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Investigation on Surface Quality of a Rapidly Solidified Al-50%Si Alloy Component for Deep-Space Applications.

ABSTRACT: To meet the requirements for high-performance products, the aerospace industry increasingly needs to assess the behavior of new and advanced materials during manufacturing processes and to ensure they possess adequate machinability, as well as high performance and an extensive lifecycles. Over the years, industrial research works have focused on developing new alloys with an increased thermal conductivity as well as increased strength. High silicon content aluminum (Al-Si) alloys, due to their increased thermal conductivity, low coefficient of thermal expansion, and low density, have been identified as suitable materials for space applications. Some of these applications require the use of intricate parts with tight tolerances and surface integrity. These challenges are often tied to the machining conditions and strategies, as well as to workpiece materials. In this study, experimental milling tests were performed on a rapidly solidified (RS) Al-Si alloy with a prominent silicon content (over 50%) to address challenges linked to material expansion in deep space applications. The tests were performed using a polycrystalline cubic boron nitride (PCBN) tool coated with amorphous diamond to reduce tool wear, material adhesion, surface oxidation, and particle diffusion. The effects of cutting parameters on part surface roughness and microstructure were analyzed. A comparative analysis of the surface with a conventionally utilized Al6061-T6 alloy showed an improvement in surface roughness measurements when using the RS Al-Si alloy. The results indicated that lower cutting speed and feed rate on both conventional and RS Al-Si alloys produced a better surface finish. Reduced vibrations were also identified in the RS Al-Si alloy, which possessed a stable cutting time at low cutting speeds but only displayed notable vibrations at cutting speeds above 120 m/min.

SUBMITTER: Chaieb O

PROVIDER: S-EPMC7436292 | biostudies-literature | 2020 Aug

REPOSITORIES: biostudies-literature

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Investigation on Surface Quality of a Rapidly Solidified Al-50%Si Alloy Component for Deep-Space Applications.

Chaieb Oussama O Olufayo Oluwole A OA Songmene Victor V Jahazi Mohammad M

Materials (Basel, Switzerland) 20200803 15

To meet the requirements for high-performance products, the aerospace industry increasingly needs to assess the behavior of new and advanced materials during manufacturing processes and to ensure they possess adequate machinability, as well as high performance and an extensive lifecycles. Over the years, industrial research works have focused on developing new alloys with an increased thermal conductivity as well as increased strength. High silicon content aluminum (Al-Si) alloys, due to their i ...[more]

PMID: 32756338

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Project description:Al-Mg-Si series aluminum alloy is a heat-treatment-strengthened alloy. Research on the impact resistance of Al-Mg-Si series aluminum alloy is of great significance to expand its application in engineering. Taking 6082-T6 aluminum alloy as the concrete research object, using the split Hopkinson pressure bar (SHPB) device, the dynamic mechanical response of the material under different temperatures and average strain rates was studied, and the service performance of the material under extreme conditions was determined. The absolute temperature rise was introduced to optimize the existing constitutive model. The results show that when the environment temperature is 298.15~473.15 K under high-speed impact, the internal thermal softening effect of the material is dominant in the competition with the work hardening, resulting in a decrease in the flow stress of the material. Through the analysis of the real stress-strain curve, it was found that the elastic modulus of the material was negatively correlated with the strain rate, negatively correlated with the temperature, and showed an obvious temperature-softening effect. Yield strength was negatively correlated with temperature and positively correlated with strain rate, which showed an obvious strain rate hardening effect. Based on SEM microscopic analysis, it was found that under given conditions, adiabatic shear bands appeared in some samples, and their internal structures demonstrated obvious change. It was judged that when high-speed impact occurs, cracks are induced at the shear bands, and the cracks will continue to develop along the adiabatic shear bands, resulting in many oblique cracks which will gradually become larger and eventually lead to material failure. Finally, based on the model, the strain rate and temperature softening terms were improved, and a rise in adiabatic temperature rise was introduced. The improved model can better describe the strain rate effect of the material and accurately describe its flow stress. It provides a theoretical basis for the engineering application of materials.

Dataset Information

Investigation on Surface Quality of a Rapidly Solidified Al-50%Si Alloy Component for Deep-Space Applications.

Publications

Investigation on Surface Quality of a Rapidly Solidified Al-50%Si Alloy Component for Deep-Space Applications.

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