Integral Channels in Metal Components and Fabrication Thereof

An internal channel in a metal body for use in applications where internal fluid flow within a metal body is desired, as in a heat exchanger. The internal channel is formed in the metal body by frictionally stirring with a pin plunged into the metal body, and traversing the metal body with the pin

Integral Channels in Metal Components and Fabrication Thereof

An internal channel in a metal body for use in applications where internal fluid flow within a metal body is desired, as in a heat exchanger. The internal channel is formed in the metal body by frictionally stirring with a pin plunged into the metal body, and traversing the metal body with the pin

Superplastic Forming of Micro Components

A method for forming a miniaturized shaped component. Bulk superplastic material is contacted with a flat rotating surface of a rotating tool to frictionally heat the bulk superplastic material with the bulk superplastic material positioned between the flat rotating surface of the tool and a micro fabricated tool die. The bulk superplastic material is forced into the microfabricated die once the bulk superplastic material is heated to a temperature between a glass transition temperature and a crystallization temperature

Evaluation of Microstructure and Superplasticity in Friction Stir Processed 5083 Al Alloy

Friction stir processing (FSP) has been developed as a potential grain refinement technique. In the current study, a commercial 5083 Al alloy was friction stir processed with three combinations of FSP parameters. Fine-grained microstructures with average grain sizes of 3.5-8.5 µm were obtained. Tensile tests revealed that the maximum ductility of 590 was achieved at a strain rate of 3 x 10-3 s-1 and 530 °C in the 6.5-µm grain size FSP material, whereas for the material with 8.5-µm grain size, maximum ductility of 575 was achieved at a strain rate of 3 x 10-4 s-1 and 490 °C. The deformation mechanisms for both the materials were grain boundary sliding (m ~0.5) However, the 3.5-µm grain size material showed maximum ductility of 315% at 10-2 s-1 and 430 °C. The flow mechanism was solute-drag dislocation glide (m ~0.33) This study indicated that establishing a processing window is crucial for obtaining optimized microstructure for optimum superplasticity

Metal Superplasticity Enhancement and Forming Process

A shaped metallic component is formed by friction stirring at least a segment of a single piece of bulk metal to impart superplasticity thereto and thereby yield a single superplastic metal blank from the single piece of bulk metal. The metal blank is then deformed by a metal deformation process such as forging, rolling, drawing, bending, extruding, gas forming, punching, and stamping

Effect of Welding Parameters on Properties of 5052 Al Friction Stir Spot Welds

Effect of process parameters on friction stir spot welding (FSSW) of 5052 Al alloy has been evaluated. a plunge type FSSW machine was used for this study. Sheet thicknesses of 1 and 1.6mm were used. the tool rotation rate was varied between 1000 and 3000 rpm. the tool plunge rate and dwell time was varied to give weld cycle of 1-4 seconds. Shear tests were performed in 2 sheet and 3 sheet configurations to determine the influence of processing parameters on the mechanical properties of lap joint FSSWs. Higher joint strengths were observed at lower tool rotation rates. Copyright © 2006 SAE International

Effect of Friction Stir Processing on the Microstructure of Cast A356 Aluminum

Friction stir processing (FSP) was applied to cast A356 Al to modify the as-cast microstructure. FSP homogenizes and refines the cast microstructure, completely eliminates porosity, and creates a microstructure with fine Si particles (0.25-0.42 μm) distributed in a fine grain aluminum matrix (3-4 μm). Further, FSP parameters significantly influence microstructural development in the processed zone of cast A356 Al. Generally, higher tool rotation rate creates a more homogeneous microstructure. at lower tool rotation rates, a macroscopically visible banded structure characterized by a low density of coarse particles, was detected in the nugget zone. However, FSP parameters did not significantly influence the Al matrix grain size. the varied distribution pattern, size, and volume fraction of Si particles at different locations within the FSP zone indicates inhomogeneous material flow. a post-FSP T6 heat treatment did not alter the Si particle distribution but did significantly coarsen the Si particles. © 2006 Elsevier B.V. All rights reserved

Superplasticity in Cast A356 Induced Via Friction Stir Processing

Super plasticity was investigated in friction stir processed A356 alloy at temperatures of 470-570 °C and initial strain rates of 3x10 -4-1x10-1 s-1. Maximum superplastic elongation of 650% was obtained at 530 °C and an initial strain rate of 1x10-3 s-1 where a maximum strain rate sensitivity of 0.45 was observed. © 2004 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved

Elevated Temperature Deformation Behavior of Nanostructured Al-Ni-Gd-Fe Alloys

The elevated temperature deformation behavior of nanostructured Al89Ni3Gd7Fe1 alloy was characterized. Tensile strength was 760 MPa at 373 K. Ductility of the alloy increases with increasing strain rate at 573 K. At high temperatures (623-673 K), the operative deformation mechanism is dislocation-climb controlled