Solid-State Recycling of Aluminum Alloy (AA-6061) Chips via Hot Extrusion Followed by Equal Channel Angular Pressing (ECAP)

Selmy, A.I.; Aal, Mohamed Ibrahim Abd El; Elgohary, Ahmed; Taha, Mohamed

doi:10.21608/eijest.2016.97183

Cited by 13 publications

(15 citation statements)

References 38 publications

(61 reference statements)

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“…So, there were no further increases after 5% B4C and the 4 th pass of hot ECAP. Rifai et al (2014) and Selmy et al (2016) confirmed with their observations that the improvement on the MMCs matrix is related to the good bonding between chips and particles during the ECAP process, in which the extensive materials deformations broke up the oxide films on the surface of the sample. Therefore, the material surface ensures better contact bonding between chips.…”

Section: Compressive Strength Testsupporting

confidence: 75%

“…The recycled MMCs after pass four had the highest hardness value, and the overall hardness values gradually increased as a result of increasing the sample's number of passes. The main reason for the material hardness values enhancement was the presence of the total strain and die fraction on the high angle boundaries (Haghighi et al 2012;Selmy et al 2016). The highest value of hardness was achieved for 4 th pass, and it is due to the material work hardening, which results in the formation at the initial stage of the hot ECAP process.…”

Section: Hardness Testmentioning

confidence: 99%

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Development of Hot Equal Channel Angular Processing (ECAP) Consolidation Technique in the Production of Boron Carbide(B4C)-Reinforced Aluminium Chip (AA6061)-Based Composite

Al-Alimi

Lajis

Shamsudin

et al. 2021

Int. J. Renew. Energy Dev.

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The production of metal matrix composites (MMCs) through recycled materials is a cost-saving process. However, the improvement of the mechanical and physical properties is another challenge to be concerned. In this study, recycled aluminium 6061 (AA6061) chips reinforced with different volumetric fractions of boron carbide (B4C) were produced through hot equal channel angular processing (ECAP). Response surface methodology (RSM) was carried out to investigate the dependent response (compressive strength) with independent parameters such as different volumetric fractions (5-15%) of added contents of B4C and preheating temperature (450 – 550°C). Also, the number of passes were examined to check the effect on the mechanical and physical properties of the developed recycled AA6061/B4C composite. The results show that maximum compressive strength and hardness of recycled AA6061/B4C were 59.2 MPa and 69 HV respectively at 5% of B4C contents. Likewise, the density and number of pores increased, which were confirmed through scanning electron microscope (SEM) and atomic force microscopes (AFM) analysis. However, the number of passes enhanced the mechanical and physical properties of the recycled AA6061/B4C composite. Therefore, the maximum compressive strength and hardness achieved were 158 MPa and 74.95 HV for the 4th pass. Moreover, the physical properties of recycled AA6061/B4C composite become denser of 2.62 g/cm3 at the 1st pass and 2.67 g/cm3 for the 4th pass. Thus, it can be concluded that the B4C volumetric fraction and number of passes have a significant effect on recycled AA6061 chips.

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Section: Compressive Strength Testsupporting

confidence: 75%

Section: Hardness Testmentioning

confidence: 99%

Development of Hot Equal Channel Angular Processing (ECAP) Consolidation Technique in the Production of Boron Carbide(B4C)-Reinforced Aluminium Chip (AA6061)-Based Composite

Al-Alimi

Lajis

Shamsudin

et al. 2021

Int. J. Renew. Energy Dev.

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“…It consists of coarse-grained structure with grain size of about 48 m. On the other hand, the microstructure of the hot extruded specimen consists of fine grains of about 13.5 m, as shown in Figure 2(b). The finer grained microstructure is caused by severe plastic strain imposed during the recycling processes and the positive effect of chip boundaries which can act as barriers between grains to prevent grain growth [25][26][27][28]. The decrease in grain size was congruent with previous work done by Haase et al [25] where the grain size of the as-received AA-6060 alloy was 385 m, while it was 31.8 m for the hot extruded chips at 450 ∘ C. Also, Selmy et al [26,27] recycled AA-6061 chips through hot extrusion; the grain size was 48 m for as-received samples while it was 15.8 and 10.9 m for the recycled samples produced by hot extrusion at 500 and 350 ∘ C, respectively.…”

Section: Resultsmentioning

confidence: 99%

Effect of Equal Channel Angular Pressing on the Surface Roughness of Solid State Recycled Aluminum Alloy 6061 Chips

Abbas

Taha

Ragab

et al. 2017

Advances in Materials Science and Engineering

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Solid state recycling through hot extrusion is a promising technique to recycle machining chips without remelting. Furthermore, equal channel angular pressing (ECAP) technique coupled with the extruded recycled billet is introduced to enhance the mechanical properties of recycled samples. In this paper, the surface roughness of solid state recycled aluminum alloy 6061 turning chips was investigated. Aluminum chips were cold compacted and hot extruded under an extrusion ratio (ER) of 5.2 at an extrusion temperature (ET) of 425°C. In order to improve the properties of the extruded samples, they were subjected to ECAP up to three passes at room temperature using an ECAP die with a channel die angle(Φ)of 90°. Surface roughness (RaandRz) of the processed recycled billets machined by turning was investigated. Box-Behnken experimental design was used to investigate the effect of three machining parameters (cutting speed, feed rate, and depth of cut) on the surface roughness of the machined specimens for four materials conditions, namely, extruded billet and postextrusion ECAP processed billets to one, two, and three passes. Quadratic models were developed to relate the machining parameters to surface roughness, and a multiobjective optimization scheme was conducted to maximize material removal rate while maintaining the roughness below a preset practical value.

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“…Similar observations of visible chips boundary and micro-voids in the recycled AA6061 chips were obtained by Refs. 19,20 In Figure 7(b), it can be observed that the number of chips boundary and the micro-voids increases during the loading deformation. Furthermore, damage evolution is clearly observed in Figure 7, where the micro-cracks and dimples are formed due to the coalescence and growth of the micro-voids.…”

Section: Tensile Behaviourmentioning

confidence: 93%

Tensile behaviour and damage characteristic of recycled aluminium alloys AA6061 undergoing finite strain deformation

Nor

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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The effects of temperature and strain rate of hot-forged recycled aluminium alloys AA6061 are examined via uniaxial tensile test implementations in this paper. The tests are conducted at elevated temperatures of 100 °C, 200 °C and 300 °C, at two different strain rates of 10−4 s−1 and 10−3 s−1. The tensile behaviour and damage characteristic are analysed in terms of stress-strain curves and microstructural analysis, respectively. The microstructure and fracture surface of such materials are observed using Scanning Electron Microscope (SEM) and Optical Microscope (OM). The flow stress of recycled AA6061 increases with increasing strain rate and decreases with increasing temperature. ImageJ software is used to quantify void characteristics. It is observed that the quantity and size of the micro-voids are strain-rate sensitive. This is due to the growth and coalescence of the micro-voids. The OM analysis shows the gap between the grain boundaries becomes wider with the increasing temperature that affects the strength of the material. The outcome of this work gives valuable information before the appropriate applications, especially in automotive and aerospace fields, can be established. It can be agreed that there is still a need for improved recycling methods to fulfil the needs in the required applications, as shown by its primary resources. It is a massive challenge and an obvious drawback in such materials due to the degradation of material’s properties related to damage.

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Solid-State Recycling of Aluminum Alloy (AA-6061) Chips via Hot Extrusion Followed by Equal Channel Angular Pressing (ECAP)

Cited by 13 publications

References 38 publications

Development of Hot Equal Channel Angular Processing (ECAP) Consolidation Technique in the Production of Boron Carbide(B4C)-Reinforced Aluminium Chip (AA6061)-Based Composite

Development of Hot Equal Channel Angular Processing (ECAP) Consolidation Technique in the Production of Boron Carbide(B4C)-Reinforced Aluminium Chip (AA6061)-Based Composite

Effect of Equal Channel Angular Pressing on the Surface Roughness of Solid State Recycled Aluminum Alloy 6061 Chips

Tensile behaviour and damage characteristic of recycled aluminium alloys AA6061 undergoing finite strain deformation

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