New Aluminum Alloys for Cylinder Liner Applications

Krug, Peter; Foss, James

doi:10.4271/2006-01-0983

Cited by 11 publications

(9 citation statements)

References 1 publication

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“…After loading with 185 MPa during N f = 3.3 × 10 8 cycles, very finely dispersed pores become visible and, adjacent to this, an increased concentration of Si. It is assumed that larger Si particles were sheared during the extrusion process, and the subsequent flow of matrix material around the newly formed small particles was too slow to cover them, meaning that cavities accumulated between them . Approximately 67% of the interior cracks show porous areas, with an element distribution like the matrix, plus an increased amount of Si.…”

Section: Discussionmentioning

confidence: 99%

“…Because interior fatigue cracks are predominantly formed at a very high number of cycles, the ultrasonic fatigue method was used in the experiments for this research, and conventional‐frequency equipment was also used for the purpose of making comparisons . Three groups of materials were tested, namely medium‐strength martensitic 12% Cr steel, spray‐formed hypereutectic aluminium–silicon alloy DISPAL©S232 and polycrystalline copper . Their chemical composition, heat treatment and mechanical properties are summarized in the following: Martensitic 12% Cr‐Steel AISI 403/410, X20Cr13 was used with a chemical composition (wt%) of: 11.9 Cr, 0.41 Mn, 0.33 Ni, 0.22 Si, 0.18 Mo.…”

Section: Methodsmentioning

confidence: 99%

“…DISPAL©S232 AlSi17Fe4Cu3MgZr served as a specially manufactured aluminium alloy with a nominal chemical composition (wt%): 17 Si, 4 Fe, 3 Cu, 1 Mg, <1 Zr, balance Al. The production process of the DISPAL©S232 included melting and rapidly solidifying, subsequently extruding seamless, non‐porous tubes and finally T6x solution annealing, quenching and artificial ageing as detailed in . The resulting microstructure consists of α‐aluminium with intermetallic compounds (Mg 2 Si and AlFeSi).…”

Section: Methodsmentioning

confidence: 99%

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Fracture mechanical characterization of the initiation and growth of interior fatigue cracks

Stanzl-Tschegg

2017

Fatigue Fract Eng Mat Struct

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The formation and growth of interior fatigue cracks have been studied thoroughly during the last decades, due to the high practical importance of accurate predictions about the fatigue lives of structures and machine components. This is of special interest in the VHCF regime, for which the ultrasonic fatigue method is especially useful. Fracture mechanical values and lifetimes can be measured at constant and variable amplitudes. Endurance limits and ΔK thresholds can also be determined very quickly (e.g. 1010 cycles within a few days). Three different materials were studied. For chromium steel, internal crack formation and a fracture mechanical analysis of its growth were carried out. For a specially manufactured Mg alloy, microstructural features leading to interior cracks were analysed. Finally, for polycrystalline high‐purity copper, the conditions for interior‐crack formation and growth were determined. The utilization of FE‐SEM microscopy assisted in interpreting the prevailing mechanisms responsible for endurance limits, lifetimes and fatigue‐crack growth thresholds.

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Section: Discussionmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

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Fracture mechanical characterization of the initiation and growth of interior fatigue cracks

Stanzl-Tschegg

2017

Fatigue Fract Eng Mat Struct

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“…Production of the material is described in Ref. . The manufacturing process starts with melting the alloy and spraying it through a nozzle into a nitrogen atmosphere.…”

Section: Materials and Experimental Proceduresmentioning

confidence: 99%

“…Spray‐formed hypereutectic aluminium silicon alloys offer great potential to be used for technical components when excellent mechanical properties and low weight are required. These alloys can be produced to have higher stiffness, greater high temperature strength, excellent wear resistance and a reduced coefficient of thermal expansion compared with cast or wrought aluminium alloys . Because spray forming is a single‐step Powder Metallurgy (PM) process, production costs are substantially lower compared with conventional PM alloys .…”

Section: Introductionmentioning

confidence: 99%

Variable amplitude loading of spray‐formed hypereutectic aluminium silicon alloy DISPAL® S232 in the VHCF regime

Fitzka¹,

Mayer²,

Schuller³

et al. 2014

Fatigue Fract Eng Mat Struct

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Spray‐formed hypereutectic aluminium silicon alloy DISPAL® S232–T6x is cycled with variable amplitude at ultrasonic frequency up to the very high cycle fatigue (VHCF) regime under fully reversed tension–compression loading. The Powder Metallurgy alloy is tested using a Gaussian cumulative frequency distribution of load cycles, and lifetimes are compared with constant amplitude data. Miner calculation delivers mean damage sums between 0.5 and 0.9 for mean lifetimes between 8 × 107 and 1.6 × 1010 cycles, respectively. Cracks are initiated at voids, at inclusions or at distributed inhomogeneities (porous areas or oxides) at the surface or in the interior. In situ analysis of vibration properties indicates that cracks are formed and start growing from the beginning of fatigue cycling, even if failure occurs in the very high cycle fatigue regime. Crack initiation stage is negligible. Lifetime prediction calculation is performed using an adapted Paris‐law and considering lifetime as cycles necessary to propagate an initial crack to failure. Measured and predicted mean lifetimes differ by factor 0.4–1.0. Large crack‐initiating defects strongly reduce the fatigue lifetimes, which is successfully covered in the crack propagation model.

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Spray Forming of Aluminium Alloys

Krug

2017

Metal Sprays and Spray Deposition

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New Aluminum Alloys for Cylinder Liner Applications

Cited by 11 publications

References 1 publication

Fracture mechanical characterization of the initiation and growth of interior fatigue cracks

Fracture mechanical characterization of the initiation and growth of interior fatigue cracks

Variable amplitude loading of spray‐formed hypereutectic aluminium silicon alloy DISPAL® S232 in the VHCF regime

Spray Forming of Aluminium Alloys

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