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Home Material Sciences Al-Base Alloys By New Economically Efficient, Environmentally Benign Technology Of Rapid Solidification

Al-Base Alloys By New Economically Efficient, Environmentally Benign Technology Of Rapid Solidification

Description

A new rapid technology based on the use of modified water atomization (see Fig. 1) followed by direct powder extrusion has been developed. The atomisation stage is innovative and realised as a pilot plant. The pilot plan built provides:
(a) cooling rates between 5x104 and 106 K/s,
(b) 2 to 10 kg of powder per atomisation run,
(c) minus 40µ size fraction amounts to 70% at water pressure of 150 atm,
(d) low surface oxidation, and
(e) powders being highly irregular in shape are easy to press.
New high-strength, corrosion resistant weldable Al based alloy compositions have been developed, produced by the proposed technology in the form of strips (Fig. 2) and tested (Table below)

High strength 7xxx alloys

  • Room temperature strength, MPa –––––––––––––––––– 500-550
  • Elongation, % –––––––––––––––––––––––––––––––––– 8-12
  • Weldability –––––––––––––––––––––––––––––––––––– Weldable
  • Strength of weldments, MPa –––––––––––––––––––––– 300-350
  • Stress corrosion cracking, MPa –––––––––––––––––––– 270-350
  • Low frequency fatigue strength, cycles/Load ––––––––– 8x104-6x105 / 160 MPa
  • Fracture toughness, K1c, MPa m1/2 –––––––––––––––– 40-65

Ultra-high strength 7xxx alloys

  • Room temperature strength, MPa –––––––––––––––––– 550-650
  • Elongation, % –––––––––––––––––––––––––––––––––– 7-9
  • Weldability –––––––––––––––––––––––––––––––––––– Welded by resistance welding
  • Strength of weldments, MPa –––––––––––––––––––––– 270-310
  • Stress corrosion cracking, MPa –––––––––––––––––––– 100-150
  • Low frequency fatigue strength, cycles/Load ––––––––– 8x104 / 160 MPa
  • Fracture toughness, K1c, MPa m1/2 –––––––––––––––– 25-30

Developed alloys

  • Room temperature strength, MPa ––––––––––––––––– 620-670
  • Elongation, % ––––––––––––––––––––––––––––––––– 8-12
  • Weldability ––––––––––––––––––––––––––––––––––– Very easy to weld
  • Strength of weldments, MPa ––––––––––––––––––––– 530-570
  • Stress corrosion cracking, MPa ––––––––––––––––––– 300-350
  • Low frequency fatigue strength, cycles/Load –––––––– 8x104 / 160 MPa
  • Fracture toughness, K1c, MPa m1/2 ––––––––––––––– 60-65

Innovative Aspect and Main Advantages

The main advantages of the proposed technology over the existing prototypes (gas atomisation and centrifugal atomisation):
(1) explosion and fire-proof,
(2) environmental safety (dust-free process),
(3) higher productivity in powder production,
(4) higher economical efficiency, and
(5) recycling of wastes of packaging aluminium.
The principal advantage of the developed alloys over the existing commercial materials consists in a unique combination of different properties. The tensile and yield strength of new alloys are similar to those of high strength commercial 7075 alloy while their stress corrosion cracking and fracture toughness are similar to the characteristics of less strength materials, such as 1973, 1949 etc alloys.

Areas of Application

Production of alloys for transport (aircraft and shipbuilding industry) and consumer goods (wheelchairs and sportive goods)

Prossesing line for Powder Manufacture
Fig. 1 Prossesing line for Powder Manufacture

Al strips (10x40 mm section)
Fig. 2 Al strips (10x40 mm section)

Stage of Development

1) Patented in Russia and Ukraine (2 Ukrainian and 2 Russian patents),
2) Pilot plant is operative, and
3) New Al alloys are produced, tested and available for demonstration

Contact Details

Frantsevich Institute for Problems of Materials Science of NASU
Krzhizhanivsky St. 3, Kiev, 03142, Ukraine
Contact Person: Alexander Krajnikov
Tel: 380–44–4240294
Fax: 380–44–4242131
E-mail: This e-mail address is being protected from spambots. You need JavaScript enabled to view it

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