1,720,970 research outputs found
Enhancing Aluminum Alloy Properties Through Low Pressure Forging: A Comprehensive Study on Heat Treatments
No full textThe weight reduction is a key objective in modern engineering, particularly in the automotive industry, to enhance vehicle performance and reduce the carbon footprint. In this context aluminum alloys are widely used in structural automotive applications, often through forging processes that enhance mechanical properties compared to the results for casting. However, the high cost of forging can limit its economic feasibility. Low pressure forging (LPF) combines the benefits of casting and forging, employing controlled pressure to fill the mold cavity and improve metal purity. This study investigates the effectiveness of the LPF process in optimizing the mechanical properties of AlSi7Mg aluminum alloy by evaluating the influence of three different magnesium content levels. The specimens underwent T6 heat treatment (solubilization treatment followed by artificial aging), with varying aging times and temperatures. Microstructural analysis and tensile tests were conducted to determine the optimal conditions for achieving superior mechanical strength, contributing to the design of lightweight, high-performance components for advanced automotive applications. The most promising properties were achieved with a T6 treatment consisting of solubilization at 540 °C for 6 h followed by aging at 180 °C for 4 h, resulting in mechanical properties of σy 280 MPa, σm 317 MPa, and A% 3.5%
Numerical and experimental analysis of a high pressure die casting Aluminum suspension cross beam for light commercial vehicles
No full textThe purpose of the present paper is to enhance and deepen the lightweight optimization in automotive, in particular for commercial vehicles and buses. In detail, aim of this research is to develop a technically reliable and cost effective safety component for Light Commercial Vehicles (LCVs) in aluminum alloy. At this purpose, different solutions of Aluminium Cross beams for an independent front suspension for LCVs have been analyzed, with a weight saving target in comparison with the traditional welded sheet metal structure of almost 40/50%. Moreover further environmental advantages have to be considered; for instance improved corrosion resistance, no painting or cataphoresis required, benefits on recyclability and residual value at the end of life. In detail, the goal of this project has been achieved through: technical and economical study of some different lightweighting solution and selection of the best case; improvement of the solution selected with the help of structural FEA and casting process simulations, a Life Cycle Assessment from cradle to grave (not here described), prototypes realization and preliminary experimental correlation
Additive Manufacturing for Rapid Sand Casting: Mechanical and Microstructural Investigation of Aluminum Alloy Automotive Prototypes
Full text linkThe automotive industry is undergoing a rapid evolution to meet today's challenges; therefore, continuous innovation and product development are needed. Validation tests on prototypes play a crucial role in moving new components into industrial production. There is also a pressing need for faster prototyping processes. In this context, rapid sand casting (RSC), based on additive manufacturing technology, offers a promising solution for a quick production of sand molds. While this technology is already employed in the industry, the need to deepen the general understanding of its impact on the casting properties is still a relevant item. In this study, different geometries of automotive prototypes made of aluminum EN AC 42100-T6 alloy were experimentally analyzed. Microstructural examinations, tensile tests, and fractography and porosity analyses were conducted. The findings demonstrate the considerable potential of RSC, giving, in general, high mechanical properties. A comparative analysis with prototypes produced through traditional sand casting revealed similar results, with RSC exhibiting superior yield strength and stress at brake. However, both technologies revealed a reduced elongation percentage, as expected. Future efforts will focus on standardizing the RSC process to enhance ductility levels
Effect of fiber orientation and residual stresses on the structural performance of injection molded short-fiber-reinforced components
No full textThe increasingly need of lightweight structures in different sectors is driving new researches about the substitution of metal with polymeric matrix composite. Objective of this work is to optimize the strength design of short-fiber injection molding manifold block, originally made with brass, with the aid of a three-dimensional flow and structural analysis simulations. These Finite Element Analyses (FEA) were based on orthotropic, linear and elastic models including process-induced residual stresses. Through an appropriate interface, the results of injection molding analysis of 35 wt.% fiber reinforced polyphthalamides (PPA) manifold block are transferred to the structural analysis software. Autodesk Moldlfow software was used to predict the fiber orientation and the in-cavity residual stresses considering the flow kinetics and moulding parameters. The Abaqus interface for Moldflow was used to translate this data into a form that can be used for the structural analysis. Finally, this paper reports some experimental tests carried out on the injection moulded component in order to evaluate the internal burst pressure values. The results not only highlighted the importance of carrying out structural simulations, which consider both the orientation of the glass fibre and the residual stresses given by molding, but also showed the usefulness and accuracy of an integrated CAD-FEA approach. The application on a real case demonstrated good agreement with numerical analysis predictions
The effect of partial recrystallization on the corrosion resistance of EN AW6082 forged components evaluated with different tests
No full textStructural automotive components are extensively made of aluminum alloy forgings, due to the elevate strength and low weight required. These products are frequently subjected to recrystallization. Recrystallization, often limited to surface or forging portions, is expected to reduce its tensile strength and corrosion resistance, but the literature is scarce on this subject. For a more comprehensive understanding, the present research studied the corrosion behavior of samples collected from EN AW 6082-T6 forged components, designed to expose both recrystallized and not recrystallized surfaces to the corrosive environment. Several standardized corrosion tests (i.e., PV 1113, ISO 11846, and VW 96380) were applied to assess the most representative with respect to real field exposure. Tensile tests were performed in four different conditions, recrystallized and not recrystallized specimens in an as-forged state or after corrosion. The recrystallization led to a reduction in tensile properties, but this gap was compensated by a higher corrosion resistance than the not recrystallized samples. Consequently, the mechanical properties became comparable after the corrosion test.The main purpose of the paper is to study the effect of recrystallization phenomenon, typically encountered in aluminum alloy forgings, on tensile and corrosion resistance. The results highlight the fact that recrystallization reduced the tensile properties, but the corrosion resistance is higher than that of not recrystallized samples. Consequently, the mechanical properties are comparable after the corrosion test. imag
Wear and Corrosion Characterization of a Ti–6Al–4V Component for Automotive Applications: Forging versus Selective Laser Melting Technologies
No full textSelective laser melting (SLM) is applied to manufacture a Ti–6Al–4V conrod, an engine component, in order to reduce the weight respect to the original version produced by forging with the same alloy. The weight reduction is achieved through a topological optimization and is about 15%. The article focuses on an experimental study of titanium SLM and hot forging components based on evaluation and comparison of properties relevant for automotive applications: metallurgy, corrosion behavior, and wear resistance. The microstructure is duplex, composed of equiaxial α and β grains for both the technologies analyzed; different morphology and distribution of α and β phases are observed as expected. The analysis on corrosion and wear resistance against 100Cr6 highlights very similar properties for the two technologies. Finally, this study confirms that Ti–6Al–4V made by SLM can substitute the traditional forging technologies in the transport field for the properties here studied
Metal Inert Gas (MIG)–Cold Metal Transfer (CMT) and Fiber Laser–MIG Hybrid Welds for 6005A T6: Experimental and Numerical Comparison
No full textAbstract: The microstructural and hardness properties of welded joints of AA 6005-T6 aluminum alloy obtained with metal inert gas (MIG), fiber laser–MIG hybrid, and cold metal transfer (CMT) welding were analyzed immediately after welding and after 3 years of natural aging. The fine hardening precipitation within the heat-affected zone, fusion zone, and base material was characterized by differential scanning calorimetry for the three different welding techniques. The elastic–plastic properties of the welded joints were characterized by means of finite element. For all investigations, the analysis on AA6005 aluminum alloy confirms a better behavior of CMT and fiber laser–MIG hybrid joints with respect to the conventional MIG processes. Graphic Abstract: [Figure not available: see fulltext.]
Corrosion behavior of primary and secondary AlSi high pressure die casting alloys
No full textThis work characterized and compared the corrosion resistance of a traditional secondary HPDC AlSiCu alloy with two innovative AlSi low-Cu and low-Fe ones. Samples were collected from both the bulk and the skin of castings to evaluate the differences. Potentiodynamic tests were performed in 3.5% NaCl and 0.05 M Borax + 0.01 M NaCl water solutions and microstructural analyses have been carried out. The results demonstrated the higher corrosion resistance of the two innovative alloys tested. Skin surface showed a worse resistance compared to bulk, especially for the traditional AlSiCu alloy
A comparative cradle-to gate impact assessment: Primary and secondary aluminum automotive components case
No full textRoad transports release a significant percentage of global CO2. In this field, one of the most effective solution is the reduction of vehicles' mass, which can be obtained through the substitution of heavy metals with light alloys (i.e. aluminum). In addition, in order to maximize the environmental benefits a current trend is to use secondary material (from scrap) in substitution to primary one (from ore). For this purpose, the present case study compared the environmental burden related to the same light-weighted automotive component (suspension cross beam) made in primary aluminum (from ore) or in secondary one (from scrap). In particular, a cradle to grave Life Cycle Assessment has been analyzed through the software SimaPro 7.3 with the Recipe impact method. The study highlighted and confirmed the relevance of the environmental benefits related to recycling and secondary material use
Evolution of prototyping in automotive engineering: a comprehensive study on the reliability of Additive Manufacturing for advanced powertrain components
Full text linkAdditive manufacturing (AM) could be used to reduce the production times of prototypes; however, further research is required to address metals structural parts. To obtain the correct properties, some relevant factors to be considered are the build volume, shape factor, and the need for specific heat treatments. This study aims to evaluate the reliability of AM prototypes applied at a new powertrain system developed to reduce vehicle emissions. Firstly, it was investigated the mechanical behavior, microstructure, and the effect of sample size and heat treatments on both specimens and prototypes made of AM 17-4PH steel. Finite Element Analysis (FEA) was performed to evaluate the structural resistance. Finally, the prototypes were produced, analyzed, and tested on a functional engine test bench to evaluate their reliability. The mechanical properties decreased with an increase in the sample volume. After heat treatment, the yield strength increased, due to the transformation of δ-ferrite in martensite and the reduction of retained austenite. The engine test bench was successfully completed. The conclusions set the basis for similar future applications of time-effective prototypes that can be dimensioned owing to appositely developed postprocesses that guarantee the required resistance
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