Unified casting (UniCast) aluminum alloy—a sustainable and low-carbon materials solution for vehicle lightweighting

Zhan, Hongyi; Zeng, Guang; Wang, Qigui; Wang, Congjie; Wang, Pan; Wang, Zhou; Xu, Yi-wu; Hess, Devin; Crepeau, Paul N.; Wang, Jeff

doi:10.1016/j.jmst.2023.02.003

Cited by 12 publications

(2 citation statements)

References 90 publications

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“…With the advantages of light weight, good electrical and thermal conductivity, high strength, corrosion resistance and easy processing, aluminum alloys are now widely used in automotive, aerospace and other fields [1][2][3][4][5]. In the application process, the joining method and process parameters are crucial [6].…”

Section: Introductionmentioning

confidence: 99%

Thermal Cycling, Microstructure, and Mechanical Properties of Al-Mg-Si-Cu Alloy Bobbin Tool Friction Stir Welded Joints Based on Thermal Index

Li,

Zhou,

Yin

et al. 2023

Coatings

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The two main process parameters of Bobbin tool friction stir welding (BT-FSW) are ω (rotational speed) and v (traverse speed). Both of these factors have a significant effect on heat input, microstructure, and mechanical properties. At present, most studies on friction stir welding adopt the control variable method to study the thermal cycling during the welding process and the mechanical properties of joints, and there are few studies on changing the two process parameters at the same time, because it can be difficult to assess the correlation between heat input and mechanical properties when changing both factors at the same time. In this study, the w/v ratio is defined as the thermal index, which is a characteristic value of heat input. The study uses ABAQUS 6.5 software to establish a BT-FSW CEL (coupled Eulerian–Lagrangian) thermal coupling model. This model explores the relationship between joint thermal cycles, microstructure, and mechanical properties for different w and v values with the same w/v ratio. The results show that increasing rotational and traverse speeds under the same w/v ratio leads to an increase in the peak temperature of the nugget zone (NZ). However, the peak temperature of the thermo-mechanically affected zone (TMAZ) and heat-affected zone (HAZ) remained almost constant. Joint strength was highest at a rotational speed of 750 r/min and a traverse speed of 650 mm/min, with a yield strength of 227 MPa. As rotational and traverse speeds increased, the recrystallized grain content of the NZ showed an increasing trend followed by a decreasing trend. The recrystallized grain content of the advancing side thermo-mechanically affected zone (AS-TMAZ) and retreating side thermo-mechanically affected zone (RS-TMAZ) showed a decreasing trend. Joint hardness had a “W” shaped distribution, with the highest average hardness value found in the NZ.

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Section: Introductionmentioning

confidence: 99%

Thermal Cycling, Microstructure, and Mechanical Properties of Al-Mg-Si-Cu Alloy Bobbin Tool Friction Stir Welded Joints Based on Thermal Index

Li,

Zhou,

Yin

et al. 2023

Coatings

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confidence: 99%

To improve robustness of mechanical properties of semi-solid cast A356 alloy using taguchi design method

Xu,

Zhan,

Tong

et al. 2023

China Foundry

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Mass reduction for automotive components has become one of the key approaches for greenhouse gas emission reduction of the automotive industry [1] . Materials selection, tooling design, and processing parameters are the three crucial pillars for achieving mass reduction in automotive castings [2] . Gravity casting and low pressure die casting processes have a relatively longer cycle time, and hence higher manufacturing cost for high volume production. Traditional high pressure die casting (HPDC) process has a much shorter cycle time, which is suitable for scaled production in the automotive industry [3] . However, some casting defects, such as gas porosities and shrinkage porosities in HPDC components, cannot be

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Semi-solid Die Casting of Some Aluminum Alloys for Lightweight Automotive Components

Gu,

Li,

Xiang

et al. 2023

Lecture Notes in Mechanical Engineering

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Unified casting (UniCast) aluminum alloy—a sustainable and low-carbon materials solution for vehicle lightweighting

Cited by 12 publications

References 90 publications

Thermal Cycling, Microstructure, and Mechanical Properties of Al-Mg-Si-Cu Alloy Bobbin Tool Friction Stir Welded Joints Based on Thermal Index

Thermal Cycling, Microstructure, and Mechanical Properties of Al-Mg-Si-Cu Alloy Bobbin Tool Friction Stir Welded Joints Based on Thermal Index

To improve robustness of mechanical properties of semi-solid cast A356 alloy using taguchi design method

Semi-solid Die Casting of Some Aluminum Alloys for Lightweight Automotive Components

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