Material Characterization and Real-Time Wear Evaluation of Pistons and Cylinder Liners of the Tiger 131 Military Tank

Material characterisation and wear evaluation of the original and replacement pistons and cylinder-liners of Tiger 131 is reported. Original piston and cylinder-liner were operative in the Tigers’ engine during WWII. The replacement piston and cylinder-liner were used as substitutes and were obtained after failure in two hours of operation in the actual engine. Material characterisation revealed that the original piston was aluminium silicon hypereutectic alloy whereas the replacement piston was aluminium copper alloy with very low silicon content. Both original and replacement cylinder-liners consisted of mostly iron which is indicative of cast iron, a common material for this application. The replacement piston average surface roughness was found to be 9.09 μm while for replacement cylinder-liner it was 5.78 μm

Influence of grain-refiner addition on the morphology of fe-bearing intermetallics in a semi-solid processed Al-Mg-Si alloy

© The Minerals, Metals & Materials Society and ASM International 2013The three-dimensional morphologies of the Fe-bearing intermetallics in a semisolid-processed Al-Mg-Si alloy were examined after extracting the intermetallics. α -AlFeSi and β-AlFeSi are the major Fe-bearing intermetallics. Addition of Al-Ti-B grain refiner typically promotes β-AlFeSi formation. β-AlFeSi was observed with a flat, plate-like morphology with angular edges in the alloy with and without grain refiner, whereas α -AlFeSi was observed as "flower"-like morphology in the alloy with grain refiner. © 2013 The Minerals, Metals & Materials Society and ASM International

Effect of intensive melt shearing on the formation of Fe-containing intermetallics in LM24 Al-alloy

Fe is one of the inevitable and detrimental impurities in aluminium alloys that degrade the mechanical performance of castings. In the present work, intensive melt shearing has been demonstrated to modify the morphology of Fe-containing intermetallic compounds by promoting the formation of compact α-Al(Fe,Mn)Si at the expense of needle-shaped β-AlFeSi, leading to an improved mechanical properties of LM24 alloy processed by MC-HPDC process. The promotion of the formation of α -Al(Fe, Mn)Si phase is resulted from the enhanced nucleation on the well dispersed MgAl 2O 4 particles in the melt. The Fe tolerance of LM24 alloy can be effectively improved by combining Mn alloying and intensive melt shearing

Solidification behavior of intensively sheared hypoeutectic Al-Si alloy liquid

The official published version of this article can be found at the link below.The effect of the processing temperature on the microstructural and mechanical properties of Al-Si (hypoeutectic) alloy solidified from intensively sheared liquid metal has been investigated systematically. Intensive shearing gives a significant refinement in grain size and intermetallic particle size. It also is observed that the morphology of intermetallics, defect bands, and microscopic defects in high-pressure die cast components are affected by intensive shearing the liquid metal. We attempt to discuss the possible mechanism for these effects.Funded by the EPSRC

Formation of hot tear under controlled solidification conditions

Aluminum alloy 7050 is known for its superior mechanical properties, and thus finds its application in aerospace industry. Vertical direct-chill (DC) casting process is typically employed for producing such an alloy. Despite its advantages, AA7050 is considered as a "hard-to-cast" alloy because of its propensity to cold cracking. This type of cracks occurs catastrophically and is difficult to predict. Previous research suggested that such a crack could be initiated by undeveloped hot tears (microscopic hot tear) formed during the DC casting process if they reach a certain critical size. However, validation of such a hypothesis has not been done yet. Therefore, a method to produce a hot tear with a controlled size is needed as part of the verification studies. In the current study, we demonstrate a method that has a potential to control the size of the created hot tear in a small-scale solidification process. We found that by changing two variables, cooling rate and displacement compensation rate, the size of the hot tear during solidification can be modified in a controlled way. An X-ray microtomography characterization technique is utilized to quantify the created hot tear. We suggest that feeding and strain rate during DC casting are more important compared with the exerted force on the sample for the formation of a hot tear. In addition, we show that there are four different domains of hot-tear development in the explored experimental window-compression, microscopic hot tear, macroscopic hot tear, and failure. The samples produced in the current study will be used for subsequent experiments that simulate cold-cracking conditions to confirm the earlier proposed model.This research was carried out within the Materials innovation institute (www.m2i.nl) research framework, project no. M42.5.09340

Constitutive behavior of an AA4032 piston alloy with Cu and Er additions upon high temperature compressive deformation

The Research and Researchers for Industry (RRi); King Mongkut’s University of Technology Thonbur