A super-ductile alloy for the die-casting of aluminium automotive body structural components

Super-ductile die-cast aluminium alloys are critical to future light-weighting of automotive body structures. This paper introduces a die-cast aluminium alloy that can satisfy the requirements of these applications. After a review of currently available alloys, the requirement of a die-cast aluminium alloy for automotive body structural parts is proposed and an Al-Mg-Si system is suggested. The effect of the alloying elements, in the composition, has been investigated on the microstructure and mechanical properties, in particular the yield strength, the ultimate tensile strength and elongation. © (2014) Trans Tech Publications, Switzerland.The EPSRC and JLR U

Microstructural characteristics of diecast AlMgSiMn alloy

Solidification and microstructural characteristics of Al-5wt.%Mg-1.5wt.%Si-0.6wt.%Mn- 0.2wt.%Ti alloy have been investigated in high pressure die casting. The average size of dendrites and fragmented dendrites of the primary α-Al phase formed in the shot sleeve is 43μm, and the globular α-Al grains formed inside the die cavity is 7.5μm. Solidification inside the die cavity also forms the lamellar Al-Mg2Si eutectic phase and the Fe-rich intermetallics. The size of the eutectic cells is about 10μm, in which the lamellar α-Al phase is 0.41μm thick. The Fe-rich intermetallic compound exhibits a compact morphology and is less than 2μm. Calculations using the Mullins and Sekerka stability criterion reveal that the solidification of the primary α-Al phase inside the die cavity has completed before the spherical α-Al globules begin to lose their stability, but the α-Al grains formed in the shot sleeve exceed the limit of spherical growth and therefore exhibit a dendritic morphology

Microstructural evolution and solidification behavior of Al-Mg-Si alloy in high-pressure die casting

Copyright @ 2013 ASM International. This paper was published in Metallurgical and Materials Transactions A, 44A(7), 3185 - 3197 and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this paper for a fee or for commercial purposes, or modification of the content of this paper are prohibited.Microstructural evolution and solidification behavior of Al-5 wt pct Mg-1.5 wt pct Si-0.6 wt pct Mn-0.2 wt pct Ti alloy have been investigated using high-pressure die casting. Solidification commences with the formation of primary a-Al phase in the shot sleeve and is completed in the die cavity. The average size of dendrites and fragmented dendrites of the primary a-Al phase formed in the shot sleeve is 43 lm, and the globular primary a-Al grains formed inside the die cavity is at a size of 7.5 lm. Solidification inside the die cavity also forms the lamellar Al-Mg2Si eutectic phase and the Fe-rich intermetallics. The size of the eutectic cells is about 10 lm, in which the lamellar a-Al phase is 0.41 lm thick. The Fe-rich intermetallic compound exhibits a compact morphology and is less than 2 lm with a composition of 1.62 at. pct Si, 3.94 at. pct Fe, and 2.31 at. pct Mn. A solute-enriched circular band is always observed parallel to the surface of the casting. The band zone separates the outer skin region from the central region of the casting. The solute concentration is consistent in the skin region and shows a general drop toward the center inside the band for Mg and Si. The peak of the solute enrichment in the band zone is much higher than the nominal composition of the alloy. The die casting exhibits a combination of brittle and ductile fracture. There is no significant difference on the fracture morphology in the three regions. The band zone is not significantly detrimental in terms of the fracture mechanism in the die casting. Calculations using the Mullins and Sekerka stability criterion reveal that the solidification of the primary a-Al phase inside the die cavity has been completed before the spherical a-Al globules begin to lose their stability, but the a-Al grains formed in the shot sleeve exceed the limit of spherical growth and therefore exhibit a dendritic morphologyEPSRC and JL

Effect of iron on the microstructure and mechanical property of Al-Mg-Si-Mn and Al-Mg-Si diecast alloys

This article is made available through the Brunel Open Access Publishing Fund. Copyright @ 2012 Elsevier B.V.This article has been made available through the Brunel Open Access Publishing Fund.Al–Mg–Si based alloys can provide super ductility to satisfy the demands of thin wall castings in the application of automotive structure. In this work, the effect of iron on the microstructure and mechanical properties of the Al–Mg–Si diecast alloys with different Mn concentrations is investigated. The CALPHAD (acronym of Calculation of Phase Diagrams) modelling with the thermodynamic properties of the multi-component Al–Mg–Si–Mn–Fe and Al–Mg–Si–Fe systems is carried out to understand the role of alloying on the formation of different primary Fe-rich intermetallic compounds. The results showed that the Fe-rich intermetallic phases precipitate in two solidification stages in the high pressure die casting process: one is in the shot sleeve and the other is in the die cavity, resulting in the different morphologies and sizes. In the Al–Mg–Si–Mn alloys, the Fe-rich intermetallic phase formed in the shot sleeve exhibited coarse compact morphology and those formed in the die cavity were fine compact particles. Although with different morphologies, the compact intermetallics were identified as the same α-AlFeMnSi phase with typical composition of Al24(Fe,Mn)6Si2. With increased Fe content, β-AlFe was found in the microstructure with a long needle-shaped morphology, which was identified as Al13(Fe,Mn)4Si0.25. In the Al–Mg–Si alloy, the identified Fe-rich intermetallics included the compact α-AlFeSi phase with typical composition of Al8Fe2Si and the needle-shaped β-AlFe phase with typical composition of Al13Fe4. Generally, the existence of iron in the alloy slightly increases the yield strength, but significantly reduces the elongation. The ultimate tensile strength maintains at similar levels when Fe contents is less than 0.5 wt%, but decreases significantly with the further increased Fe concentration in the alloys. CALPHAD modelling shows that the addition of Mn enlarges the Fe tolerance for the formation of α-AlFeMnSi intermetallics and suppresses the formation of β-AlFe phase in the Al–Mg–Si alloys, and thus improves their mechanical properties.EPSRC and JL

Microstructure and mechanical properties of ductile aluminium alloy manufactured by recycled materials

The present paper introduces the microstructure and mechanical properties of the Al-Mg- Si-Mn alloy made by recycled materials, in which the impurity levels of iron are mainly concerned. It is found that the increased Fe content reduces the ductility and yield strength but slightly increases the UTS of the diecast alloy. The tolerable Fe content is 0.45wt.%, at which the recycled alloys are still able to produce castings with the mechanical properties of yield strength over 140MPa, UTS over 280MPa and elongation over 15%.The Fe content is steadily accumulated in the alloy with the increase of recycle times. However, after 13 cycles, the recycled alloys are still able to produce ductile alloys with satisfied mechanical properties.The TSB (UK

Effect of iron on the microstructure and mechanical property of Al-Mg-Si-Mn and Al-Mg-Si diecast alloys

This article is made available through the Brunel Open Access Publishing Fund. Copyright @ 2012 Elsevier B.V.This article has been made available through the Brunel Open Access Publishing Fund.Al–Mg–Si based alloys can provide super ductility to satisfy the demands of thin wall castings in the application of automotive structure. In this work, the effect of iron on the microstructure and mechanical properties of the Al–Mg–Si diecast alloys with different Mn concentrations is investigated. The CALPHAD (acronym of Calculation of Phase Diagrams) modelling with the thermodynamic properties of the multi-component Al–Mg–Si–Mn–Fe and Al–Mg–Si–Fe systems is carried out to understand the role of alloying on the formation of different primary Fe-rich intermetallic compounds. The results showed that the Fe-rich intermetallic phases precipitate in two solidification stages in the high pressure die casting process: one is in the shot sleeve and the other is in the die cavity, resulting in the different morphologies and sizes. In the Al–Mg–Si–Mn alloys, the Fe-rich intermetallic phase formed in the shot sleeve exhibited coarse compact morphology and those formed in the die cavity were fine compact particles. Although with different morphologies, the compact intermetallics were identified as the same α-AlFeMnSi phase with typical composition of Al24(Fe,Mn)6Si2. With increased Fe content, β-AlFe was found in the microstructure with a long needle-shaped morphology, which was identified as Al13(Fe,Mn)4Si0.25. In the Al–Mg–Si alloy, the identified Fe-rich intermetallics included the compact α-AlFeSi phase with typical composition of Al8Fe2Si and the needle-shaped β-AlFe phase with typical composition of Al13Fe4. Generally, the existence of iron in the alloy slightly increases the yield strength, but significantly reduces the elongation. The ultimate tensile strength maintains at similar levels when Fe contents is less than 0.5 wt%, but decreases significantly with the further increased Fe concentration in the alloys. CALPHAD modelling shows that the addition of Mn enlarges the Fe tolerance for the formation of α-AlFeMnSi intermetallics and suppresses the formation of β-AlFe phase in the Al–Mg–Si alloys, and thus improves their mechanical properties.EPSRC and JL

Effect of nickel on the microstructure and mechanical property of die-cast Al–Mg–Si–Mn alloy

The effect of nickel on the microstructure and mechanical properties of a die-cast Al–Mg–Si–Mn alloy has been investigated. The results show that the presence of Ni in the alloy promotes the formation of Ni-rich intermetallics. These occur consistently during solidification in the die-cast Al–Mg–Si–Mn alloy across different levels of Ni content. The Ni-rich intermetallics exhibit dendritic morphology during the primary solidification and lamellar morphology during the eutectic solidification stage. Ni was found to be always associated with iron forming AlFeMnSiNi intermetallics, and no Al3Ni intermetallic was observed when Ni concentrations were up to 2.06 wt% in the alloy. Although with different morphologies, the Ni-rich intermetallics were identified as the same AlFeMnSiNi phase bearing a typical composition of Al[100–140](Fe,Mn)[2–7]SiNi[4–9]. With increasing Ni content, the spacing of the α-Al–Mg2Si eutectic phase was enlarged in the Al–Mg–Si–Mn alloy. The addition of Ni to the alloy resulted in a slight increase in the yield strength, but a significant decrease in the elongation. The ultimate tensile strength (UTS) increased slightly from 300 to 320 MPa when a small amount (e.g. 0.16 wt%) of Ni was added to the alloy, but further increase of the Ni content resulted in a decrease of the UTS.The Engineering and Physical Sciences Research Council (EPSRC), Technology Strategy Board (TSB) and Jaguar Land Rover (JLR) in the United Kingdom

Semi-Supervised Learning of Hidden Markov Models via a Homotopy Method

Hidden Markov model (HMM) classifier design is considered for analysis of sequential data, incorporating both labeled and unlabeled data for training; the balance between labeled and unlabeled data is controlled by an allocation parameter lambda in [0, 1), where lambda = 0 corresponds to purely supervised HMM learning (based only on the labeled data) and lambda = 1 corresponds to unsupervised HMM-based clustering (based only on the unlabeled data). The associated estimation problem can typically be reduced to solving a set of fixed point equations in the form of a “natural-parameter homotopy”. This paper applies a homotopy method to track a continuous path of solutions, starting from a local supervised solution (lambda = 0) to a local unsupervised solution (lambda = 1). The homotopy method is guaranteed to track with probability one from lambda = 0 to lambda = 1 if the lambda = 0 solution is unique; this condition is not satisfied for the HMM, since the maximum likelihood supervised solution (lambda = 0) is characterized by many local optimal solutions. A modified form of the homotopy map for HMMs assures a track from lambda = 0 to lambda = 1. Following this track leads to a formulation for selecting lambda in [0, 1) for a semi-supervised solution, and it also provides a tool for selection from among multiple (local optimal) supervised solutions. The results of applying the proposed method to measured and synthetic sequential data verify its robustness and feasibility compared to the conventional EM approach for semi-supervised HMM training

Staphylococcus aureus products subvert the Burkholderia cenocepacia-induced inflammatory response in airway epithelial cells

Introduction. Chronic pulmonary infection is associated with colonization with multiple micro-organisms but host-microbe and microbe-microbe interactions are poorly understood.Aim. This study aims to investigate the differences in host responses to mono- and co-infection with S. aureus and B. cenocepacia in human airway epithelial cells.Methodology. We assessed the effect of co-infection with B. cenocepacia and S. aureus on host signalling and inflammatory responses in the human airway epithelial cell line 16HBE, using ELISA and western blot analysis.Results. The results show that B. cenocepacia activates MAPK and NF-κB signalling pathways, subsequently eliciting robust interleukin (IL)-8 production. However, when airway epithelial cells were co-treated with live B. cenocepacia bacteria and S. aureus supernatants (conditioned medium), the pro-inflammatory response was attenuated. This anti-inflammatory effect was widely exhibited in the S. aureus isolates tested and was mediated via reduced MAPK and NF-κB signalling, but not via IL-1 receptor or tumour necrosis factor receptor modulation. The staphylococcal effectors were characterized as small, heat-stable, non-proteinaceous and not cell wall-related factors.Conclusion. This study demonstrates for the first time the host response in a S. aureus/B. cenocepacia co-infection model and provides insight into a staphylococcal immune evasion mechanism, as well as a therapeutic intervention for excessive inflammation.</p

Design and implementation of magnetron power supply and emulator

The paper presents a novel resonant based high performance power converter solution for industrial magnetron systems. Based the characteristics of the magnetron, an emulator prototype is also proposed to represent the magnetron load behaviour in a laboratory environment. A detailed design and implementation procedure is presented, including the design and control of the resonant power converter, together with the magnetron emulator in practical aspects. Experimental results are provided in order to demonstrate the feasibility of the proposed converter and emulator