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SYNTHESIS AND EVEALUATION OF MECHANICAL AND WEAR PROPERTIES OF Mg-Al ALLOY FOR AEROSPACE APPLICATIONS
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Wear Properties of Thixoformed Al-5.7Si-2Cu-0.3Mg Aluminium Alloy
Earlier work has shown that Al-5.7Si-2Cu-0.3Mg aluminium alloy is suitable for
thixoforming process. Here, the dry sliding wear behaviour of the alloy, in the as-cast and
thixoformed conditions were investigated. The cooling slope technique was used to produce the alloy
with globular microstructure for the thixoforming process. Both the thixoformed and cast samples
were subjected to T6 heat treatments prior to the wear tests. The tests were carried out using a
pin-on-disc tribometer, against a hardened M2 tool steel disc of 62 HRC at different loads, under dry
sliding conditions at fixed sliding speed and sliding distance of 1 m.s–1 and 5 km respectively. The
microstructural response, worn surfaces was thoroughly and carefully examined using various
methods such as scanning electron microscopy, energy dispersive spectroscopy, and differential
scanning calorimetry. The density of the heat treated thixoformed alloys showed significant increase
in the hardness property, among others, due to its reduced porosity. Their wear test results also
observed that the weight loss of materials increase with an increase in the input load and the sliding
distance for all samples. However, the as-cast alloy displayed higher wear rate compared with the
thixoformed alloys. In general, the wear mechanisms showed a mixture of abrasive, oxidative and
delamination wear (mild wear) at low applied loads and mainly an adhesive (severe wear) at high
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Effect of rice husk ash on compressive strength of concrete
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Katitra
- 1. SYNTHESIS & EVALUATION OF MECHANICAL & WEAR PROPERTIES OF Mg–Al ALLOY FOR AEROSPACE APPLICATION Under The Guidance Of – DR. T. RAM PRABHU DEPUTY. DIRECTOR / SCIENTIST, HAL BANGALORE PRESENTED BY MR. KATITRA DEBNATH
- 2. THE INTRO - Magnesium(The Primary material), the reason for aerospace applications. - Casting are made but there are problems related to inconsistency in mechanical properties. - The Heat Treatment Cycle : Avoiding Grain Coarsening - Main motive : Addition of grain refineries to the melt
- 3. Method Followed – Sand Casting (Reason – Uniform properties and high yield strength) Hexachloroethane addition – Used for alloys containing Aluminium as major alloying element. To add volatile carbon-containing compounds (synthetic graphite, activated charcoal) Grain refinement has been attributed to inoculation of the melt. Release of chlorine causes degassing of the melt. Grain size obtained using is 100 μm. WHY GRAIN REFINEMENT ??
- 4. GA9 is magnesium casting alloy - French specification. The equivalent specifications are AZ81 and AZ91. AZ81 is a sand cast alloy and AZ91 is a die cast alloy. GA9 alloy can be used for sand casting. It has good castability (good fluidity, less shrinkage, no hot cracking, less defects). THE Mg-Al ALLOY
- 5. APPLICATIONS o Aerospace engine, oil pump and cover. o Casings of aerospace engines. o Plate oil pump of engines. SAND CASTING PART OF AN AEROSPACE ENGINE
- 6. Preparation of the molten melt alongwith the heat treatment. Preparation of the test specimens for the testing and investigations. Evaluating the results on the basis of mechanical properties. Microstructural analysis Tensile and Hardness tests OBJECTIVE
- 7. Mould Making Charge Preparation Charged Materials Remelts Magnesium metal and Mg-2 % Mn alloy Aluminum 99.7 % purity and Zinc 99.95 % purity Flux – magnesium electron and C2Cl6 tablets (100 grams each) Synthetic graphite (grain refineries) of particle size 21um (320 grams approx.) Activated charcoal (grain refineries) of similar sizes for next 2 batches METHODOLOGY
- 8. Melting Knocking Fettling Heat treatment Radiography Experiments METHODOLOGY contd… GRAIN REFINERY POWDERS
- 9. Cleaning Steel Crucible Materials charged (standard procedure) Molten metal preheated and poured into sand moulds Temperature raised to 750°C Molten metal mixed thoroughly Two tablets of hexachloroethane was plunged (Degassing) Temperature was raised to 780°C (750°C - grain refineries) Next the moulds were broken by knocking and fettling MELTING
- 10. The 24 hours solutionising heat treatment in three steps to avoid grain coarsening. Solutionising: at 410 ± 5 0 C for 6 hrs. ± 5 minutes Solutionising: at 350 ± 5 0 C for 2 hrs. ± 5 minutes Solutionising: at 410 ± 5 0 C for 10 hrs. ± 5 minutes 2:1 mixture of FeS and S powder used (Prevent Mg from burning) Radiography was followed to find the porosities/inclusions HEAT TREATMENT
- 11. TESTS CONDUCTED o Tensile Test – According to ASTM standards o Hardness Test – (Brinnel Hardness Machine) o Microstructure Analysis (At 100X) o Wear Test (future)
- 12. RESULTS
- 13. MICROSTRUCTURAL ANALYSIS WITHOUT GRAIN REFINERIES SYNTHETIC GRAPHITE ACTIVATED CHARCOAL(0.98%) ACTIVATED CHARCOAL(0.04%)
- 14. TENSILE GRAPHS
- 16. CONCLUSIONS Activated charcoal (0.98%) batch has higher tensile test values as compared to the other batches. Improvement in the hardness values of the samples of batches of activated charcoal compared with the base alloy from 76.5bhn to 98.6bhn. Improvement in the microstructure with the addition of grain refineries. The average mechanical properties of the test bars in as solutionised condition meets the specification requirements of GA9. Effective filters should be used to avoid inclusions.
- 17. For any queries contact me at katitradebnath@gmail.com