Multi-Objective Optimization of a Multi-Cavity, Significant Wall Thickness Difference Extrusion Profile Mold Design for New Energy Vehicles.

With the rapid development of the new energy vehicle market, the demand for extruded profiles for battery trays, mainly characterized by significant wall thickness differences in multiple chambers, is increasing, posing new challenges to production and quality control. This study examines the multi-objective optimization problem in the design process of aluminum profile dies with multi-cavity profiles and significant wall thickness differences. Using QFORM-extrusion professional aluminum extrusion finite element analysis software and the response surface analysis method, the standard deviation of the velocity (SDV), standard deviation of the pressure (SDP), and thick wall hydrostatic pressure (TWHP) on the profile section at the die exit are optimized. By analyzing the functional relationship between the key die structure parameters (the height of the baffle plates, the length of the bearing, and the height of the false mandrel) and the optimization objective, the optimal combination scheme of die structure parameters was obtained using the NSGA2 (non-dominated sorting genetic algorithm-2) multi-objective genetic optimization algorithm. The results show that, compared with the initial design scheme, the standard deviation of profile section velocity was reduced by 5.33%, the standard deviation of pressure was reduced by 11.16%, and the thick wall hydrostatic pressure was increased by 26.47%. The die designed and manufactured using this scheme successfully completed the hot extrusion production task, and the profile quality met the predetermined requirements, thus verifying the effectiveness of this study in optimizing the design of a multi-cavity aluminum profile die with significant differences in wall thickness for complex structures.

Influence of Severe Plastic Deformation and Aging on Low Cycle Fatigue Behavior of Al-Mg-Si Alloys.

Strain-controlled low cycle fatigue (LCF) tests were conducted on conventionally grained (CG) and ultrafine-grained (UFG) Al-Mg-Si alloys treated under various aging conditions. In the cyclic stress response (CSR) curves, CG peak-aged (PA) alloys showed initial cyclic hardening and subsequent saturation, whereas CG over-aged (OA) alloys displayed cyclic softening behavior close to saturation. The UFG materials exhibited continuous cyclic softening except for UFG 3; it originates from the microstructural stability of the UFG materials processed by severe plastic deformation (SPD). Using a strain-based criterion, the LCF behavior and life of the CG and UFG materials were analyzed and evaluated; the results are discussed in terms of strengthening mechanisms and microstructural evolution. In the CG materials, the LCF life changed markedly owing to differences in deformation inhomogeneity depending on the precipitate state. However, the UFG materials displayed a decreasing LCF life as cyclic softening induced by dynamic recovery became more severe; additionally, a relationship between the microstructural stability of the UFG materials and the cyclic strain hardening exponent n' was suggested.

Microstructure and Mechanical Properties of the Joints from Coarse- and Ultrafine-Grained Al-Mg-Si Alloy Obtained via Friction Stir Welding.

In the present study, the welding of coarse- (CG) and ultrafine-grained (UFG) Al-Mg-Si alloy using friction stir welding (FSW) was attempted. The purpose of welding the UFG material was to check the possibility of applying FSW to materials with a thermally unstable microstructure, which is achieved by severe plastic deformation. This group of materials has significant potential due to the enhanced mechanical properties as a result of the elevated number of structural defects. The CG sample was also examined in order to assess whether there is an influence of the base material microstructure on the weld microstructure and properties. To refine the microstructure, incremental equal channel angular pressing was used. Plastic deformation resulted in grain refinement from 23 µm to 1.5 µm. It caused an increase in the microhardness from 105 HV0.1 to 125 HV0.1 and the tensile strength from 320 MPa to 394 MPa. Similar welds obtained using an FSW method exhibited good quality and grain size in a stir zone of 5 µm. For both welds, a decrease in the microhardness occurred in the stir zone. However, for the weld of UFG Al-Mg-Si, the microhardness distribution was homogeneous, while for the weld of the CG, it was inhomogeneous, which was caused by different characteristics of the second-phase precipitates. The tensile strength of the welds was lowered and equaled 269 MPa and 220 MPa for the CG and UFG welds, respectively.

Effect of the Solid Solution and Aging Treatment on the Mechanical Properties and Microstructure of a Novel Al-Mg-Si Alloy.

A novel Al-Mg-Si aluminum alloy with the addition of the micro-alloying element Er and Zr that was promptly quenched after extrusion has been studied. The solid solution and aging treatment of the novel alloy are studied by observing the microstructure, mechanical properties, and strengthening mechanism. Scanning electron microscopy (SEM) and transmission electron microscopy (TEM) techniques are employed to examine the changes in the microstructure resulting from various solid solution treatments and aging treatments. The best strengthening effect can be achieved when the solubility of the MgSi phase and precipitate ß″ (Mg2Si phase) is at their maximum. The addition of Er and Zr elements promotes the precipitation of the ß″ phase and makes the b″ phase more finely dispersed. The aging strengthening of alloys is a comprehensive effect of the dislocation cutting mechanism and bypass mechanism, the joint effect of diffusion strengthening of Al3(Er,Zr) particles and the addition of Er and Zr elements promoting the precipitation strengthening of ß″ phases. In this paper, by adding Er and Zr elements and exploring the optimal heat treatment system, the yield strength of the alloy reaches 437 MPa and the tensile strength reaches 453 MPa after solid solution treatment at 565 °C/30 min and aging at 175 °C/10 h.

Microstructure, Precipitates Behavior, and Mechanical Properties of Age-Hardened Al-Mg-Si Alloy Sheet Fabricated by Twin-Roll Casting.

Twin-roll casting (TRC), as a near-net-shape technology, is employed to fabricate age-hardened Al-Mg-Si alloy. Compared with conventional direct chill (DC) casting, the TRC method is much more economical and efficient. In this work, the microstructure, precipitates behavior, and mechanical properties of age-hardened Al-Mg-Si alloy sheet fabricated by TRC were investigated by hardness measurements and tensile tests, metallographic microscopy, field emission gun scanning electron microscope, electron backscatter diffraction, transmission electron microscopy, and differential scanning calorimetry analyses. It was found that the size of recrystallized grains for DC casting alloy with finely dispersed particles was larger than that of TRC alloy with coarse particles. Typical CubeND texture accompanied by P texture formed after solution treatment made the value of r reach ~0.7 in the TRC alloy due to the PSN effect caused by the segregation of particles. More GP zones resulted in the strength of TRC alloy being higher than that of DC casting alloy after T8X treatment. With the time of paint-bake hardening extended to 8 h, few segregation particles remained in the TRC alloy. This decreased the concentration of supersaturated atoms. The hardness of the TRC alloy with the lower density of the ß″ strengthening phase was lower compared to the DC casting alloy.

Microstructure and Mechanical Properties of Al-Mg-Si Similar Alloy Laminates Produced by Accumulative Roll Bonding.

As the applications of heterogeneous materials expand, aluminum laminates of similar materials have attracted much attention due to their greater bonding strength and easier recycling. In this work, an alloy design strategy was developed based on accumulative roll bonding (ARB) to produce laminates from similar materials. Twin roll casting (TRC) sheets of the same composition but different cooling rates were used as the starting materials, and they were roll bonded up to three cycles at varying temperatures. EBSD showed that the two TRC sheets deformed in distinct ways during ARB processes at 300 °C. Major recrystallizations were significant after the first cycle on the thin sheet and after the third cycle on the thick sheet. The sheets were subject to subsequent aging for better mechanical properties. TEM observations showed that the size and distribution of nano-precipitations were different between the two sheet sides. These nano-precipitations were found to significantly promote precipitation strengthening, and such a promotive effect was referred to as hetero-deformation induced (HDI) strengthening. Our work provides a new promising method to prepare laminated heterogeneous materials with similar alloy TRC sheets.

Impact of Impulses on Microstructural Evolution and Mechanical Performance of Al-Mg-Si Alloy Joined by Impulse Friction Stir Welding.

Impulse Friction Stir Welding (IFSW) was utilized to join 6082-T6 alloy plates at various impulse frequencies. A distinctive feature of IFSW is the generation of mechanical impulses that enhances the forging action of the tool, and thereby, alters the weld microstructure. The microstructural evolution in the Stir Zone (SZ) with special focus on the strengthening precipitation behavior, and overall mechanical properties of the IFSW joints have been investigated. It was demonstrated that the strengthening ß″ precipitates reprecipitated in the SZ of the IFSW joints during natural aging. In contrast, no precipitates were found in the SZ of the Friction Stir Welding (FSW) weld. Partial reversion of ß″ after IFSW is supposed to occur due to more developed subgrain network and higher dislocation density introduced by impulses that accelerated precipitation kinetics. Dynamic recrystallisation was facilitated by impulses resulting in a fine, homogeneous structure. There was no significant difference between the microhardness in the SZ, tensile and yield strength of the FSW and IFSW joints. However, the application of impulses demonstrated the smoothing of the hardness reduction in the transition region at the advancing side. The shift of the fracture location from the Heat-Affected Zone (HAZ) by FSW to the SZ as well as higher elongation of the joints by IFSW of lower frequencies could be related to the grain refinement and the change of the grain orientation.

Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation.

One of the main challenging issues in friction stir welding (FSW) of stiffened structures is maximizing skin and flange mixing. Among the various parameters in FSW that can affect the quality of mixing between skin and flange is tool plunge depth (TPD). In this research, the effects of TPD during FSW of an Al-Mg-Si alloy T-joint are investigated. The computational fluid dynamics (CFD) method can help understand TPD effects on FSW of the T-joint structure. For this reason, the CFD method is employed in the simulation of heat generation, heat distribution, material flow, and defect formation during welding processes at various TPD. CFD is a powerful method that can simulate phenomena during the mixing of flange and skin that are hard to assess experimentally. For the evaluation of FSW joints, macrostructure visualization is carried out. Simulation results showed that at higher TPD, more frictional heat is generated and causes the formation of a bigger stir zone. The temperature distribution is antisymmetric to the welding line, and the concentration of heat on the advancing side (AS) is more than the retreating side (RS). Simulation results from viscosity changes and material velocity study on the stir zone indicated that the possibility of the formation of a tunnel defect on the skin-flange interface at the RS is very high. Material flow and defect formation are very sensitive to TPD. Low TPD creates internal defects with incomplete mixing of skin and flange, and high TPD forms surface flash. Higher TPD increases frictional heat and axial force that diminish the mixing of skin and flange in this joint. The optimum TPD was selected due to the best materials flow and final mechanical properties of joints.

Analysis of Friction Stir Welding Tool Offset on the Bonding and Properties of Al-Mg-Si Alloy T-Joints.

Research on T-configuration aluminum constructions effectively decreases fuel consumption, increases strength, and develops aerial structures. In this research, the effects of friction stir welding (FSW) tool offset (TO) on Al-Mg-Si alloy mixing and bonding in T-configurations is studied. The process is simulated by the computational fluid dynamic (CFD) technique to better understand the material mixing flow and the bonding between the skin and flange during FSW. According to the results, the best material flow can be only achieved at an appropriate TO. The appropriate TO generates enough material to fill the joint line and results in formation of the highest participation of the flange in the stir zone (SZ) area. The results show that, in the T-configuration, FSW joints provide raw materials from the retreating side (RS) of the flange that play a primary role in producing a sound mixing flow. The selected parameters were related to the geometric limitations of the raw sheets considered in this study. The failure point of all tensile samples was located on the flange. Surface tunneling is the primary defect in these joints, which is produced at high TOs. Among the analyzed cases, the most robust joint was made at +0.2 mm TO on the advancing side (AS), resulting in more than 60% strength of the base aluminum alloy being retained.

Development of Al-Mg-Si alloy performance by addition of grain refiner Al-5Ti-1B alloy.

Aluminum alloys are the most essential part of all shaped castings manufactured, mainly in the automotive, food industry, and structural applications. There is little consensus as to the precise relationship between grain size after grain refinement and corrosion resistance; conflicting conclusions have been published showing that reduced grain size can decrease or increase corrosion resistance. The effect of Al-5Ti-1B grain refiner (GR alloy) with different percentages on the mechanical properties and corrosion behavior of Aluminum-magnesium-silicon alloy (Al-Mg-Si) was studied. The average grain size is determined according to the E112ASTM standard. The compressive test specimens were made as per ASTM: E8/E8M-16 standard to get their compressive properties. The bulk hardness using Vickers hardness testing machine at a load of 50 g. Electrochemical corrosion tests were carried out in 3.5 % NaCl solution using Autolab Potentiostat/Galvanostat (PGSTAT 30).The grain size of the Al-Mg-Si alloy was reduced from 82 to 46 µm by the addition of GR alloy. The morphology of α-Al dendrites changes from coarse dendritic structure to fine equiaxed grains due to the addition of GR alloy and segregation of Ti, which controls the growth of primary α-Al. In addition, the mechanical properties of the Al-Mg-Si alloy were improved by GR alloy addition. GR alloy addition to Al-Mg-Si alloy produced fine-grained structure and better hardness and compressive strength. The addition of GR alloy did not reveal any marked improvements in the corrosion properties of Al-Mg-Si alloy.

Influence of Minor Zn Addition on Precipitation Behavior and Intergranular Corrosion Properties of Al-Mg-Si Alloy.

The effect of 0.2 wt.% Zn addition on microstructure, age hardening and intergranular corrosion (IGC) properties of Al-Mg-Si alloy were investigated by scanning electron microscope, transmission electron microscope, hardness testing, and electrochemistry testing. The results showed that the addition of Zn can accelerate the transformation of GP zones into ß″, and make the intragranular precipitates become smaller and with higher density. This is beneficial to the precipitation strengthening of the alloy, leading to obtaining higher hardness and enhancing the age hardening response. The peak hardness of the alloy with the addition of Zn is 125.8 HV which means increasing the hardness by 12.7 HV, compared with the alloy without Zn. However, the addition of Zn makes the precipitate-free zone (PFZ) of the alloy wider, and coarsens the grain boundary precipitates slightly, which result in the reduction of IGC resistance of Al-Mg-Si alloy. The maximum corrosion depth of the Zn-containing alloy is 121.3 µm in the peak age condition, which is 35.7 µm deeper than the alloy without Zn. The result of the potentiodynamic polarization curves also demonstrated the increase of IGC sensitivity. The corrosion current density of the alloy with added Zn is 0.595 µA/cm2 in the peak age condition, while that for the alloy without Zn is 0.199 µA/cm2.

Effect of a Trace Addition of Sn on the Aging Behavior of Al-Mg-Si Alloy with a Different Mg/Si Ratio.

In this paper, the effect of trace Sn on the precipitation behavior and mechanical properties of Al-Mg-Si alloys with different Mg/Si ratios aged at 180 °C was investigated using hardness measurements, a room-temperature tensile test, transmission electron microscopy and differential scanning calorimetry. The results shown that Sn reduces the precipitation activation energy, increases the number density of ß″ precipitates, and then increased the aging hardenability and mechanical properties of the Al-Mg-Si alloy. However, the positive effect of Sn on the mechanical properties of the Al-Mg-Si alloy drops with the decrease of the Mg/Si ratio of the alloy.

A Novel Approach to Improve the Microstructure and Mechanical Properties of Al-Mg-Si Aluminum Alloys during Twin-Roll Casting.

The main purpose of this present study was to investigate the different processing conditions on the microstructure, segregation behavior of alloying elements, and mechanical properties of Al-Mg-Si alloy twin-roll cast slab prepared using a novel twin-roll casting technology. The simulation of temperature field, distribution of alloying elements, tensile properties, hardness, and conductivity were examined by a Leica optical microscope, scanning electron microscopy, energy dispersion spectroscopy, electron probe microanalysis, and tensile tests. The results indicated that when the traditional twin-roll casting method was used to produce aluminum alloy strip, there are obvious centerline segregation defects due to the deep crystallization front depth and symmetrical solidification characteristics. When the forced-cooling technology was applied in the twin-roll casting process, by virtue of the changing of crystallization front depth and crystallization front shape, the segregation defects are obviously suppressed. Suggesting that this method can significantly improve the uniformity of alloying elements in the thickness direction of the twin-roll cast slab, ultimately improve the mechanical properties of AA6022 aluminum alloy.

Effect of starch on the corrosion behavior of Al-Mg-Si alloy processed by micro arc oxidation from an ecofriendly electrolyte system.

In addition to being environmentally friendly and ecologically acceptable, starch-based materials are inexpensive, readily available and renewable. The capability of starch, therefore, to inhibit the corrosion of Al-Mg-Si alloy processed via micro arc oxidation (MAO) process was investigated. For this aim, MAO coating was carried out on the present sample under AC conditions in an alkaline electrolyte with and without starch. The oxide layer formed on an Al-Mg-Si alloy created from electrolyte with starch was denser and thicker than that without starch. Whilst the oxide layer formed from electrolyte without starch was only composed of γ-Al2O3, the addition of starch into the electrolyte helped to decelerate the rate of cooling during the solidification of molten alumina, resulting in the formation of α-Al2O3 as well. Accordingly, the inhibiting action in the sample coated from the electrolyte containing starch was superior to that without starch.

Effects of the Quenching Rate on the Microstructure, Mechanical Properties and Paint Bake-Hardening Response of Al-Mg-Si Automotive Sheets.

The quenching rate of Al-Mg-Si alloys during solution treatment is an important parameter for the automotive industry. In this work, the effect of the different quenching rates on the microstructures, mechanical properties, and paint bake-hardening response of Al-Mg-Si sheets was studied. Large dimples form on the fracture surface of a sample at a quenching rate of 0.01 °C/s. When the quenching rate increased to 58.9 °C/s, the dimples became smaller. The recrystallized grains and textures were slightly affected by quenching rates beyond 1.9 °C/s. Thus, higher r values of the samples were achieved with slower quenching rates. Furthermore, only the Al(FeMn)SiCr insoluble phases were observed in samples with a rapid quenching rate. Sufficient solute atoms and vacancies resulted in the improvement of the precipitation kinetics and paint bake-hardening capacity for Al-Mg-Si sheets at rapid rates. With a decrease in the quenching rate, the formation of the rod-like coarse ß' phases consumed many solute atoms and vacancies, leading to the deterioration of the paint bake-hardening capacity. This study provides a critical reference on quenching rates for industrial practices, so that good mechanical properties can be achieved using precision control of the quenching process.

Influence of Zn and Sn on the Precipitation Behavior of New Al-Mg-Si Alloys.

In this study, we demonstrate how Zn and Sn influence hardening behavior and cluster formation during pre-aging and paint bake treatment in Al-Mg-Si alloys via hardness tests, tensile tests, and atom probe tomography. Compared to the standard alloy, the Sn-modified variant shows reduced cluster size and yield strength in the pre-aged condition. During the paint bake cycle, the clusters start to grow very fast and the alloy exhibits the highest strength increment. This behavior is attributed to the high vacancy binding energy of Sn. Adding Zn increases the formation kinetics and the size of Mg-Si co-clusters, generating higher yield strength values for both the pre-aged and paint baked conditions. Simultaneous addition of Zn and Sn creates a synergistic effect and produces an alloy that exhibits moderate strength (and good formability) in the pre-aged condition and accelerated hardening behavior during the paint bake cycle.

Elemental electron energy loss mapping of a precipitate in a multi-component aluminium alloy.

The elemental distribution of a precipitate cross section, situated in a lean Al-Mg-Si-Cu-Ag-Ge alloy, has been investigated in detail by electron energy loss spectroscopy (EELS) and aberration corrected high angle annular dark field scanning transmission electron microscopy (HAADF-STEM). A correlative analysis of the EELS data is connected to the results and discussed in detail. The energy loss maps for all relevant elements were recorded simultaneously. The good spatial resolution allows elemental distribution to be evaluated, such as by correlation functions, in addition to being compared with the HAADF image. The fcc-Al lattice and the hexagonal Si-network within the precipitates were resolved by EELS. The combination of EELS and HAADF-STEM demonstrated that some atomic columns consist of mixed elements, a result that would be very uncertain based on one of the techniques alone. EELS elemental mapping combined with a correlative analysis have great potential for identification and quantification of small amounts of elements at the atomic scale.

Influence of Li2Sb Additions on Microstructure and Mechanical Properties of Al-20Mg2Si Alloy.

It is found that Li2Sb compound can act as the nucleus of primary Mg2Si during solidification, by which the particle size of primary Mg2Si decreased from ~300 to ~15-25 µm. Owing to the synergistic effect of the Li2Sb nucleus and adsorption-poisoning of Li atoms, the effect of complex modification of Li-Sb on primary Mg2Si was better than that of single modification of Li or Sb. When Li-Sb content increased from 0 to 0.2 and further to 0.5 wt.%, coarse dendrite changed to defective truncated octahedron and finally to perfect truncated octahedral shape. With the addition of Li and Sb, ultimate compression strength (UCS) of Al-20Mg2Si alloys increased from ~283 to ~341 MPa and the yield strength (YS) at 0.2% offset increased from ~112 to ~179 MPa while almost no change was seen in the uniform elongation. Our study offers a simple method to control the morphology and size of primary Mg2Si, which will inspire developing new Al-Mg-Si alloys with improved mechanical properties.