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Report discusses use of solution potential as measure of temper of aluminum alloys. Technique based on fact that different tempers or heat treatments exhibit different solution potentials as function of aging time.
Bending tests were made of two circular cylinders of corrugated aluminum-alloy sheet. In each test failure occurred by bending of the corrugations in a plane normal to the skin. It was found, after analysis of the effect of short end bays, that the computed stress on the extreme fiber of a corrugated cylinder is in excess of that for a flat panel of the same basic pattern and panel length tested as a pin-ended column. It is concluded that this increased strength was due to the effects of curvature of the pitch line. It is also concluded from the tests that light bulkheads closely spaced strengthen corrugated cylinders very materially.
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In this paper, we report on the electrochemical behavior and corrosion resistance of as-prepared aluminum alloy, A360 (AlSi10Mg), fabricated by additive manufacturing, with and without a trivalent chromium process conversion coating. Selective laser melting was the 3D printing process used for the alloy build. The corrosion suppression provided by the coating system was assessed through electrochemical measurements and accelerated degradation testing during a 14-day continuous neutral salt-spray exposure. The results indicate that the conversion coating can be formed by solution pretreating (degreasing and deoxidation) the alloy (X-Z plane perpendicular to the build plane) with its native surface roughness (as-prepared) followed by immersion for 10, 15 or 20 min in the coating bath. All three immersion times provide an equivalent level of corrosion protection to the alloy. The conversion coating suppresses both anodic and cathodic currents, increases the polarization resistance, and provides both anodic and cathodic corrosion protection to the as-prepared alloy. The conversion-coated specimens exhibit good stand-alone corrosion resistance during a 14-day neutral salt-spray exposure with corrosion intensity values (g/m 2 -year) ~10x lower than values for the uncoated, as-prepared alloy specimens.
In this paper, a new high strength and wear resistant aluminum cast alloy invented by NASA-MSFC for high temperature applications will be presented. Developed to meet U.S. automotive legislation requiring low-exhaust emission, the novel NASA 398 aluminum-silicon alloy offers dramatic improvement in tensile and fatigue strengths at elevated temperatures (500 F-800 F), enabling new pistons to utilize less material, which can lead to reducing part weight and cost as well as improving performance. NASA 398 alloy also offers greater wear resistance, surface hardness, dimensional stability, and lower thermal expansion compared to conventional aluminum alloys for several commercial and automotive applications. The new alloy can be produced economically using permanent steel molds from conventional gravity casting or sand casting. The technology was developed to stimulate the development of commercial aluminum casting products from NASA-developed technology by offering companies the opportunity to license this technology.
Additive manufacturing (AM) of high-strength aluminum alloys can produce high-performance aerospace and biomedical parts with unique geometries and functions. However, many high-performance alloy systems such as AA 7075 pose challenges during AM due to thermal cycles that cause hot cracking, limiting AM to casting-friendly alloys. Stock AA 7075 alloy poses additional challenges due to the excessive growth of insoluble precipitates during casting and needs to be thermomechanically processed to obtain acceptable mechanical properties. Here, this work uses liquid metal jet printing to produce high-resolution pure AA 7075 parts at high strength (593 MPa) and ductility (10 pct), surpassing the specific strength of any type of steel. The parts are printed by depositing fine droplets on a high-temperature substrate that reduces cooling rates, preventing hot cracking. The results show that fully dense, crack-free parts can only be printed at substrate temperatures of 500 °C with a cooling rate threshold of < 2000 K/s to prevent cracking and < 500 K/s to eliminate porosity. The tensile strength, microhardness, and ductility of the parts matched or were beyond the wrought alloy specifications after heat treatment, possibly due to high solidification rates that produce finer insoluble precipitates. Our results indicate that many challenging high-performance alloy systems can now be 3D printed based on the critical thresholds for cooling rates using any AM method that can satisfy these conditions.
Materials data handbooks summarize all presently known properties of commercially available structural aluminum alloys 2014, 2219, and 5456 and structural stainless steel alloy 301. The information includes physical and mechanical property data and design data presented in tables, illustrations, and text.
Stress ratio effect on axial load fatigue and crack propagation tests on aluminum alloy sheets
Radiographic markings in gas tungsten arc welds of aluminum alloys studied for cause of Laue spots
A revised edition of the materials data handbook on the aluminum alloy 2014 is presented. The scope of the information presented includes physical and mechanical property data at cryogenic, ambient and elevated temperatures, supplemented with useful information in such areas as material procurement, metallurgy of the alloy, corrosion, environmental effects, fabrication and joining techniques. Design data are presented, as available, and these data are complemented with information on the typical behavior of the alloy.
A study of the opening mode of crack initiation in 7075-T6 aluminum alloy sheets has been conducted with the aid of a scanning electron microscope. Observations were made from several orientations, including the top view of the specimen which showed the notch profile and the edge view of the specimen which showed the entire notch front along the specimen thickness. It was found that the edge view exhibited the first signs of permanent deformation at about 55% of the breaking strength. These changes took the form of deformation bands which were aligned in the direction of the tensile axis and apparently defined limiting regions of homogeneous slip. It is felt that the appearance of microcracks at loads approaching the breaking strength was of fundamental importance in the formation of the final fracture surface. Many of these microcraks were initiated at intermetallic particles and other metallurgically weak regions on the notch surface. It was also possible to correlate the strain in the notch with the stress intensity factor for the various loads. Very large plastic strains were observed on the notch tip as compared to published values of elongation at fracture for unnotched specimens.
A systematic investigation was conducted to examine the fracture behavior of the structural aluminum alloys 2024, 6061, 7075, and 7178 (in selected heat treatments) tested under several controlled conditions. The investigation included both time independent (tensile, shear, and precracked notch-bend) fractures and time dependent (fatigue and stress corrosion) fractures. Specimens were obtained from both sheet and plate material and tested in longitudinal and transverse orientations. Strain rate effects on fracture morphology were examined in tension and shear tests. Fatigue fracture studies included an examination of the influence of minimum-to-maximum-load ratio on fracture morphology. Second-phase particles observed on fracture surfaces and metallographically prepared sections and corrosion products associated with stress corrosion fractures were analyzed chemically using scanning electron microscopy and energy-dispersive X-ray analysis. Fracture morphology was related to the microstructural features, the testing conditions, and the form of commercial product.
Compact specimens of 25 mm thick aluminum alloy plate were subjected to constant amplitude fatigue testing at a load ratio of 0.2. Crack growth rates were determined at frequencies of 1 Hz and 10 Hz in hard vacuum and laboratory air, and in mixtures of water vapor and nitrogen at water vapor partial pressures ranging from 94 Pa to 3.8 kPa. A significant effect of water vapor on fatigue crack growth rates was observed at the lowest water vapor pressure tested. Crack rates changed little for pressures up to 1.03 kPa, but abruptly accelerated at higher pressures. At low stress intensity factor ranges, cracking rates at the lowest and highest water vapor pressure tested were, respectively, two and five times higher than rates in vacuum. Although a frequency was observed in laboratory air, cracking rates in water vapor and vacuum are insensitive to a ten-fold change in frequency. Surfaces of specimens tested in water vapor and vacuum exhibited different amounts of residual deformation. Reduced deformation on the fracture surfaces of the specimens tested in water vapor suggests embrittlement of the plastic zone ahead of the crack tip as a result of environmental interaction.
The effects of water vapor on fatigue crack growth in 7475-T651 aluminum alloy plate at frequencies of 1 Hz and 10 Hz were investigated. Twenty-five mm thick compact specimens were subjected to constant amplitude fatigue testing at a load ratio of 0.2. Fatigue crack growth rates were calculated from effective crack lengths determined using a compliance method. Tests were conducted in hard vacuum and at water vapor partial pressures ranging from 94 Pa to 3.8 kPa. Fatigue crack growth rates were frequency insensitive under all environment conditions tested. For constant stress intensity factor ranges crack growth rate transitions occurred at low and high water vapor pressures. Crack growth rates at intermediate pressures were relatively constant and showed reasonable agreement with published data for two Al-Cu-Mg alloys. The existence of two crack growth rate transitions suggests either a change in rate controlling kinetics or a change in corrosion fatigue mechanism as a function of water vapor pressure. Reduced residual deformation and transverse cracking specimens tested in water vapor versus vacuum may be evidence of embrittlement within the plastic zone due to environmental interaction.
The effects of water vapor on fatigue crack growth in 7475-T651 aluminum alloy plate at frequencies of 1 Hz and 10 Hz were investigated. Twenty-five mm thick compact specimens were subjected to constant amplitude fatigue testing at a load ratio of 0.2. Fatigue crack growth rates were calculated from effective crack lengths determined using a compliance method. Tests were conducted in hard vacuum and at water vapor partial pressures ranging from 94 Pa to 3.8 kPa. Fatigue crack growth rates were frequency insensitive under all environment conditions tested. For constant stress intensity factor ranges crack growth rate transitions occurred at low and high water vapor pressures. Crack growth rates at intermediate pressures were relatively constant and showed reasonable agreement with published data for two Al-Cu-Mg alloys. The existence of two crack growth rate transitions suggests either a change in rate controlling kinetics or a change in corrosion fatigue mechanism as a function of water vapor pressure. Reduced residual deformation and transverse cracking specimens tested in water vapor versus vacuum may be evidence of embrittlement within the plastic zone due to environmental interaction.
A large vacuum chamber (580 mm diameter) was fabricated from an aluminum alloy surface treated by a special process normally used on small chambers. The chamber was tested unbaked and baked at various temperatures, pressures, and holding periods. The chamber was filled with N2 gas, and the outgassing rate was measured after one hour. Then the ultimate pressure was measured. Outgassing rates for baked and unbaked groups were compared. It is concluded that the same surface treatment technique can be used on both large and small chambers produced by the same special extrusion process.
The thermal response and aging behavior of three 2XXX-series powder metallurgy aluminum alloys have been investigated, using Rockwell B hardness measurements, optical and electron microscopy, and energy-dispersive chemical analysis, in order to correlate microstructure with measured mechanical properties. Results of the thermal response study indicated that an increased solution heat treatment temperature was effective in resolutionizing large primary constituents in the alloy bearing more copper but had no apparent effect on the microconstituents of the other two. Aging studies conducted at room temperature and at 120, 150, and 180 C for times ranging up to 60 days indicated that classic aging response curves, as determined by hardness measurements, occurred at lower aging temperatures than were previously studied for these alloys, as well as at lower aging temperatures than are commonly used for ingot metallurgy alloys of similar compositions. Microstructural examination and fracture surface analysis of peak-aged tension specimens indicated that the highest tensile strengths are associated with extremely fine and homogeneous distributions of theta-prime or S-prime phases combined with low levels of both large constituent particles and dispersoids. Examination of the results suggest that refined solution heat treatments and lower aging temperatures may be necessary to achieve optimum mechanical properties for these 2XXX series alloys.