Metallurgy Commons^™

Development Of Stronger, More Extrudable 6xxx Series Alloys For Automotive Applications, Eli A. Harma

Dissertations, Master's Theses and Master's Reports

6xxx alloys are widely used in automotive extrusion structures for their high specific strength and formability. Advanced designs require greater formability and strength, creating an opportunity for high-strength, formable alloys. The 6xxx series forms β”-Mg₅Si₆ precipitates during age hardening and develops a fibrous microstructure during extrusion, both strengthening the alloy. Increasing Mg and Si to form more β” decreases formability. Thus, modifying texture can increase strength without reducing formability. Current alloys like 6005A add Mn and Cr to form dispersoids that inhibit recrystallization and promote strengthening textures; however, high Mn and Cr concentrations reduce formability. Replacing Mn …

Aqueous Iron Electrowinning: From Electrolyte Engineering To The Unexplored Potential Of Acetate Systems, Chodwell N. Verenga

Dissertations, Master's Theses and Master's Reports

Iron electrowinning and electrodeposition sit at the intersection of classical metallurgy and developing sustainable manufacturing. With the iron and steel industry responsible for 7 - 9% of global CO₂ emissions, low-temperature electrochemical pathways for iron production have garnered significant research interest. This review examines the fundamental electrochemical principles governing iron deposition, the thermodynamic constraints imposed by the iron-water system, and the kinetic challenges posed by the parasitic hydrogen evolution reaction (HER). The three key electrolyte systems are objectively evaluated: acidic sulfate and chloride electrolytes, alkaline suspension electrolytes and water-in-salt electrolytes. Their operating parameters, faradaic efficiencies, energy consumption and deposit characteristics …

Methodology Development For Evaluating Relative Heat Checking Resistance Of Open-Die Forge Tooling, Jack F. Schaller

Dissertations, Master's Theses and Master's Reports

Heat checking, characterized by biaxial networks of surface cracks induced by thermomechanical cycling, can cause premature failure of open-die forge tooling. To facilitate the evaluation of heat checking resistance of die steels, a simulation‑informed out-of-phase thermomechanical fatigue (OP-TMF) testing methodology was developed using 4330V steel as a baseline material. Temperature‑dependent material properties and flow stress data were collected and compiled into a material data file for use with finite element analysis software. Forging and cooling scenarios were simulated across a range of die preheat temperatures. Temperature and in-plane strain histories extracted from the die surface provided a foundation for laboratory …

Design Of Aluminum-Copper Alloy With Scandium In Solution, Austin M. Depottey

Dissertations, Master's Theses and Master's Reports

The 2xxx series of precipitation-strengthened aluminum-copper alloys are commonly used in high-temperature applications (up to 300°C) where lightweight metals are required. Scandium additions to aluminum-copper alloys have gained recent academic interest due to improved high-temperature mechanical properties, by forming coarsening- resistant Al3Sc dispersoids and stabilization of θ′ precipitates. However, gaps in knowledge about the effects of scandium present a challenge to successful commercialization of aluminum-copper-scandium alloys. This work seeks to explore these knowledge gaps and ultimately design and test a commercially feasible aluminum- copper alloy with scandium. To better understand the processing conditions required to avoid the detrimental W-phase (Al8Cu4Sc), …

Machine Learning Design And Experimental Production Of Recycled Aluminum Alloys With Magnesium And Iron, Skylar Patten

Dissertations, Master's Theses and Master's Reports

Recycling aluminum saves up to 95% of the energy required for primary production but introduces impurities such as iron that limit alloy performance. The Al-Mg-Fe system, though commercially used, remains underexplored. This work applies machine learning with Multi-Objective Bayesian Optimization (MOBO) using Thermo-Calc simulations to design Al-Mg-Fe-Si-Cu-Zn alloys with improved castability and reduced porosity. The optimization targeted freezing range, shrinkage, drag coefficient, and microstructural parameters, identifying compositions with high Mg, Si, and Cu and low Zn as optimal. Predicted alloys were experimentally cast and characterized, with yield strengths exceeding 95 MPa and elongation comparable to commercial 319 aluminum in the …

Bayesian Alloy Design With Additive Synthesis, Michael R. Sulwer

Dissertations, Master's Theses and Master's Reports

To reduce carbon emissions and increase power out, steam powerplants need to increase the operating temperatures and pressures of steam turbines to improve efficiency. This necessitates the development of high temperature alloys with superior strength and stability. This research aims to design a class of solid solution High Entropy Alloys (HEAs) to exceed the high temperature performance of commercial alloys like Haynes 230 while maintaining comparable costs for Advanced Ultra Supercritical (A-USC) steam cycles. This project integrates Bayesian optimization and Calculation of Phase Diagrams (CALPHAD) within an Integrated Computational Materials Engineering (ICME) framework to predict and optimize key material properties: …

Iron Ore Tailings Reprocessing By Electrostatic Separation Plus Two Stages Froth Flotation, Vincent Bailey Arohunmolase

Dissertations, Master's Theses and Master's Reports

The reprocessing of tailings is crucial for recovering valuable iron and reducing the environmental impact associated with tailings disposal. This study investigates the practicality of reprocessing tailings to enhance iron oxide content, combining electrostatic separation with a two-stage froth flotation process using oleic acid (direct flotation) and amine (reverse flotation). The primary goal is to efficiently recover valuable iron from tailings, thereby reducing waste and promoting sustainable resource utilization. The process aims to upgrade the iron oxide content to around 93-99% Fe₂O₃, making the recovered material suitable for the production of direct-reduced iron.

Electrostatic separation was …

Solidification Cracking In Additively Manufactured High Entropy Alloy Nicrcofe With V Or W, Andrew R. Walch

Dissertations, Master's Theses and Master's Reports

Recent sustainability efforts have reduced CO2 emissions from electricity generation by increasing operating temperatures and pressures in advanced ultra-supercritical (A-USC) power plants. However, the extreme operating conditions in these A-USC power plants require new high temperature materials. The recent study of nickel-based high-entropy alloys (HEA) represents the latest approach to meet the specifications for A-USC operations. A CALculation PHase Diagram (CALPHAD) driven Bayesian optimization method was used to design the composition of alloys composed of NiCrCoFe with V or W, which were fabricated via wire-based additive manufacturing to enable high throughput development. Although the alloy was designed to minimize solidification …

F-Temper Vs O-Temper Brazing Of 3003 Aluminum Return Bends, Mieka R. Clark

Dissertations, Master's Theses and Master's Reports

As-extruded (F-temper) 3003 return bends can provide cost savings over annealed (O-temper) return bends in aluminum heat exchangers. To assess if F-temper return bends are an alternative to the baseline O-temper bends, the grain structure, bending performance, and melting behavior were assessed through:

• Quantifying the effect of dispersoids on recrystallization
• Tracking bending behavior through grain morphology and surface texture
• Measuring the number and volume fraction of the α-Al(Mn,Fe)Si intermetallic
• Inducing incipient melting through high temperature thermal exposure.

When homogenized at 620°C and 630°C, the F-temper bends had no orange peel texture, the grain size was equivalent to the annealed product, …

Improving Cast Steel Rail Coupler Fatigue Resistance Through Local Wire-Arc Additive Manufacturing, Andrew M. Bunge

Dissertations, Master's Theses and Master's Reports

Every year, thousands of cast-steel railcar couplers suffer from corrosion-initiated fatigue cracking in similar areas of the coupler’s knuckle; between 2015 and 2018 about 90,000 knuckles were replaced, otherwise these couplers would have been at risk for unexpected failures. These types of couplers have been common in industrial use as early as 1932, hence it is desirable for a countermeasure to the fatigue cracking that does not involve significantly altering the geometry or casting process. Wire arc additive manufacturing (WAM) is a developing technology which boasts the ability to produce complex near-net-shape components; however, less attention has been paid to …

High Temperature Strength Reduces Soldering In Aluminum High Pressure Die Casting, Jacob A. Belke

Dissertations, Master's Theses and Master's Reports

Die soldering, an adhesion defect in high pressure die casting (HPDC), is a symptom of localized sticking where a localized portion of the cast material is adhered to the tooling surface causing build up over time. This requires the tooling to be serviced which incurs additional costs to the process that gets passed on to the parts. Historically, soldering has been mitigated using lubricants, coatings, and alloy chemistry modifications but solder persists.

The Tresca friction thermomechanical model suggests soldering occurs when the local interfacial shear stress between the casting and die surface exceeds the local shear strength of the casting. …

Nickel Superalloy Composition And Process Optimization For Weldability, Cost, And Strength, Sophie A. Mehl

Dissertations, Master's Theses and Master's Reports

To advance sustainability efforts, electric power plants have reduced specific carbon dioxide emissions by increasing operating temperatures and pressures to improve power generation efficiency. The latest improvements are utilized in advanced ultra-supercritical power generation. To meet these operating conditions, nickel superalloys are used in the highest temperature components; however, they are expensive and present weldability challenges. This project aims to experimentally optimize a nickel superalloy to improve material weldability and decrease cost without compromising strength. Three optimized compositions were developed, and their microstructures and mechanical properties were compared to Nimonic 263, a common nickel superalloy in electric power plants. The …

Anaerobic Reductive Bioleaching Of Manganese Ores, Neha Sharma

Dissertations, Master's Theses and Master's Reports

Manganese extraction by biological methods is a green and economical way to produce manganese from low as well as high grade manganese ores. This is especially important for US ores, which are primarily either small in extent, low-grade with a high iron content, or both. They are therefore not suitable for conventional mining, which is very capital-intensive and requires a large up-front investment and are therefore imported at high costs. The goal is therefore to develop a process that can be applied at small scales, with minimal startup costs, and low equipment and labor requirements. It is also critical to …

Fatigue Resistant Cast Steel Railcar Couplers Produced By Wire-Arc Additive Manufacturing (Waam), Samuel Vellequette

Dissertations, Master's Theses and Master's Reports

Every year, approximately 90,000 cast steel railcar coupler knuckles are replaced preemptively to avoid fatigue failure. The coupler geometry has been in service since the early 1930s, so geometry changes are restricted to maintain compatibility with the existing fleet. Defects from the casting process, decarburization during heat treatment, and in-service exposure to corrosive environments combine to promote fatigue crack nucleation in high-stress regions of the knuckle. Wire-arc additive manufacturing (WAAM), which uses traditional welding techniques to build material to near-net shapes, was employed to deposit higher-strength materials in critical regions. By replacing the cast steel in the high-stress region of …

Effect Of Sc On Recrystallization Resistance Of Aa7050, Keaton Schmidt

Dissertations, Master's Theses and Master's Reports

The extrusion process involves high temperatures and strains that can result in undesirable microstructures, especially along the surface. Extruded alloys tend to exhibit surface recrystallization during heat treating at regions of higher strains, which can lead to reduced fatigue strength and corrosion resistance. By adding Sc to AA7050, nano-sized dispersoids are formed with Sc cores and Zr shells that restrict recrystallization more than the base alloy that only utilizes Zr. Billets with varying Sc content and a control with only Zr were cast, and extrusions were made in order to compare surface microstructures at varying strains in the as-extruded and …

Optimizing The Extrudability Of 6082 Aluminum By Varying The Magnesium And Silicon Concentration, Eli A. Harma

Dissertations, Master's Theses and Master's Reports

Alloy 6082 aluminum is used for high-volume manufacturing in the automotive industry due to its high strength, impact performance, and corrosion resistance. However, given these improved properties, the alloy has decreased formability compared to other 6xxx series alloys, especially in the extrusion process. Controlling the dynamic recovery and recrystallization properties by changing the additions of Mg and Si can improve the hot deformation properties. Five alloys of varying Mg and Si concentrations between 0.6 to 1.2wt% Mg and 0.7 to 1.3wt% Si were made with constant concentrations of Cr, Fe, and Mn and the same homogenization heat treatment. The proposed …

The Effects Of Molybdenum, Chromium, And Niobium On Gray Iron For Brake Rotor Applications, Matthew Hasbrouck

Dissertations, Master's Theses and Master's Reports

Brake rotor composition and microstructure must be optimized for thermal and mechanical performance to avoid thermal-mechanical cracking, excessive wear, and to reduce noise. Niobium is an element that increases the strength and wear resistance of gray iron; however, the interaction of niobium with other common alloying elements (chromium and molybdenum) is not well understood. Thirteen gray cast iron alloys were produced with varying levels of carbon equivalent (CE), Cr, Mo, and Nb. Bars with four different diameters (8, 14, 22, and 30 mm) were cast from each alloy and microstructural and physical properties such as graphite flake morphology, pearlite spacing, …

Exploring Rapid Solidification And Equal Channel Angular Pressing In The Fabrication Of Mg-Based Alloys For Medical Applications, Emily Tom

Dissertations, Master's Theses and Master's Reports

The development of magnesium bioresorbable implants has become increasingly popular due to the increased need for temporary implants and magnesium’s excellent biocompatibility and suitable elastic modulus. Even though magnesium is an excellent candidate, when alloyed with other metals magnesium’s corrosion rate becomes too rapid for bioresorbable medical applications. The investigation into novel processing techniques to control the formation of precipitates to improve mechanical strength and ductility as well as corrosion rates has become of interest. This work investigates the combination of two nonequilibrium processing techniques, rapid solidification (RS) and equal channel angular pressing (ECAP), and the effects it has on …

Analyzing Variation In Dispersoid Formation In Aluminum Alloys By Minor Changes In Homogenization Temperature, Brendan Treanore

Dissertations, Master's Theses and Master's Reports

The homogenization of billets in the aluminum extrusion industry is a critical step that removes chemical segregation from casting, dissolves low melting point phases, forms nanoscale dispersoid phases, and promotes the beta to alpha transformation of iron particles in the matrix. With ever increasing use of aluminum extrusion in the automotive industry there is a constant need for increased efficiency and consistency in processing of extruded aluminum. The work in this thesis explores the effects of 10°C differences in the homogenization temperature on the formation of dispersoids in 6082 alloys used in the automotive industry. The role of dispersoids is …

New Horizons For Processing And Utilizing Red Mud, M. Archambo

Dissertations, Master's Theses and Master's Reports

Red mud is an industrial slurry waste that is produced as a byproduct of the Bayer process for alumina. The waste is generated in large quantities, up to a ratio of 2:1 against the valued product alumina. Red mud exhibits many chemical and physical properties that categorize it as a hazardous material. Due to the addition of sodium hydroxide in processing, the pH is typically at values close to 13. Small particle size discourages separation from water for disposal, so drying red mud happens over many years.

The pH of red mud can be reduced with inexpensive reagents. Carbon dioxide …

Anaerobic Reductive Bioleaching Of Manganese Ores, Neha Sharma

Dissertations, Master's Theses and Master's Reports

The increasing demand of manganese in the industries and various hindrances in its production from low grade ores by conventional method has made it imperative for researchers around the world to develop a method of manganese extraction from low grade ores that is both environment friendly and economical. Bioleaching has shown significant potential in manganese extraction and efficiencies of extraction have been found to be 70-98% with the help of various bacteria and fungi.

This study focuses on extraction of manganese with the help of mixed bacterial strains that have been collected from their natural anaerobic environment. The extraction of …

Thermomechanical Mechanisms That Cause Adhesion Of Aluminum High Pressure Die Castings To The Die, Alex Monroe

Dissertations, Master's Theses and Master's Reports

In high pressure die casting (HPDC) of aluminum, cast material adhering to die is a significant defect. Adhesion occurs in two primary ways. The casting may stick preventing its removal from the die. Aluminum can also adhere to the die and buildup in local areas on the die surface with additional casting cycles. This second form of adhesion is called soldering. Lubricant is the best technology to control all forms of adhesion, but it comes at the cost of casting porosity, blisters, reduced die life, and increased die casting machine wear. New strategies to prevent adhesion are desired to eliminate …

Atomistic Monte Carlo Simulation Study Of Phase Transitions In Metal Alloys, Xiaoxu Guo

Dissertations, Master's Theses and Master's Reports

The atomic-scale Monte Carlo simulation study focuses on the intrinsic behaviors of a defect-free crystal that undergoes a cubic-to-tetragonal martensitic transformation. The quasi-spin variable associated with the lattice sites characterizes the local unit cells of the orientation variants of the ground-state martensite phase, which interact with each other through long-range elastic interactions. It is shown that the diffuse scattering in the premartensitic austenite state results from the spatial correlation of the atomic-scale heterogeneous lattice displacements and manifests the displacement short-range ordering. The effects of temperature, elastic anisotropy, and shear modulus softening on the diffuse scattering and displacement short-range ordering are …

Role Of Eta Phase Evolution On Creep Properties Of Nickel Base Superalloys Used In Advanced Electric Power Generation Plants, Ninad Mohale

Dissertations, Master's Theses and Master's Reports

Advanced fossil energy power generation plants require materials that withstand high temperatures and corrosive environments. One such material that is used in steam turbines is Nimonic 263. It is a nickel-base superalloy that is principally strengthened by gamma primephase (Ni₃(Ti, Al)) and has an L1₂structure. At extended times and at turbine operating temperatures however, eta (Ni₃Ti) phase is known to form at the expense of gamma prime. Eta has a complex DO₂₄structure and is the stable phase between 750°C and 900°C, but with slow kinetics of formation. Little is understood about eta …

Effect Of Cerium And Magnesium Additions On The Strength And Morphology Of The Intermetallic Compound Layers In Aluminum-Steel Dissimilar Castings, Matt Thomas

Dissertations, Master's Theses and Master's Reports

Dissimilar castings are under investigation due to their light-weighting opportunities within the automotive industry. In this case, dissimilar castings consist of a solid steel core and a poured aluminum component. The strength and integrity of the casting relies on the coherency of the bond between the two components; by optimizing the metallurgical component of the bonding phenomena, the weight and complexity of the insert can be reduced, further increasing the light-weighting opportunities. An interface comprised of intermetallics, generally Fe₄Al₁₃ and Fe₂Al₅, forms between the two components with the latter forming nearest the steel. …

Influence Of Rapid Solidification And Wrought Processing On Precipitation Strengthening And Deformation Mechanisms In Al-Sc-Zr Alloys, Yang Yang

Dissertations, Master's Theses and Master's Reports

Al-Sc-Zr alloys have drawn increasing attention in the last several decades due to their strengthening and coarsening resistance. In this study, solute concentrations of Sc and Zr were increased beyond their equilibrium solubilities without primary precipitate formation using melt-spinning. The melt-spun ribbon was metallurgically bonded into bulk shape using extrusion. With the proper aging treatment, the mechanical properties of the supersaturated melt-spun ribbon and extruded rod were found to be significantly higher than a baseline dilute alloy. Increased mechanical properties include microhardness, tensile strength at ambient-temperature, and compressive strength and threshold stress at and elevated-temperature. These increases were related to …

The Effects Of Carbon Equivalent, Return Ratios, Mold Preparation, Riser Feed And Casting Temperature On The Microstructural And Mechanical Properties Of 100-70-03 Pearlitic Ductile Iron, Erin Vandusen

Dissertations, Master's Theses and Master's Reports

The most common and costly detriments to ductile iron foundries are casting defects, particularly in new and complex components. The ability to understand the factors and processes that create microstructures and the associated properties would allow accurate virtual predictions of casting outcomes. An experimental study of standard foundry variables, carbon equivalent, return ratio, mold preparation, riser feed, and casting temperature on a target of 100-70-03 pearlitic, hypereutectic ductile iron provided the groundwork for an ICME database. Density decreased when the fraction of graphite nodules was greater due to the low density of graphite. A greater percentage of return scrap and …

Integrated Computational Materials Engineering (Icme) Investigation Of Electrical Conductivity And Thermodynamic Stability For Precipitation Strengthened Al-Zn-Zr And Al-Zn-Ni Ternary Alloys, Oladeji Fadayomi

Dissertations, Master's Theses and Master's Reports

High electrical conductivity Al-Zn-TM (TM=Transition metals) alloys with improved mechanical properties and thermal resistance are developed with an integrated computational material engineering (ICME) strategy. From a series of ab initio density functional theory (DFT) simulations assessing combinations of ternary alloys, Al-Zn-Ni and Al-Zn-Zr are determined as alloys with relatively high electrical conductivity compared to several other ternary Al alloy combinations. The zero-temperature stable structure of precipitates formed in these alloys are determined from computed enthalpy of formation as L1₂, with particular focus of examining the influence of Zn on stabilizing the desired L1₂ precipitate phase.

Scanning transmission …

Effect Of Development Of Scandium Trialuminide Precipitates On Corrosion And Mechanical Behavior In Aluminum-Magnesium Alloys, Carson Williams

Dissertations, Master's Theses and Master's Reports

Development of aluminum alloys has seen an increase in attention in recent years. The 5xxx series of Al-Mg alloys has the potential to provide strong, lightweight materials in various industry applications, however issues with strain formability and corrosion hinder the development of these alloys. The addition of Sc for developing Al₃Sc precipitates provides considerable precipitation strengthening as well as grain refinement characteristics that can help mitigate these issues. Alloys with varied Mg content were analyzed for heat treatment aging responses and precipitate formation, changes in mechanical behavior related to the Portevin-le Chatelier effect, and effects on intergranular corrosion …

Investigating Microalloying Elements To Accelerate Zirconium Trialuminide Precipitation In Aluminum Alloys, Philip D. Staublin

Dissertations, Master's Theses and Master's Reports

Precipitation of the L1₂-structured coherent Al₃Zr trialuminide phase in aluminum-zirconium alloys increases the alloy strength. Precipitation of a more refined dispersion of Al₃Zr can further increase the strength of these alloys. The addition of microalloying elements which bind to zirconium may accelerate the precipitation kinetics, allowing for nucleation of a greater number of precipitates and faster precipitate growth. Zirconium binding energies are computed for a wide range of elements, based on which the elements tin, antimony, and tellurium were selected for investigation. Ternary Al-Zr-X alloys (X = Sn, Sb, Te) were cast and heat …