Materials Science and Engineering Commons^™

Investigation Of Outlife Time On The Environmental Durability Of P2-Etched, Adhesively-Bonded Aluminum Alloys Using The Astm Wedge Test, Daniel Gross, Corey Sutton

Materials Engineering

P2 etchant is an environmentally-friendly aluminum etchant which has the potential to replace the Forest Products Laboratory (FPL) etchant as the industry standard. Environmental durability of adhesively-bonded aluminum surfaces etched using a paste version of the P2 etchant were tested using the Boeing-developed wedge test (ASTM D3762 - 03(2010)). This project specifically aimed to examine the relationship between outlife time (the time between etching and adhering) and the ability of bonded aluminum samples to pass the wedge test. Two aluminum alloys, 2024-T3 and 7075-T6, were wedge tested and the etched surfaces examined with an atomic force microscope (AFM) and a …

Processing Of Al-12si-Tnm Composites By Selective Laser Melting And Evaluation Of Compressive And Wear Properties, Konda Prashanth, Sergio Scudino, Anil Chaubey, Lukas Löber, Pei Wang, Hooyar Attar, Frank Schimansky, Florian Pyczak, Jürgen Eckert

Research outputs 2014 to 2021

Al-12Si (80 vol%)-Ti52.4Al42.2Nb4.4Mo0.9B0.06 (at.%) (TNM) composites were successfully produced by the selective laser melting (SLM). Detailed structural and microstructural analysis shows the formation of the Al6MoTi intermetallic phase due to the reaction of the TNM reinforcement with the Al-12Si matrix during SLM. Compression tests reveal that the composites exhibit significantly improved properties (∼140 and ∼160 MPa higher yield and ultimate compressive strengths, respectively) compared with the Al-12Si matrix. However, the samples break at ∼6% total strain under compression, thus showing a reduced plasticity of the composites. Sliding wear tests were carried out for both the Al-12Si matrix and the Al-12Si-TNM …

Hybrid Manufacturing Processes For Fusion Welding And Friction Stir Welding Of Aerospace Grade Aluminum Alloys, Megan Alexandra Gegesky

Masters Theses

"Friction stir welding and processing can provide for joints in aerospace grade aluminum alloys that have preferable material properties as compared to fusion welding techniques. Aerospace grade aluminum alloys such as AA2024-T3 and AA7075-T6 are considered non-weldable by traditional fusion welding techniques. Improved mechanical properties over previously used techniques are usually preferable for aerospace applications. Therefore, by combining traditional fusion welding and friction stir processing techniques, it could be plausible to create more difficult geometries in manufactured parts instead of using traditional techniques. While this combination of fusion welding and friction stir processing is not a new technology, its introduction …

Investigation And Modeling Of Al3(Sc, Zr) Precipitation Strengthening In The Presence Of Enhanced Supersaturation And Within Al-Cu Binary Alloys, Kyle Deane

Dissertations, Master's Theses and Master's Reports

Diffuse Al-Sc and Al-Zr alloys have been demonstrated in literature to be relatively coarsening resistant at higher temperatures when compared with commonly used precipitation strengthening alloys (e.g. 2000 series, 6000 series). However, because of a limited strengthening due to the low solubility of scandium and zirconium in aluminum, and owing to the scarcity and therefore sizeable price tag attached to scandium, little research has been done in the way of optimizing these alloys for commercial applications.

With this in mind, this dissertation describes research which aims to tackle several important areas of Al-Sc-Zr research that have been yet unresolved. In …

Effect Of Time Delay Between Etching And Adhesive Bonding (“Outlife” Time) On Lap-Shear Strength Of Aluminum Alloys Using Environmentally-Friendly P2 Etch, Josh Barkhimer, Matthew Erich, Gokul Nair

Materials Engineering

Raytheon Company currently uses a Forest Products Laboratory (FPL) paste etchant for preparing aluminum surfaces for adhesive bonding, and FPL is a source of hazardous hexavalent chromium. The goal of this study was to evaluate a less-toxic P2 paste etchant as a possible replacement. Coupons of 2024-T3, 6061-T6, and 7075-T6 grades of aluminum alloy were solvent-degreased, abrasively cleaned, and etched at room temperature using P2 paste following a strict protocol adopted from Raytheon. Coupons were then left exposed to air for assigned time intervals (or “outlife” times) of 0, 1, 4, 8, 16, and 63 or 72 hours. The aluminum …

Elevated Temperature Effects On The Mechanical Properties Of Age Hardened 6xxx Series Aluminum Alloy Extrusions, Rachael Donovan, Rose Fortune, Robert Trout

Materials Engineering

The purpose of this project is to determine if over-aging of aluminum causes the yield or tensile strength to fall below the minimum strength values set by the aluminum industry. Extruded aluminum alloys, 6061-T6, 6063-T6, and two proprietary alloys, HS6X-T6 and RX82-T6, were exposed to reheating treatments at extended times and temperatures. The three temperatures were 350°F, 390°F, and 425°F. The times of reheat increased logarithmically from 30 minutes to 64 hours. The samples were tensile tested to determine the tensile strength and yield strength. Statistical methods helped model the behavior of yield and tensile strength as a function of …

Generation Of Multi-Charged Aluminum Ions From Femtosecond Laser Induced Plasma, Frederick Guy Wilson

Electrical & Computer Engineering Theses & Dissertations

Laser-induced plasma multi-charged ion (MCI) sources have gained in popularity over the last thirty years with the advent of reliable, high peak power, short temporal pulse laser systems. Utilization of laser-induced plasma MCI sources allows for production of a wide array of ion species from a variety of source target materials. In this thesis an investigation of the generation of MCis from an aluminum (Al) target source through laser-induced plasma from a femtosecond (fs) pulsed laser system is outlined and the results presented and analyzed. In order to characterize the production of the Al MCis resulting from the fs laser …

Producing High Strength Aluminum Alloy By Combination Of Equal Channel Angular Pressing And Bake Hardening, Hamid Alihosseini, Mohsen Asle Zaeem, Kamran Dehghani, Ghader Faraji

Materials Science and Engineering Faculty Research & Creative Works

A combination of severe plastic deformation by equal channel angular pressing (ECAP) and bake hardening (BH) was used to produce high strength ultrafine-grained AA6061 aluminum alloy. 2, 4 and 8 passes of ECAP were performed, and the bake hardenability of samples was tested by 6% pre-straining followed by baking at 200 °C for 20 min. The microstructures obtained for various passes of ECAP were characterized by XRD, EBSD, and TEM techniques. The microstructures were refined from an average grain size of 20 µm to 212 nm after 8 passes of ECAP. Maximum bake hardenability of 110 MPa, and final yield …

High Cycle Rotating Bending Fatigue Of 6061-T6 Friction Stir Welded Extrusions, John Chang, Travis Miller

Materials Engineering

Fatigue testing was done on friction stir welded joints of 6061-T6 aluminum extrusions. Tests were run using a rotating bending fatigue machine at stresses from 111.5 to 138.7 MPa. Failures occurred on the order of 10⁵ to 10⁷ cycles, and an S-N curve was generated based off of the failure results. After the samples failed, the location of the failure and the number of cycles to failure were noted. Fatigue samples were designed in SolidWorks with a tapered 2 inch reduced section. The 2 inch reduced section will include the entire weld region as seen from the microhardness …

Relationship Between Bagging Methods And Pre-Weld Holding Times On Porosity Formation In 2219 Aluminum Ac-Tig Welds, Mariah Grace Head, Tyson Daniel Mobley

Materials Engineering

The purpose of this study was to determine relationships between bagging methods and pre-weld holding times on the formation of porosity when AC-TIG welding 2219 aluminum. Considering the strict guidelines and specifications required within the aerospace industry, maintaining quality welds is of paramount importance to control part integrity for aerospace applications. This project focused on two parameters involved in the preparation of aluminum parts for welding: bagging method and pre-weld holding time. Welding geometry was simplified to bead-on plate instead of the standard joint welds. Radiographic analysis of the samples showed that all levels of both parameters produced “passing welds.” …

Development Of Precipitation Hardenable Al-Sc-Zr-Hf Quaternary Alloys Through Thermodynamic Modeling, And Room-Temperature And Elevated Temperature Hardness, Matthew J. Wong

Dissertations, Master's Theses and Master's Reports - Open

Aluminum alloyed with small atomic fractions of Sc, Zr, and Hf has been shown to exhibit high temperature microstructural stability that may improve high temperature mechanical behavior. These quaternary alloys were designed using thermodynamic modeling to increase the volume fraction of precipitated tri-aluminide phases to improve thermal stability. When aged during a multi-step, isochronal heat treatment, two compositions showed a secondary room-temperature hardness peak up to 700 MPa at 450°C. Elevated temperature hardness profiles also indicated an increase in hardness from 200-300°C, attributed to the precipitation of Al₃Sc, however, no secondary hardness response was observed from the Al …

Residual Stress Measurement Of 7050 Aluminum Alloy Open Die Forgings Using The Hole-Drilling Method, Alexandra Viksne

Materials Engineering

Open die forged 7050 aluminum alloy has residual stresses that can be measured by the hole-drilling method following standard ASTM E837-01. Weber Metals (Paramount, CA) assumes that the stress is uniform throughout the thickness of an open die forged plate. Four different stress relieved 7050 aluminum samples were tested to confirm if the measurements by the hole-drilling method at the surface of a plate is indicative of the stress throughout. The different stress relief methods included: two water quenched samples at temperature ranges of 60°-90°F and 120°-130°F and two samples plastically deformed by forging at room temperature 1% and 3%. …

Evaluation Of Forging Strain For Maximum Grain Size In Open-Die Forged 6061 Aluminum, Eric Strehl

Materials Engineering

In an effort to maximize grain growth of open-die forged 6061 aluminum alloy parts, samples from three of Weber Metals’s suppliers (Hidal Co-Almex USA Inc., TST Inc., and Vista Metals Corp.; to be called Supplier H, Supplier T, Supplier V respectively) were cut into cylinders with diameters of 0.75˝ and heights of 2˝, and put through a simulated forging process and heat treatment. It is possible that additional alloying elements may be promoting or inhibiting grain growth in the final part. Maximizing grain growth for aluminum alloy parts results in improved resistance to intergranular corrosion. Samples from each vendor had …

Interdiffusion And Impurity Diffusion In Magnesium Solid Solutions, Catherine Kammerer

Electronic Theses and Dissertations

Magnesium, being lightweight, offers potential to be developed into extensive structural applications. The transportation segment has particular interest in Mg and Mg alloy for applications where reduced vehicle weight is proportional to increased fuel efficiency. Aluminum and zinc are two of the most common alloying elements in commercial Mg alloys. They improve the physical properties of Mg through solid solution strengthening and precipitation hardening. Diffusion plays a key role in the kinetics of and microstructural development during solidification and heat treatment. However, there is limited diffusion data available for Mg and Mg alloys. In particular, because Al is monoisotopic, tracer …

Development Of Nitrogen Concentration During Cryomilling Of Aluminum Composites, Clara Hofmeister

Electronic Theses and Dissertations

The ideal properties of a structural material are light weight with extensive strength and ductility. A composite with high strength and tailorable ductility was developed consisting of nanocrystalline AA5083, boron carbide and coarser grained AA5083. The microstructure was determined through optical microscopy and transmission electron microscopy. A technique was developed to determine the nitrogen concentration of an AA5083 composite from secondary ion mass spectrometry utilizing a nitrogen ionimplanted standard. Aluminum nitride and amorphous nitrogen-rich dispersoids were found in the nanocrystalline aluminum grain boundaries. Nitrogen concentration increased as a function of cryomilling time up to 72hours. A greater nitrogen concentration resulted …

Experimental Study On The Fabrication Of Advanced Materials For Energy Applications Using High Energy Mechanical Milling, Ashvin Kumar Narayana Swamy

Open Access Theses & Dissertations

The reaction of aluminum (Al) powder with water has the potential for on demand hydrogen generation. Conventional Al powders, however, react with water slowly due to a highly protective oxide layer on the particle surface. Current methods for Al activation involve harmful and expensive materials. The nano-scale Al powders also remain very expensive and have problems such as a large amount of oxide on the surface. The use of aluminum in an energy generation cycle is also hindered by the fact that, although Al is the most abundant metal in the Earth's crust, its recovery from ore consumes a lot …

Corrosion Assessment Of Cast Aluminum Parts In Ethanol Fuel Blends, P. Wirot, J. Troset, W. Khonraeng, S. Mahabunphachai, E. Viyanit

Journal of Metals, Materials and Minerals

Nowadays, the use of ethanol fuel blends in automobiles has become more and more worldwide since the ethanol mixture would enhance the performance of the engine and fuel economy ($/mile), while reducing the hazardous exhaust released to the environment. However, the use of ethanol fuel blends may induce some material compatibility issues on some automotive parts that were not designed to be used in contact with ethanol. In other words, the humidity in the ethanol would cause corrosion problem on these parts. The goal of this study is to assess the corrosion value of two cast aluminum parts in a …

An Exploratory Investigation Into How Cold Working Can Affect The Acoustic Performance Of Thin Aluminum Foil In A Ribbon Microphone, Alexander (Alex) Stanley

Materials Engineering

Ribbons of 4 μm thin 99.1% pure aluminum foil were cut and corrugated to replace the stock ribbon in an Apex 205 ribbon microphone. Prior to corrugation, half of the ribbons were sandwiched between two KimWipes and two pieces of cardstock then hammered to impart strain hardening. Each ribbon was placed into the microphone capsule and the frequency response of each ribbon was measured. A 10 second sine sweep from 20-20,000 Hz was played through a KRK Rokit 5 speaker and recorded through a ribbon microphone placed 6 inches away from the speaker cone. The signal generated by the ribbon …

Characterization Of Positive Macrosegregation At The Subsurface Of Direct-Chill Cast 7050 Aluminum Forging Billets, Aaron Youril

Materials Engineering

Segregation of alloying elements during casting of forging billets may persist to the final forged component leading to unacceptable surface appearance. Determination of the elements or compounds that segregate is the essential first step to solving this problem. Differential Scanning Calorimetry (DSC) was used to determine a composition profile of the macrosegregation occurring at the subsurface of an as-cast 7050 aluminum alloy billet. Data collection was carried out by separating 10 to 20 mg samples from the outer centimeter along the radius of the billet, as well as samples from the bulk interior of the billet for comparison with the …

Fabrication Of Horizontal Silicon Nanowires Using A Thin Aluminum Film As A Catalyst, Khaja Hafeezuddin Mohammed

Graduate Theses and Dissertations

Silicon nanowires have been the topic of research in recent years for their significant attention from the electronics industry to grow even smaller electronic devices. The semiconductor industry is built on silicon. Silicon nanowires can be the building blocks for future nanoelectronic devices. Various techniques have also been reported in fabricating the silicon nanowires. But most of the techniques reported, grow vertical silicon nanowires. In the semiconductor industry, integrated circuits are designed and fabricated in a horizontal architecture i.e. the device layout is flat compared to the substrate. When vertical silicon nanowires are introduced in the semiconductor industry, a whole …

Process-Dependent Microstructure And Severe Plastic Deformation In Sicp?? Reinforced Aluminum Metal Matrix Composites, Catalina Uribe-Restrepo

Electronic Theses and Dissertations

Discontinuously reinforced MMCs with optimized microstructure are sought after for exceptional high strain rate behavior. The microstructure evolution of a stir-cast A359 aluminum composite reinforced with 30 vol.% SiCp after isothermal anneal, successive hot-rolling, and high strain rate deformation has been investigated. Quantitative microstructural analysis was carried out for the as-cast, annealed (470°C, 538°C and 570°C) and successively hot rolled specimens (64, 75, 88, and 96% rolling reductions). Selected composites were also examined after high strain rate deformation. X-ray diffraction, optical microscopy, scanning electron microscopy and transmission electron microscopy were employed for microstructural characterization. The strength and ductility of the …

Effect Of Process Parameter On Temperature Distribution, Microstructure, And Mechanical Properties Of Self-Reacting Friction Stir Welded Aluminum Alloy 6061-T651, Monica Adriana Torres

Open Access Theses & Dissertations

Self-reacting friction stir welding is the latest FSW tool configuration developed, it employs two shoulders--one on top and one on the bottom of the workpiece-- this tool configuration offers many advantages over conventional welding techniques. However, the current lack of information and specifications limits its understanding and application. This investigation analyzed the effect of process parameters on temperature distribution, microstructure evolution, and final mechanical properties of 6061-T651 SR-FS welds. A factorial experiment was carried out, in which three-process parameters were analyzed--rotational speed, travel speed, and tool plunge force-- three levels were analyzed for each parameter, except for a tool plunge …

Processing And Composition Effects On The Fracture Behavior Of Spray-Formed 7xxx Series Al Alloys, Mala M. Sharma, Constance W. Ziemian, Timothy J. Eden

Faculty Journal Articles

The fracture properties of high-strength spray-formed Al alloys were investigated, with consideration of the effects of elemental additions such as zinc,manganese, and chromium and the influence of the addition of SiC particulate. Fracture resistance values between 13.6 and 25.6 MPa (m)^1/2 were obtained for the monolithic alloys in the T6 and T7 conditions, respectively. The alloys with SiC particulate compared well and achieved fracture resistance values between 18.7 and 25.6 MPa (m)^1/2. The spray-formed materials exhibited a loss in fracture resistance (KI) compared to ingot metallurgy 7075 alloys but had an improved
performance compared to high-solute powder …

Characterization Of Aluminum-Boron Carbide Particulate Metal Matrix Composites, Eric Blank

Materials Engineering

The analysis of die-cast 380 aluminum-boron carbide particulate metal matrix composites (MMC) was performed in order to see if the samples had the required tensile strength of 300 MPa. 10wt% B4C die-cast samples were produced and tested. Half were heat treated to the T6 condition and the others were left as cast. Using ASTM standard B 557M it was found that the average tensile strength for the as-cast samples was 130 MPa and the heat treated samples had a tensile strength of 93 MPa. These values were both lower than expected. The heat treated samples were not expected to have …

Friction Stir Processing Of Commercial Grade Marine Alloys To Enable Superplastic Forming, Christopher B. Smith, Arun Mohan, Rajiv S. Mishra, Murray Mahoney, Mike Miles, Scott M. Gillis, Lee M. Cerveny, Gerald Opichka

Materials Science and Engineering Faculty Research & Creative Works

The use of friction stir processing (FSP) on marine grade aluminum sheet has been investigated with the objective of locally enhancing the material properties. This can potentially allow low-cost commercial grade aluminum to be used in superplastic forming applications or further enhance the formability to allow more complex geometries to be formed. FSP has been demonstrated to enable super plasticity (uniform elongations >250%) in 5083-H116 over a range of friction stir processing conditions. © (2010) Trans Tech Publications.

Electrodeposition Of Al On Magnesium Alloy In Ionic Liquid, Wen-Ta Tsai, Shu-You Chen, Mu-Huan Zhuang, Jeng-Kuei Chang, Yi-Wen Sun

Journal of Electrochemistry

Electrodeposition of a metallic aluminum on a magnesium alloy in acidic aluminum chloride-1-ethyl-3-methylimidazolium chloride ionic liquids(AlCl₃-EMIC) was investigated.The effects of current density and AlCl₃ content in the ionic liquid on the electrodeposition behavior were studied.The results showed that aluminum could be successfully electrodeposited on the AZ91D substrate.At-0.2 V,the ionic liquid containing 60 m/o AlCl₃ was optimum for Al electrodeposition.The current efficiency was higher if electrodeposition was performed at a lower applied current density.The existence of Al coating could caused a substantial increase in open circuit potential,reducing the susceptibility of Mg alloy to corrosion.The results of electrochemical …

Shielding Effectiveness Of Superalloy, Aluminum, And Mumetal Shielding Tapes, Cindy Suit Cheung

Master's Theses

Using MIL-HDBK-419A, MATLAB and Nomographs, Shielding Effectiveness for the Magnetic Field, Electric Field, and Plane Wave were calculated over a frequency range from 10 Hz to 1 GHz. The three shielding tapes used included superalloy, aluminum, and mumetal. Calculations for Shielding Effectiveness involve the computation of Absorption Loss, Reflection Loss, and Re-Reflection Correction Factor. From the outcome of the calculations, it was suitable to conclude that all three metals fulfill the 40 dB Shielding Effectiveness requirements for SGEMP fields for frequencies greater or equal to 1 MHz. Accordingly, all three shielding tapes provide at least 40 dB of shielding to …

Metal Induced Crystallization Of Silicon Thin Films, Sandeep Kumar Raju Sangaraju

UNLV Theses, Dissertations, Professional Papers, and Capstones

Low temperature crystallization of thin film silicon is important for many industrial applications including flat panel displays and silicon thin film solar cells. Unfortunately this remains a major challenge since crystallization temperature of silicon is above 1,000 degrees Celsius, thus limiting to substrates that can tolerate high temperatures. The inability to deposit crystalline thin films on glass substrates is the reason why flat panel display industry uses amorphous silicon for LCD active matrix displays. Thus the ability to deposit crystallized thin film silicon at low temperatures will have significant impact on thin film silicon applications. It has been observed that …

Surface Pre-Treatments And Fabrication Of Highly Ordered Anodic Aluminum Oxide Nanopores At Room Temperature, Sampath Chennuri

Electrical & Computer Engineering Theses & Dissertations

The object of this work is to develop a novel approach to fabricate model membranes of well-defined and well aligned nanostructured materials in a robust environment. The main focus is on electrochemical synthesis, involving anodic oxidation of high purity aluminum sheets to form porous oxide films. Alumina films were prepared by anodizing highly pure aluminum (99.999%) in acidic electrolytes. Anodization parameters (current density, temperature, applied voltage, anodization time and electrolyte concentration) were selected with respect to the electrolyte used.

The primary challenge in nanotechnology is the creation of nanometer-scaled objects with as narrow a size distribution as possible for a …

Microstructural Characterization Of Diode Laser Deposited Ti-6al-4v, Tian Fu, Zhiqiang Fan, Syamala R. Pulugurtha, Todd E. Sparks, Jianzhong Ruan, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser Direct Metal Deposition (DMD) is an effective approach to manufacturing or repairing a range of metal components. The process is a layer-by-layer approach to building up a three dimensional solid object. The microstructure influences mechanical properties of the deposited parts. Thus, it is important to understand the microstructural features of diode laser deposited parts. This paper presents a microstructure analysis of a diode laser deposited Ti-6Al-4V onto a Ti-6Al-4V substrate. laser deposited parts. This paper presents a microstructure analysis of a diode laser deposited Ti-6Al-4V onto a Ti-6Al-4V substrate.