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By G. Guiglionda, A. Deschamps, F. De Geuser, M. Langille, B. J. Diak

"Increased demand for light-weighting in passenger vehicles has created a need for strong, light, ductile materials to be used in body-in-white applications. The AA6xxx-series of aluminum alloys are suitable candidates meeting most requirements but can fall short of the formability demands of designers, necessitating an understanding of what controls the formability in this alloy series. This work examines the effect of copper alloying in AA6xxx on the pre-ageing and natural ageing responses of the microstructure and mechanical properties. The changes in microstructure observed by differential scanning calorimetry and hardness testing are related to the work-hardening and strain-rate sensitivity parameters for these alloys measured by tensile testing. An observed asymmetry in the measured strain-rate sensitivity associated with increasing versus decreasing strain rate changes suggests that a different mechanism operates for the two conditions. It is postulated how this asymmetry in strain-rate sensitivity will impact the necking and ductility behaviour of these alloys.INTRODUCTION The widespread use of AA6xxx series alloys in the form of sheets has provided the need for a more thorough understanding of the complex interactions between composition, processing, resulting microstructure and ultimately, the mechanical properties of the alloys. Conventional industrial practices involve the production of rolled AA6xxx sheet (typically 1 mm thick) to be used for body-in-white (BIW) applications for auto body panels (Hirsch, 2004, 2014). The final metallurgical step prior to the shipment of these panels to manufacturers involves a solution heat treatment (SHT) reverting the ageing products of the alloys into solid solution and the product is then shipped to the customer. During this shipping time and while sheets are waiting to be used, the natural ageing (NA) process occurs whereby the strength of the alloys increases resulting in reduced formability. This can result in a product that is unable to meet the formability demands of the automotive manufacturer. As a result, industry has moved towards performing pre-ageing (PA) treatments to prolong the “shelf-life” of the material prior to it having insufficient formability. Once formed into BIW panels, the parts are then painted and subsequently undergo the paint curing heat treatment which consists of a short period of time at medium temperature, typically 20 minutes at 170–190°C. This short artificial ageing (AA) treatment, known as the paint bake (PB), provides additional strength and improved dent resistance for the material, but reduced formability. The PB result is strongly dependent on the PA treatment performed prior to the forming operation. Furthermore, the addition of copper (Cu) to a base Al-Mg-Si composition is known to increase the alloy’s strength. The goal of this work is to study the effect of Cu on strength, strain hardening, and strain-rate sensitivity (SRS) of these alloys, to understand the strength-formability compromise, for two separate heat treatment schedules; one including and one excluding the PA treatment, both followed by NA."

Jan 1, 2018

By C. H. Buck, A. J. Taylor

"In 2015 Vale’s Clarabelle Mill began the process change to enable a higher degree of Cu separation. The flowsheet modification was part of a complete divisional flowsheet change being implemented in Vale’s Sudbury Operations. This paper will centre on some of the Operational Readiness (OR) work, culminating in the commissioning of the circuit in March 2017. The emphasis will be on the implementation of an integrated test plan to prepare for the process flow change through the mill.BackgroundClarabelle Mill (CBM) began making a saleable Cu concentrate in 2006 with the installation of the Cu separation circuit. Typical separation rate was 35-40% of Cu in feed reporting to Cu concentrate based on a target Ni concentrate Cu:Ni target of 0.7-0.8. The remainder of the recovered Cu (55-60%) reported to Ni concentrate and was smelted through the Copper Cliff Smelter.In 2013 a capital project, Surface Facility Upgrade (SFU), was implemented to focus on matching the surface plants capacities with the future mine plan to maximize revenues. This was to be achieved by redistributing the metal flow, specifically Cu, through CBM to increase metal unit content through the Smelter. The amount of redistribution of Cu was determined to be based on maintaining a stable Cu to Ni ratio (Cu:Ni) in the Ni concentrate.The change in Cu:Ni ratio in the Ni concentrate would affect the Sudbury divisional flowsheet, and required process changes across the all of the surface plants. The detail that surrounds the flowsheet changes as a whole will not be discussed, but the outcome of the decisions plays a large role in the operational readiness interactions between the mill, its suppliers and its downstream customers."

Jan 1, 2018

By K. Regl, J. Berneder

"AMAG investigated different aspects to improve the resistance against grain coarsening in aerospace alloys during recrystallization and was successful in finding several opportunities to minimize this effect. The studies show that one aspect to counteract grain coarsening is the chemical composition and subsequently all phases that are formed during homogenization. Starting with a fine grain (~ 50 µm) can lead to a final grain size of few mm. On the other hand with a coarse initial grain size (approximately 150 µm) and the right chemical composition the grain size can stay almost constant despite different deformation steps. Additional we investigated different sequences for the component production to eliminate the problem of grain coarsening as a coarse grain has a detrimental effect on product performance.INTRODUCTION In the aircraft industry, aluminium sheets are most commonly deformed in their soft state, followed by solution heat treatment and natural or artificial aging. If the preceding deformation is in a critical amount, during the recrystallization at solution heat treatment grain coarsening can occur. A subsequent deformation to this condition leads to an orange peel surface, which requires additional polishing. Next to this extra effort the coarse grain size produces a drop in the mechanical properties, often below specification limits. If there is no subsequent deformation, this effect is not visible and without destructive testing there is no possibility to detect the error. As mentioned before, this effect occurs during recrystallization, which is a process that is driven by the stored energy in the microstructure. The two most important aspects for an increase of the stored energy are the increase of the grain boundaries fraction (smaller grain size) and the increase of the dislocation density caused by deformation. The increase in dislocation density during the deformation arise from trapping of existing dislocations and from the generation of new dislocations. During recrystallization all grains are built completely new, so all dislocations are removed (Humphreys & Hatherly, 2004). There are three requirements for recrystallization:"

Jan 1, 2018

By R. Kaibyshev, I. Zuiko

"The effect of thermomechanical processing (TMP) including cold working by tension or rolling before aging on mechanical properties and a dispersion of secondary phase particles of an AA2519 alloy (Al–5.64Cu–0.33Mn–0.23Mg–0.15Zr–0.11Ti–0.09V–0.08Fe–0.01Si (wt. %)) was examined. It was shown that the use of tension to impart pre-strain =10% in the alloy provides the best combination of properties in peak aging condition of the material. The AA2519T87 alloy processed by tension exhibits the yield stress, ultimate tensile strength and elongation to failure of 425.4±2.4, 475±2.4, 12.1±0.4, respectively. The one pass rolling leads to -5% decreases in yield stress and –20% decreases in ductility. Dislocations serve as heterogeneous nucleation sites for ?'-phase precipitation. The positive effect of tension is attributed to the formation of more homogeneous dislocation structure, uniform distribution of ?'-phase particles with higher aspect ratio. Precipitation of the O–phase plates on {111}a habit plane was detected. In addition it was shown that the low angle boundaries are heterogeneous nucleation sites for ?' and O particles.INTRODUCTION Precipitation-hardened alloys are a commercially important group of the materials because their mechanical properties can be modified by treating and changing the microstructure. Age-hardenable aluminum alloys belonging to the Al–Cu–Mg system are widely used due to their attractive combination of high specific strength, good fracture toughness and enhanced creep resistance attributed to the highly efficient strengthening by the ?'-phase (Palmer, StJohn, Nie, & Qian, 2017). An AA2519 alloy exhibiting superior mechanical properties among high-strength Al–Cu alloys (2XXX-serie) due to minor Mg additives. It is known that, in alloys with high Cu/Mg ratio (=5.6) the classic precipitation sequence (Palmer et al., 2017; Wang & Starink, 2005; Wang et al., 2010) of supersaturated solid solution (SSSS) decomposition occurs: SSSS ? GP zones (Al3Cu) ? ?? (Al3Cu) ? ?' (Al2Cu) ? ? (Al2Cu) (1)"

Jan 1, 2018

By J-S. Marois, F. Cappucitti, Y. Dodier, D. Downey, G. Matton

"The flotation processes of the Niobec Mine have been affected by a seasonal loss of recovery and a significant increase in reagent consumption over the past few winters. This paper discusses the problem-solving methodology that was used to identify the root causes, to develop solutions and to implement changes that resolved the problem to restore the process to summer-like conditions year-round. Mainly, it was found that the process water was contaminated by phosphates ions, which adversely affected the carbonate pre-flotation, and caused detrimental effects on the subsequent niobium flotation. The phosphate ions were being generated by the process itself, but were consumed by algae in summer conditions. It was determined in laboratory studies that concentrations as low as 5 ppm were enough to affect the circuit and that the multiple additions of process water throughout the circuit was worsening the effect. Also, temperature was found to have an impact on the reagent performance. The performance of the plant was restored by implementing a natural treatment of our process water with a simple cost-free rearrangement of our circuit streams. In addition to that, our extensive geometallurgical program was used to provide ore to the plant restricting phosphate generation in the process. Also, a modification of the collector was developed and introduced in the carbonate pre-flotation that provided improved performance during the periods of low pulp temperature.INTRODUCTION Niobec is one the three major global producers of niobium presently in operation. Situated in the Saguenay-Lac-St-Jean region of Quebec and in operation since 1976, the site produces ferroniobium (FeNb) to be used mainly in High Strength Low Alloy (HSLA) steel, which is known to have better mechanical properties than carbon steel. The Niobec operation consists of an underground mine, a concentrator and a converter plant. The concentrator concentrates niobium-bearing minerals, mainly pyrochlore and columbite, to produce a high-content Nb2O5 concentrate which is then converted to FeNb in the converter plant by an aluminothermic reaction. The Niobec concentrator flowsheet, which has gone through many expansions and optimisation over the years, consists of grinding, desliming, flotation and leaching steps. The flotation steps are numerous, sensitive and difficult to operate due to the non-selective nature of oxide mineral collectors. Thus, the pyrochlore concentration process at Niobec still faces many challenges and is constantly going through periods of continuous improvement."

Jan 1, 2018

By S. G. Luckey, N. R. Harrison, F. Nadeau, U. Brüx

"The adoption of tailored-rolled or tailor-welded blanks (i.e. TRB/TWB) in the automotive industry has been known to offer great potential for the optimization of weight, function, cost and complexity. Vehicle light weighting can further be achieved by using high strength aluminum alloys like the 7xxx-series. 7xxx-series alloys are capable of delivering specific strengths equal to or greater than high strength steels. However, room temperature formability of this aluminum class is limited, so one approach to forming 7xxx-series alloys is by hot stamping. Hot stamping utilizes an elevated temperature blank and the high pressure stamping contact of the forming die to simultaneously quench and form the sheet. This paper explores the initial feasibility of tailored thickness material for body-in-white applications when processed under hot stamping conditions.INTRODUCTION Steel tailor-rolled blanks (TRB) or tailor-welded blanks (TWB) have been used within the automotive industry as a method of reducing weight, expanding material utilization, and decreasing overall part/assembly cost (Ganeasan et al., 2015; Merklein et al., 2014; Hirt et al., 2005; Kridli et al., 2000). The production of such tailored thickness materials has resulted in over $2.5 billion (2016) in combined industry sales (Mubea, 2018). As automakers begin to adopt the manufacturing practices traditionally reserved for steel such as tailor rolling/welding with greater enthusiasm for vehicle light weighting, there exist an opportunity to expand the material database to extend beyond the traditional aluminum alloys found in current production. High strength aluminum alloys, i.e. 7xxx-series, are ideal for structural automotive applications due to their high specific strength; however, they have limited room temperature formability. Hot stamping, another manufacturing practice used by the steel industry, can be used to form these high strength materials. The combination of tailoring the thickness of a sheet material and hot stamping provides an opportunity for significant weight saving within an existing manufacturing footprint. This paper explores the potential and challenges of this approach when applied to structural body-in-white components. The methods for tailor rolling, tailor welding and hot stamping are described and applied to the production of a 7075 aluminum alloy B-pillar. The results are discussed in terms of feasibility and weight savings."

Jan 1, 2018

By Hidenori Hatta, Takero Watanabe, Hideo Yoshida

"The effect of the quenching rate on age hardening in an Al-6.0mass%Zn-0.75mass%Mg alloy sheet was investigated. The quenching rates and aging conditions were as follows: water quenching (WQ) or furnace cooling (FC) followed by pre-aging at 20°C,then artificial aging at 120, 160 or 200°Cwere performed. The peak strength of the FC and the WQ are very similarat120°C aging. It is important high strength was obtained even at the extremely slow quenching rate. On the other hand, the strength of the WQ significantly decreased compared to the FCat200°C aging. GP(I) zones were formed during the pre-aging at 20°C even if the cooling rate was very slow like the FC, and were transformed into the GP(II) ones at 70°C or higher and then into the ?’ phase. However, these zones were dissolved by reversion during heating to 200°C. Thus the strength of the WQ decreased. On the other hand, it is considered that an unknown cluster or GP zone with a thermal stability formed during the FC was not dissolved up to 200°C and was transformed into the ?’ phase. Therefore, a higher strength was obtained in the FC for the200°Caging.INTRODUCTIONAl-Zn-Mg alloys are widely available in commercial production because these alloy have lower quench sensitivity and can be produced by air cooling (AC). Heat treatable aluminum alloys are usually produced by water quenching (WQ) to increase their strength because a high cooling rate inhibits the precipitation of the stable phase during cooling and increases supersaturated solute atoms. However, Baba(1967)reported the strength of an Al-6%Zn-1.8%Mg(mass%) alloy without additional elements quenched by very slow cooling (15°C/min) was 96% of that quenched by WQ. Furthermore,the age hardening at room temperature (RT) occurs after annealing at 410°C followed by furnace cooling (FC, 0.5ºC/min or less)in these alloys. Therefore, the process of annealing at 410 to 430°C for 120 min followed by AC, and reheating at 230°C for 240 min, then cooling is recommended in the specifications (Japan Aluminum Association, 2011). Matsuda and Yoshida(1996)also recommended annealing at 300°C for Al-Zn-Mg alloy extruded products to inhibit age hardening at RT by precipitating the solute atoms and decreasing them in the matrix. It has been considered that the higher the content of excess quenched-in vacancy becomes by WQ, the higher aging rate at RT is obtained. Therefore,it is theoretically and commercially important to clarify the reason why the age hardening occurs relatively quickly in almost no excess quenched-in vacancies such as the FC, and why the same strength as the WQ can be obtained in the FC"

Jan 1, 2018

By Francis Breton, Daniel Larouche, Pierre Heugue, Rémi Martinez

"Nowadays, in order to fit environmental restrictions, automotive markets are demanding cast aluminum alloys working at high temperature (180–300°C). New generations of alloys are required for higher strength components in engine downsizing or start-stop systems which lead to higher loading and higher specific power and stretch current materials to their limits. Recently, transition metals, such as zirconium and vanadium, have been added as alloying elements into an AlSi7Cu3.5Mg0.1 alloy to improve physical, mechanical, thermodynamic properties with the aim of increasing service life of parts. In such alloys, the best mechanical properties are associated with the formation of precipitates through an optimum heat treatment sequence, including: solutionizing, quenching and artificial aging. This study is focused on the modified AlSi7Cu3.5Mg0.1 cast alloy with Mn, Zr and V additions for high temperature application. The characterization of the cast alloy in this study, firstly, helps to evaluate and understand its performance both chemically and structurally according to their physical state: as-cast or as-quenched. Comparison of precipitation kinetics between a binary Al-3.5%wt.Cu alloy and the AlSi7Cu3.5Mg0.1 (Mn, Zr, V) alloy has been characterized by differential scanning calorimetry, TEM observations and micro-hardness testing. The Kissinger analysis was applied to extract activation energies from non-isothermal DSC runs conducted at different stationary heating rates. The study focuses on the impact of the chemical composition such as Si content on the kinetics parameters.INTRODUCTION Pure metal Aluminum shows poor mechanical properties and its malleability is high, that is why alloying elements are added to the mixture before casting to improve physical, mechanical and thermodynamic properties (Javidani, 2015); such as Silicon (Si) for casting properties (castability, cold crack capability, wear resistance, shrinkage behavior), Magnesium (Mg) and Copper (Cu) to generate precipitation hardening systems. Aluminum hypoeutectic alloys (<12% Silicon) with Cu, Mg additions used in the automotive industry for manufacturing mechanical parts (Larouche & Javidani, 2014) are mostly subject, after casting, to precipitation hardening heat treatment (Mohamed & Samuel, 2012) according to specifications and associated standards. The best mechanical properties are associated with the formation of precipitates through an optimum heat treatment sequence, generally including: solutionizing, water quenching and artificial aging (Manente & Timelli, 2011). Hypoeutectic aluminum-copper alloy with amount of Cu around 1 to 4.5wt% is an elementary case for precipitation in heat treatable aluminum alloys. Researchers essentially focused their work on the full precipitation sequence of binary Al-Cu alloy during aging which is presented below."

Jan 1, 2018

By S. Bozorgi, K. Anders

"The automotive applications of heat treatable AlCu cast alloys are designed for performance at high temperature, which can be improved using specially alloying element as well as different heat treatment. In this research work an effect of alloying element such as Cu, Ni and heat treatment on microstructures and mechanical properties of AlCu alloy were investigated using optical microscope (LIMI), scanning electronic microscope (SEM) equipped with energy dispersive X-ray detection (EDS), Differential scanning calorimetry (DSC) and mechanical testing. It was found that during solidification most of the elements Cu, Mg and Ni segregated at the grain boundaries in the form of Al2CuMg or Al7Cu4Ni and a very small part of Cu and Ni element dissolved in the FCC-Al matrix. The latter is not completely reclaimable for strengthening mechanisms in FCC-Al matrix in its as-cast state. The results of mechanical test show that yield strength and ultimate tensile strength increases after heat treatment significantly compared with the as-cast state. Furthermore the mechanical properties at elevates temperature (240°C) is higher with higher Cu+Ni+Si containing alloys compared with the less Cu+Ni+Si containing alloy.INTRODUCTION Due to the high strength-to-weight ratio, high strength and ductility at room- and elevated temperature, AlCuSi cast alloys are widely applied in the automotive industries specially for producing cylinder head and engine block, where modified alloys with enhanced metallurgical properties are always needed to satisfy the ever increasing demands for the applications. The AlCu based cast alloys can be strengthened by age hardening. The precipitation processes from which this hardening is derived can be attributed to the presence of selected trace element additions or micro alloying, which can change the process or kinetics of precipitation in age hardenable AlCu cast alloys (Polmear, 1998; Morris, 1991). Furthermore their strength is mainly controlled by the aging process through the precipitation and growth of very fine precipitates of the ?'-phase (a semi-coherent, metastable form of the equilibrium Al2Cu phase) from the Al and Cu Guinier-Preston (GP) zones. Several studies have shown that solute clustering occurs prior to the precipitation of GP zones, and this modifies both the nature and kinetics of the precipitation process. The typical size of GP zones is in the order of tens of nanometers, and the chemical composition of these precipitates is not easily measured, even with a typically analytical electron microscope (Polmear, 1989)."

Jan 1, 2018

By N. Birbilis, S. Kairy, C. R. Hutchinson, D. Jiang, D. R. Feenstra, O. Gharbi

"Recent developments in metal-based additive manufacturing (AM) technology have generated considerable interest in multiple industries, owing to flexibility in design and the ability to produce final components in their net shape. The AM of high-strength aluminium alloys has not been widely explored, due to findings of undesirable microstructures leading to short fatigue life and poor fracture toughness; restricting the application of AM to lower strength aluminium alloys (with cast-like Al-alloy compositions) to date. Herein, aluminium alloy AA2024 (Al-3.6Cu-1.2Mg) was additively manufactured via selective laser melting (SLM), with the resultant microstructures and corrosion properties characterised and compared to wrought AA2024-T3. Microstructural characterisation was carried out using transmission electron microscopy (TEM), revealing SLM produced AA2024 included a population of ?-phase (Al2Cu) in preference to S-phase (Al2CuMg) typical of wrought AA2024. Additionally, the corrosion properties were investigated by potentiodynamic polarisation in a range of NaCl concentrations, whilst elemental corrosion rates were also determined (including for open circuit exposure conditions) and quantified in situ with an inductively coupled plasma mass spectrometer coupled with an electrochemical flow cell. Results revealed a significant improvement in the corrosion resistance, and elemental dissolution of AM prepared 2024 relative to wrought AA2024-T3.INTRODUCTION Aluminium alloys remain the preferred candidate materials in applications requiring a balance of low density and strength. The ability to produce net shape components from aluminium alloys has accelerated due to recent developments in metal-based additive manufacturing (AM) technology, including selective laser melting (SLM) and powder bed 3D printing. The AM of Al-alloys, including Al-Si-Mg (namely AlSi10Mg), has become widespread commercially in recent years. Alloys including AlSi10Mg offer reliable and reproducible production by AM, however such alloys (and variants thereof) are not high strength alloys. The pursuit of higher strength AM Al-alloys presents significant merit to multiple industries; however, such higher strength AM Al-alloys have not been widely studied to date. The solidification of high strength Al-alloys during conventional (casting) operations needs to be executed in a manner that avoids so-called =hot-tearing‘, which can arise as a result of the solute type and loading. A report on the solidification of a high strength Al-alloy prepared by AM, along with factors related to solidification, was recently covered by Pollock and co-workers (Martin et al., 2017). It was reported that AM of high-strength aluminium alloys (which have to date been principally based on the compositions of wrought high strength Al-alloys) may lead to undesirable microstructures that reduce fatigue life and result in poor fracture toughness; presently limiting the application of AM to lower strength aluminium alloys (with cast-like Al-alloy compositions) to date."

Jan 1, 2018

By M. A. Vasina, I. A. Matveeva, E. A. Naumova, V. V. Doroshenko, N. A. Belov

"Using the calculated (Thermo-Calc software) and experimental methods (SEM, TEM, EMPA, DSC, XRD, etc.) the phase composition, structure and hardening of aluminium alloys of the Al-Ca-Zn-Mg system were studied in the following range: 2. 5%Mg, up to 10% Ca, and up to 14% Zn (wt%). Fragments of this quaternary phase diagram in the aluminium corner were constructed, including the liquidus surface, as well as some vertical sections. It was shown that the relatively large amount of zinc enters in the Ca-containing phase, which formula can be described as (Al,Zn)4Ca. An increase of Zn content leads to formation of Al4Ca primary crystals at lower concentrations of calcium. The eutectic (Al)+(Al,Zn)4Ca has a fine structure and aluminide particles are capable to spheroidization during the heat treatment at temperature 500 C. The maximal level of hardness observed on calcium containing alloys was higher than 200 HV, what gives the reason to expect good strength properties. With an example of an Al-9% Zn-2,5%Mg-3,5% Ca model experimental alloy based on the (Al)+(Al,Zn)4Ca eutectic, a principal possibility of manufacturing thin rolled sheets was demonstrated.INTRODUCTION Aluminum alloyed with calcium was first studied in 1970-80s by such authors as Piatti (1976), Moore (1978, 1980), Il'enko (1985), Swaminathan (1990), and Perez-Prado (1997) as superplastic materials. In particular, the alloy systems Al-Ca-Zn were studied (Il'enko, 1985, Swaminathan, 1990, Perez-Prado, 1997). For some time there was no new published works concerning the aluminum-calcium alloys. During the last years many works were published dedicated to the calcium alloying of magnesium alloys (Kim, 2011; Xu, 2011; Aljarrah, 2008; Bakhsheshi, 2014). This urged the authors (Belov, Naumova & Akopyan, 2016) to start studying cast and wrought aluminum-calcium alloys for construction (2008–2014). There is almost no information in the literature concerning triple and more complex diagrams of the aluminum-based system states with calcium and other elements. In recent work, parts of the state diagrams are plotted for the aluminum angle zone: Al-Ca-Mg-Sc (Belov, Naumova & Bazlova, 2016), Al-Ca-Ni-Sc (Belov, Naumova & Bazlova, 2017), Al-Ca-Si-Sc (Belov, Naumova & Akopyan, 2017) and others. Special attention was paid to the study of the system Al-Ca-Zn-Mg (Naumova, 2017). Based on this system creation of advanced extra-high tensile alloys is planned. Wrought extra-high tensile alloys series 7??? based on the system Al-Zn-Mg-Cu are well studied."

Jan 1, 2018

By Ram Song, Yohei Harada, Shinji Kumai, Kazuho Otsuka

"Recently, vertical-type high-speed twin-roll casting (HSTRC) has been developed. The HSTRC shows extremely high cooling rates over 1,000 K/s even at the mid-thickness area. The fabricated strip has many metallurgical characteristics; super-saturation of alloying elements, fine solidified structure, and homogeneous distribution of fine constituent particles. In Al-Mn based alloys, the Mn alloying element can be supersaturated in the a-Al matrix and also form Mn-containing constituent particles during solidification. The Mn supersaturation and the distribution of primary/secondary particles in cast products affect the metallurgical behavior in the down-stream processing and can improve mechanical properties of the final products. In this study, Al-Mn based alloy strips were fabricated by HSTRC with various Mn contents. The solidified microstructure, constituent particles and its distribution, and Mn solubility were investigated in the as-cast condition. Due to the high cooling rate of HSTRC, fine constituent particles were homogeneously distributed, and coarse intermetallics were not observed. Mn solid solubility was estimated by electrical conductivity. The estimated Mn solubility was equivalent between strip surface and mid-thickness area.INTRODUCTION Al-Mn based alloys, as non-heat treatable wrought aluminum alloys, are widely used in packaging and heat exchanger for automobile industry. Besides Mn, Al-Mn based alloys often contain Fe and/or Si as alloying elements or natural impurities. During solidification, Mn can be super-saturated in the Al matrix, and also form Mn-containing constituent particles. Additionally, in the subsequent thermal-mechanical processes such as homogenization, rolling, and intermediate annealing, Mn in solid solution precipitates out of the Al matrix as secondary particles. The size, distribution, type, and the amount of dispersoids including constituent particles affect to texture evolution, recrystallization behavior, and final mechanical properties of wrought Al-Mn based alloys (Huang et al., 2016; Huang & Marthinsen, 2015; Engler et al., 1995; Muggerud et al., 2013). Therefore, controlling the initial level of Mn super-saturation and the distribution of constituent particles are important in the cast Al-Mn based alloys."

Jan 1, 2018

By F. Andrieux

"Extruded aluminum profiles are increasingly used for lightweight vehicle construction. Since fracture strains of aluminum profiles are relatively low, damage modeling is crucial for reliable crash simulation. For aluminum profiles, not only the stress state but also the orientation influenced both the deformation and damage behavior. For the material characterization smooth tensile tests were performed in six orientations, both stress-strain curves and r-values were registered. Moreover notched tensile and shear-tension tests were performed in three directions. Finally punch specimens were tested to investigate biaxial loading. Digital image correlation (DIC) analyses were performed to determine local strain values such as critical values at failure. Numerical investigations were conducted with the strain based damage model GISSMO, which is well suited and widely applied for crash simulation. For a strain based failure model the choice of the deformation model is crucial. Deformation models with increasing complexity were investigated to find the best compromise over all experiments. It was found that there is still a great requirement on development of a material model which describes the orientation dependence of the hardening behavior over all stress states in order to be able to use a strain based failure model reliably.INTRODUCTION Weight reduction is an important step for less energy consumption and as a consequence aluminium is increasingly used in automotive parts. An important field of application is the well-established aluminium extrusion which allows the realisation of quite complex shapes of profiles required for an innovative lightweight design with integrated functions. Typical applications are chassis parts, bumpers, crash elements, air bags, etc. Especially the Al–Mg–Si medium strength alloys of the 6000 series can be easily extruded to form complex profiles and prevail for extrusion. Since fracture strains of aluminum profiles are relatively low, damage modeling is crucial for reliable crash simulation. For aluminum profiles not only the influence of the stress state but also the orientation with respect to the extrusion direction have an influence on both the deformation and damage behavior and need to be characterized. The effect of orientation on deformation behavior has been intensively investigated in the last decades and material models haves been proposed (e.g. Barlat & Lian, 1989; Barlat, Lege, & Brem, 1991; Barlat et al., 2003) to describe accurately anisotropic behavior. However it can be noticed that the parameters of anisotropic material models often rely on the yield stress in different directions, which means that the effect of strain hardening is not automatically accounted for. The accuracy of the models at large deformation is not guaranteed and has to be verified. In contrast to deformation models both the characterisation and the modeling of anisotropic damage behavior are not systematically studied. Isotropic failure models based on a critical strain as function of stress triaxiality (ratio of the hydrostatic stress to von Mises equivalent stress) are widely used for crash application (e.g., Bai & Wierzbicki, 2010; Sun, Andrieux & Feucht, 2009; Sun et al., 2013). The mechanisms of failure are manifold and not fully understood; to develop an anisotropic failure model it is mandatory to also have experimental data in different orientations for loading scenarios other than uniaxial tension, e. g. shear, biaxial tension, which implies an extensive experiment plan. This makes the development of failure models more challenging than deformation models for which it is possible to develop a reasonable anisotropic model using the framework of yield function and calibrate the material parameters based on results of tensile tests in different directions. Moreover the development of deformation and failure models are intricate as the variables governing the damage evolution are predicted by the def"

Jan 1, 2018

By C. K. Baxter, A. Odeshi, M. Mohammadi, E. D. Cyr

"Metal additive manufacturing has been a revolutionary step in designing new complex shapes with faster and cleaner building capacity in comparison to subtractive manufacturing processes. The ability to print lightweight alloys such as aluminum has made metal 3D printing attractive to different industrial sector from aerospace to energy and bioengineering. Of particular interest in this study, are the mechanical and microstructural properties of AlSi10Mg-200°C alloys. In this project, samples were 3D-printed in horizontal direction using an EOS M290 machine by Direct Metal Laser Sintering (DMLS) technique. Uniaxial tensile tests and high strain-rate impact e tests were carried out to investigate the mechanical properties and to study the repeatability of the process. A constitutive model is developed to predict the results of the mechanical tests at varying strain rates to better understand the high strain-rate behaviour of these alloys. Using optical microscopy, features such as scan tracks and melt pools within the AlSi10Mg-200°C samples were observed, and the microstructure was observed to be homogenous. The previously listed tests were compared to the results obtained for similar cast alloy counterpart, i.e. A360.0.INTRODUCTION A relatively new way of manufacturing parts is on the increase as rapid prototyping becomes increasingly popular throughout the world. Additive manufacturing is a process which, given a 3D model, uses metallic material in powder form to build a part layer by layer until completion (Gu, Meiners, Wissenbach, & Poprawe, 2013). This way of rapid prototyping is very attractive in comparison to other possibilities because of its ability to accommodate complex design and geometries. Conventional manufacturing methods have limitations when it comes to complex geometries, but additive manufacturing allows for increased design flexibilities while maintaining a light and stable final product (Murr et al., 2012). It also allows for a reasonable cost, especially for small batch sizes that would otherwise be extremely expensive."

Jan 1, 2018

By Jan Kvinge, Aina Opsal Bakke, Yanjun Li, Jan-Ove Løland, Svein Jørgensen

"Compound casting is a very attractive approach to reduce the weight of components for some specific applications while keep both the functional and the mechanical property requirements. In this work, Al-7Si-Mg alloy /copper compound castings were produced through a low pressure die casting process. To reduce the oxide present in the interface, flux coating of the copper pipes was tested. The interface layer formed between the two alloys was investigated using Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS). Vickers Micro-hardness was also measured across the interface. Results showed that the flux coating prevented the formation of the metallic bond between copper and aluminum. Instead, high concentrations of potassium, magnesium and fluoride, coinciding with formation of KMgF3 and MgF2, were detected in the interface. In the castings without surface treatment, a continuous metallurgical bond was achieved. In the bond layer, various Al-Cu intermetallic phases have been detected. In addition, formation of primary silicon particles in the reaction layer was observed in all castings. The mechanism for the formation of the intermetallic phases and the strength of the interface layer have been discussed.INTRODUCTION Recent development in the automotive industry has focused on producing lightweight components, which can reduce CO2 emission and increase the efficiency. Often, one material alone is not able to meet the requirements for a specific use. The need for lightweight bimetallic components has therefore increased. Aluminum-copper bimetallic components can be used in wires and bus bars where conductivity is an important factor (Lee, Bang, & Jung, 2005). Compared to Al-Cu alloys, Al-Cu bimetallic components can reduce both weight and cost without reducing electrical and thermal conductivity (Sheng, Yang, Xi, Lai, & Ye, 2011). A challenge is, however, that aluminum and copper have high affinity to each other, especially at elevated temperatures. This causes formation of brittle intermetallic phases with high electric resistance (Liu, Wang, Sui, Wang, & Wenjiang, 2016). In addition, both metals are subjected to oxide formation on the surface. Copper is especially exposed to oxidation at elevated temperatures (Pinnel, Tompkins, & Heath, 1979), while a thermodynamically stable oxide layer will spontaneously form on the aluminum surface (Papis, Loeffler, & Uggowitzer, 2009). Oxides are known to be passive substrates, which will reduce wettability and will thus prevent the formation of metallic bonding between aluminum and copper (Papis, Hallstedt, Löffler, & Uggowitzer, 2008)."

Jan 1, 2018

By G. Scamans, J. Lazaro-Nebreda, Z. Fan, J. B. Patel

"Melt quality is crucial for both continuous and shape casting of light alloys and in order to improve it, removal of excessive inclusions, accumulated impurities and unwanted gases becomes necessary. To address this problem, a new multi-purpose high shear liquid metal treatment technology, based on intensive melt shearing by a rotor/stator unit, has been developed. The device ensures achieving uniform temperature and chemical composition and an efficient dispersion of gas and solid phases in the melt with minimal disturbance of melt surface, and can be used, among other things, for de-gassing and de-ironing of Al-alloy melts. Efficient degassing is achieved by dispersing each argon bubble into many small ones, which significantly increases the overall surface area of the bubbles and the time they remain in the melt capturing hydrogen before reaching the surface. This allows using much lower inert gas flow and mixing times than conventional rotary degassing. When applied to Al-alloy scrap, with accumulated iron, the high shear melt treatment speeds up the nucleation and growth of primary Fe-rich intermetallic particles, allowing a faster removal rate. Therefore it reduces processing times, increasing recycling productivity, and facilitates full metal circulation of secondary Al-alloys.INTRODUCTION Aluminium and magnesium alloys are widely considered in various industrial sectors for the purpose of weight saving (Polmear, 1995). In particular, they are used in the automotive sector, where components are mostly manufactured by high pressure die casting (HPDC) because of its simplicity and relatively low cost, but efficiency and mechanical properties are quite low compared with other processes. To date, the main focus to overcome this problem has been for improving the HPDC machinery (Dahle, 2001) but little attention has been paid to the opportunities of controlling the nature and quality of the molten metal supplied to the die. In this way, liquid metal treatment, which involves a variety of physical and/or chemical processing methods to improve melt quality prior casting, is crucial for both continuous and shape casting products."

Jan 1, 2018

By J. Fixter, P. Prangnell, Z. Pinter, E. Eimer, B. Chehab

"High deposition rate Wire and Arc Additive Manufacture (WAAM) can provide benefits to the aerospace industry, including a reduction in lead time, reduced material waste and, through higher solidification rates, refinement of the as-built microstructure relative to a cast material. However, candidate 2xxx series high strength alloys for this process normally require a solution treatment, which is problematic for large near-net-shape components, and age hardening to achieve maximum mechanical properties. With each layer being subject to multiple thermal cycles, exploiting the thermal conditions in the WAAM process to avoid post-build solution treatment is therefore of interest. A solutionisation model has been developed for the WAAM process, based on diffusion controlled dissolution using DICTRA, which was validated through thermal simulations combined with 2D and 3D image analysis. The model has subsequently been used to simulate the solutionisation behavior during a typical WAAM thermal cycle and to explore what could theoretically be achieved by, for example, refining the starting microstructure.INTRODUCTION There is currently great interest in exploiting additive manufacturing (AM) in the aerospace sector due to several benefits it can potentially provide; including reduced material waste, shorter product lead times and greater design freedom (Herzog, Seyda, Wycisk, & Emmelmann, 2016). However, with aluminium alloys the material properties obtained are generally inferior to those of conventional high-strength wrought products; therefore more research is required to explore the potential for exploiting the unique process conditions in AM to improve the as-deposited microstructure. A range of AM techniques are now available (Debroy et al., 2018), which differ in terms of the feedstock type and power source and it is necessary to match the appropriate technology to a particular application. This generally requires a compromise between the build rate and shape resolution. Wire and plasma-arc additive manufacturing involves using an electric arc to melt wire onto a substrate, and fabricates a part by building up overlapping layers of deposited weld beads (Addison et al., 2015; Williams et al., 2015). The benefits of this process over other AM methods are the much higher deposition rates (e.g. kg’s/hour) achievable and lower capital equipment costs relative to powder bed techniques, which makes it suitable for large scale applications. However, limitations include a lower part complexity, lower solidification rates and a greater need for post-process machining (Frazier, 2014)."

Jan 1, 2018

"Conveyed coal flows have been diverted on the basis of real time ash analysis since the 1980s. Many coarse particle separation methods are available through screens, jigs, heavy media separation, particle sorters, to name a few, however bulk diversion requires a representative, continuous analysis to ensure diversion decisions can be made with confidence. Sensors also need to be able to provide measurements at useful time increments so that small tonnages can be diverted for maximum selectivity. Particle separation typically requires high capital costs and there are limitations either in throughput tonnage or particle size or both. Few techniques are able to provide robust and representative analysis of conveyed flows in a useful time basis. Prompt Gamma Neutron Activation Analysis provides multi-elemental analysis of conveyed bulk materials and has been proven in the minerals industry since 2003. This paper outlines the success of this technology in minerals applications in iron ore, phosphate rock and most recently in copper-gold ores, including its use in bulk diversion.INTRODUCTION Naturally occurring quality variability, or heterogeneity, in mineral deposits enables separation and recovery of the valuable components through mining and processing operations. There are distinct advantages in processing the minimum quantity of material to achieve the highest possible yield. Unfortunately, declining ore grades has resulted in larger scale operations and a subsequent loss in selectivity for mining operations. As limits are approached on the practical size of equipment, there is more motivation to investigate alternative solutions. Mining companies are subject to increasing social resistance to growing waste disposal requirements in addition to higher energy and transport costs. Major savings are available by reducing the quantities of material processed where pre-concentration can be effectively applied at early stages in the process. One of the simplest ways to pre-concentrate is to measure the bulk material and reject waste soon after mining so that minimal expense is incurred and that only higher quality material is sent to processing operations. This bulk sorting can occur within the mining operations and has major benefits through energy and other consumables savings. This paper discusses the application of real time analysis technologies suitable for bulk sorting within the minerals industry. Technology that has proven representative for conveyed material bulk analysis and its successful applications to date is explained. Analysis using a sensing technique is only one component of a successful bulk sorting process; the importance of effective diversion systems and a bulk sorting strategy are also discussed. The bulk sorting stage may be one component of a system that could include additional downstream technologies such as particle based sorting systems on a diverted stream."

Jan 1, 2018

By W. Lodge, G. Rasmussen

"The carbon-in-pulp (CIP) process has been the dominant gold recovery technology since the 1980s. During all this time carbon measurement, and control of the carbon transfer pumps has been largely manual in nature. Such manual operation inevitably limits process efficiency, potentially resulting in higher gold solution losses, and higher cost of circuit operation. Based on the authors’ experience, average plant solution loss is in the range of 0.02-0.03 ppm Au, as opposed to the general industry target of 0.01 ppm Au or less. Gekko Systems, in conjunction with Curtin University’s Gold Technology Group, has developed a carbon concentration meter, the ‘Carbon Scout’ meter. The meter automatically measures carbon concentration in all tanks, providing more frequent and more precise data. Combined with SIMCIL, a CIP circuit process model which is used to determine the optimum set points for the circuit, the meter should ensure lower gold solution losses, and more efficient operation of the carbon circuit. This paper will review they critical factors for good carbon management, the development of the meter and results from the first plant installation. Additional benefits of the Carbon Scout, including improved health and safety and the opportunity to measure other key variables in the leach/adsorption circuit from one central location will also be described.INTRODUCTION The carbon-in-pulp (CIP) process was first introduced to the gold industry in the early 1950s at the Carlton Mill in the USA (Fast, 1988), with the modern version of CIP becoming fully developed with large scale installations in South Africa in the late 1970s (Laxen, 1982). CIP quickly became the technology of choice for new operations, and for the retrofitting or upgrading of existing operations. In the 1980s the carbon-in-leach (CIL) circuit configuration became the process design of choice due mainly to its lower capital costs. With 40 years of operational experience, CIP/CIL for gold recovery is now mature a technology, whose operations and limitations are well understood. To extract further efficiencies from such technologies, by improving recoveries and/or reducing operating costs, is challenging and may require new approaches to circuit management. Gekko Systems, in association with the Gold Technology Group at Curtin University, has developed the Carbon Scout, an automated carbon measurement device. This device replaces manual measurement of carbon concentration in carbon adsorption tanks, providing more frequent and more accurate data for control of the CIP process. Data from the Carbon Scout can be used to automatically control the carbon forwarding pumps."

Jan 1, 2018

By D. J. Lloyd

"Bending is involved in the forming of many sheet parts and it is important to understand the phenomena involved. In this paper the basic equations describing bending on a global scale are compared with strain measurements of bent sheet. The development of strain on a local, microstructural scale is also investigated, as is the general aspects of plasticity and the failure process. It is shown that the global equations can be used to estimate the strains involved and the local strains can be attributed to various aspects of the plasticity. The bendability can be related to the fracture strain of the sheet and the ability of a sheet alloy to accommodate the necessary bending to form the part can be assessed.INTRODUCTION The ability of a sheet alloy to undergo bending without failure is an important capability in the forming of many parts and it is useful to be able to assess the bendability of an alloy during its development. The basic mechanics of bending were developed in the 1950s (Lubhan & Sachs, 1950; Hoffman & Sachs, 1953). When a sheet is bent the upper bend surface is in tension, the lower surface in compression and at some point within the sheet there is a plane of zero strain which is referred to as the neutral axis. For sheet exhibiting limited plasticity the neutral axis is static and occurs at the mid-point of the sheet thickness but for sheet exhibiting extensive plasticity the neutral axis progresses deeper in to the sheet as bending progresses. This results in two expressions for the maximum strain at the upper bend surface depending on the motion of the neutral axis. For Al alloys such as AA6111, AA6016 and the like extensive plasticity occurs and the neutral axis is expected to move during bending. However, very few studies have examined how the neutral axis motion and the strains develop, compared with the mechanics analysis. Geist and Parker (1984) used hardness measurements to investigate neutral axis motion but these experiments did not have the resolution necessary to compare the results with experiment but did indicate neutral axis motion. To understand the nature of plasticity and failure during bending it is important to know the extent of neutral axis motion, the scale of strain gradients developed through the sheet and the maximum strains occurring at the bend surface, finally comparing experimental results with the theoretical predictions. The influence of microstructure on the evolution of strain and failure can then be considered in the context of these parameters. Recently, bending in some automotive Al alloys has been reported mainly from the microstructural perspective (Lloyd, 2000, Lloyd et al., 2002, Mattei et al., 2013) and FEM studies have also investigated the development of plasticity under bending, demonstrating the tendency for strain localization (Becker, 1992, Shi et al., 2014)."

Jan 1, 2018