Optimized 380/383/EN-AC46000, 206, 319, 6061 and 7075 alloys for SSM Applications
Optimal composition window established and recommended
Conducted Beta trials to validate simulation results
Newly developed Al-Zn-Mg alloys show potential for SSM applications
Task 2 Achievements to Task 2 Achievements to DateDate
Task 3 Achievements to Date
Established optimal T5 HT schedule for SSM castings
Established optimal T6 HT schedule for SSM castings
Fluidized Bed heat treatment results are promising, with high strengths and QI
What’s Next?
Additional CRP Beta trials will
be scheduled in July/August,
2007 at SAG
More T5/T6 samples will be
produced and examined
Project Status/Update#139 Thin Wall Zinc
New Alloy developed with 40% higher fluidity than Alloy 7
Project meeting at NADCA Congress2 trials planned for 2007 –
conventional and 4-slide machinesAdditional trial sites sought
Project Status/Update #144 Zinc Alloy Properties for Market
Development Support
ILZRO, DOE ARCExcel database sent to sponsorsSmall amount of fatigue work
remains to be done (3,5,8)Creep work underway (2 and 5)
#144 Zinc Alloy Properties for Market Development Support
Database contents Tensile and compressive data between -40 and 135C Flexural modulus curves Compressive test curves Coefficient of thermal expansion data, both showing changes in
length with temperature and the slope of this data which is the coefficient.
Fatigue data, including S-N and fatigue limit curves. Also data in which skin was removed vs. skin kept on the castings.
Impact testing, both Charpy and Izod tests, including impact testing shows the impact energy vs. time.
Impact testing at five temperatures between -40 and room temperature
High strain rate testing, similar to the impact testing, in which stress/strain pairs are reported.
ln time to 1% creep strain vs ln stressfilled symbols: tentative test results
open symbols: proposed tests and actual start dates
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2 2.5 3 3.5 4 4.5
ln(stress:MPa)
ln(ti
me(
s) to
1%
cre
ep s
train
) .
√ 2/26/07
√ 2/22/07
√ 2/27/07
√ 5/1/07
√ 5/1/07
√ 2/16/07
√ 2/23/07
5/16/07(in progress)
√ 5/10/07
√ 4/27/07
√ 3/13/07
√ 3/13/07
√ 4/26/07
√ 4/23/07
√ 4/23/07
5/25/07(in progress)
No Load Tests Alloy 2 at 120° C - 5/7/07
Alloy 5 at 120° C - 5/7/07
Project Status/Update#146 Die Casting Mechanical Property
Improvements Through Process Enhancements
GM, WPI
Yet to start
Project Status/Update#152 High Production Rate Process for Metal Matrix Composite Components
CO School of Mines Objective: Rapid production of composites
using auto-ignition combustion synthesis: Metal matrix, ceramic matrix & intermetallic
matrix composites via squeeze DC & SSM Predict 20-60% ceramics in PDC, 90% in
squeeze DC & SSM
Progress
Produced 3 inch diameter x 4 inch cylinder with 47% TiC in an aluminum matrix
Acted like an SSM billet Microstructural analyses performed Mechanical testing to follow Machining is very difficult
TiC Grain Size and Morphology
2) Grain size grows as TiC content increases due to increase in reaction temperatures.
1) Grain Size remains under 5 micron for small samples, (50-100 grams) and 10 – 15 microns for 2 kilo sample lower photo
Project Status/Update #153 AMC CIR program: High
Performance Die Casting Alloys, WPI
1.1.1.1 Subtask: Target applications/alloy to be optimized; discussions with industry colleagues/partners. (Scheduled time; 3/1/06 - 8/31/06)
Partnership established with Contech (formerly SPX); mechanical property improvement requirements under discussion.
#153 AMC CIR program: High Performance Die Casting Alloys,
WPI 1.1.1.2 Subtask: Use i-Select to optimize alloy(s) for the
specified application. (Scheduled time; 6/1/06 - 9/30/06) Analyzed most possible requirements for Al die casting
alloys using iSelect and have proposed composition ranges of target alloys.
Focus on improving alloy properties, specifically strength, ductility,
thermal conductivity, and surface finish etc., as well as improve alloy castability and corrosion resistance, and reduce costs
1.1.1.3 Subtask: Cast samples of the select grade (premium grade) alloy – laboratory trials (Scheduled time; 10/2/06 - 3/29/07) 38 alloys cast and were examined in great detail by metallography and microstructural analysis; the following observations are made:
Mg at 2 to 4% significantly refines the Al-Si eutectic. When Si content is between 10 to 15% all the other constituents
within the eutectic structure are refined. At 3%Mg, inclusions found when Si > 12%. Size and amount of
the inclusions increased with increasing Si Addition of Mn significantly changed the morphology of Fe-rich
phases. At lower Cu level the Cu-rich phase was in the form of clusters
of small particles in the intergranular areas. With increasing Cu the particles became bigger and the string–like clusters became wider and agglomerated
Mechanical testing of selected alloys in progress
Project Review Dates
#137 Innovative SSM Processing: During ACRC Meetings, 5/25 and 12/7/05, NADCA R&D 10/19/06, 10/17/07
#139 Thinwall Zinc: 10/19/06, 10/17/07
#144 Zinc Alloys for Market Development Support: 2/23/06, 2/21/07
Project Review Dates (cont’d.)
#146 Die Casting Mechanical Property Improvements Through Process Enhancements, 6/13/07
#152 High Production Rate Process for Metal Matrix Composite Components, 6/13/07
#153 High Performance Die Casting Alloys: 10/19/06, 10/17/07
Proposals for Balloting
#155 Plating and Finishing of Zinc Die Castings-Survey of Next Generation Finishes
#156 SSM Processing Databases for Designers and Metalcasters
Open Items
Status of Project Summaries for Completed Projects
Needed Research – Cast Materials Area
Ideas from February 21Task Force Meeting
Determination of compliance of all alloys in NADCA Product Standards with RoHS Development of friction stir welding as replacement for traditional fastening techniquesThin section die casting for Al, Mg alloys