| 1. |
- Belov, Ilja, et al.
(författare)
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Simulation and Experimental Methodology for Virtual Prototyping of Annealed Industrial Coils
- 2023
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Ingår i: Heat Transfer Engineering. - : Taylor & Francis. - 0145-7632 .- 1521-0537. ; 44:4, s. 353-367
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Tidskriftsartikel (refereegranskat)abstract
- The finite element three-dimensional transient model of the annealing process, including conductive and convective heat transfer in an aluminum (Al) coil was developed, implemented, and validated. It combines winding force dependent effective radial thermal conductivity model and the novel convective heat transfer modeling methodology. Experimental validation of the finite element model was performed for two industrial coils having different dimensions, strip thickness and crowning depth. The general agreement between the predicted and measured temperatures for most of the probes was better than 10% at the target material temperature. A series of measurements were configured and performed to supply both the input and validation data for the simulations. The effect of the additional wetted area on the convective heat transfer at the coil base was quantified. The guidelines on the virtual prototyping of the Al coil annealing process were provided, which can be of interest for the process designers.
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| 2. |
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| 3. |
- Matsushita, Taishi, et al.
(författare)
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Influence of contact pressure on the thermal contact conductance of layered metallic sheets
- 2022
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Ingår i: High Temperatures-High Pressures. - : Old City Publishing. - 0018-1544 .- 1472-3441. ; 51:1, s. 63-82
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Tidskriftsartikel (refereegranskat)abstract
- For the optimisation of the annealing process of aluminium coils, simulation of the process is often performed. To simulate the process with higher accuracy, reliable input parameters are required, and thermal conductivity (thermal contact conductance) is one of them. In the present study, a method to measure the thermal conductivity and thermal contact conductance of metallic sheets were developed based on the steady-state comparative longitudinal heat flow. The apparatus was built with a compression test machine, and thus it allows to control the pressure to the sample and carry out the measurements at different contact pressure. An equipped heater allows to heat the sample to 573 K. To evaluate the thermal conductance at the interface, a thermal resistance network model was applied. The measurements were carried out with an aluminium alloy (AA3003 sheets). In addition to the thermal contact conductance measurements, the surface roughness of the sheets was also investigated. The semi-empirical equation for the relationship between thermal contact conductance and contact pressure was obtained based on the measurement results.
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| 4. |
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| 5. |
- Awe, Samuel A., et al.
(författare)
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Development of new Al-Cu-Si alloys for high temperature performance
- 2017
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Ingår i: Advanced Materials Letters. - : VBRI Press. - 0976-3961 .- 0976-397X. ; 8:6, s. 695-701
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Tidskriftsartikel (refereegranskat)abstract
- In a quest to develop new light metal alloys that can perform excellently at elevated-temperatures (from 300°C to 400°C), a ternary eutectic Al-Cu-Si alloy was exploited to gain a deeper understanding of the alloy system and its suitability for high temperature applications. The alloys studied, with chemical composition of Al-27%Cu-5%Si (by weight percent) with Ni addition in the range of 0 to 1.5%wt, were cast in a rapid solidification casting technique. The solidification characteristics of the alloy was studied using the Thermo-Calc software. Microstructures were characterized in a scanning electron microscope coupled with energy dispersive spectrometry (SEM-EDS). Finally, the elevated-temperatures tensile properties of the alloys were investigated. Comparing the microstructures and mechanical properties of these Al-Cu-Si(-Ni) alloys with conventional Al-Si alloy A319, the refined microstructure with dispersed Ni intermetallic particles formed in the as-cast Al-Cu-Si(-Ni) alloys deliver improved elevated temperature properties. In particular, the yield strength and ultimate tensile strength of the new alloy with 1.5% Ni at 400?C were observed to be 220% and 309% higher, respectively, than for conventional A319 alloy.
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| 6. |
- Belov, Ilja, et al.
(författare)
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Effect of fillets on heat transfer in a rheocast aluminium heatsink
- 2016
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Ingår i: 2016 17th International Conference on Thermal, Mechanical and Multi-Physics Simulation and Experiments in Microelectronics and Microsystems (EuroSimE). - : IEEE. - 9781509021062
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Konferensbidrag (refereegranskat)abstract
- The effect of fillets formed between the base and plate fins of rheocast aluminium heatsinks on the thermal resistance of the heatsinks has been quantified by simulation. Simulation methodology, including sequential optimization has been developed in order to determine hotspot distributions where the fillets have the maximum effect. Combination of different fillet dimensions with various base thickness levels and aluminium alloys having inhomogeneous thermal conductivity have been investigated. For the studied cases, the effect of fillets on heatsink thermal resistance differs from negligible to 6%. The results would guide thermal designers on contribution of fillets to the heat transfer in multi-fin heatsinks for natural convection.
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| 7. |
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| 8. |
- Bjurenstedt, Anton, 1979-
(författare)
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On the influence of imperfections on microstructure and properties of recycled Al-Si casting alloys
- 2017
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- There are great energy savings to be made by recycling aluminium; as little as 5% of the energy needed for primary aluminium production may be required. Striving to produce high quality aluminium castings requires knowledge of microstructural imperfections, which is extra important when casting recycled aluminium that generally contains higher levels of imperfections compared to primary aluminium. Imperfections include amongst others Si, Fe, and Mn as well as oxides. Si is needed for castability, but it may also initiate fracture. There are different types of Fe-rich intermetallics influencing properties of castings, generally in a negative direction. Oxides constitute cracks and they are elusive because they are difficult to quantify.This thesis aims to increase knowledge about imperfections in recycled aluminium castings originating from alloying elements and the melt. Experiments were performed in advanced laboratory equipment, including X-radiographic imaging during solidification and in-situ tensile testing in a scanning electron microscope. Experiments were also performed at industrial foundry facilities.The experiments showed that the nucleation temperature of primary α-Fe intermetallics increased with higher Fe, Mn, and Cr contents. Primary α-Fe are strongly suggested to nucleate on oxides and to grow in four basic morphologies. Lower nucleation frequency of α-Fe promoted faster growth and hopper crystals while higher nucleation frequency promoted slower growth rates and massive crystals. Results also showed that a decrease in the size of the eutectic Si and plate-like β-Fe intermetallics improved tensile properties, foremost the elongation to fracture. In β-Fe containing alloys the transversely oriented intermetallics initiated macrocracks that are potential fracture initiation sites. In alloys with primary α-Fe foremost clusters of intermetallics promoted macrocracks. In fatigue testing, a transition from β-Fe to α-Fe shifted the initiation sites from oxides and pores to the α-Fe, resulting in a decrease of fatigue strength. Oxides in Al-Si alloys continue to be elusive; no correlations between efforts to quantify the oxides and tensile properties could be observed.
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| 9. |
- Bogdanoff, Toni, et al.
(författare)
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A simple procedure to assess the Complete Melt Quality in aluminium castings : implementation in a die-casting and a rheo-casting
- 2024
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Ingår i: International Journal of Cast Metals Research. - : Taylor & Francis. - 1364-0461 .- 1743-1336. ; 37:1, s. 71-79
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Tidskriftsartikel (refereegranskat)abstract
- A new simple approach was developed to assess the Complete Melt Quality of aluminium cast alloys throughout the production line. The approach relies on the concurrent use of reduced pressure tests (RPT) and tensile tests at each station in the production line when the melt is transferred and/or processed. These tests can be used to determine the source of melt-related problems in the production line. Two case studies from the procedure of both an aluminium die-casting and a rheo-casting plant showed that melts were significantly damaged in the tower furnace and got progressively more damaged through the production line proven by the RPT, tensile test, and fracture surface analysis results.
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| 10. |
- Bogdanoff, Toni, et al.
(författare)
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On the combined effects of surface quality and pore size on the fatigue life of Al–7Si–3Cu–Mg alloy castings
- 2023
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Ingår i: Materials Science & Engineering. - : Elsevier. - 0921-5093 .- 1873-4936. ; 885
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Tidskriftsartikel (refereegranskat)abstract
- This study has aimed to determine the effects of surface quality and pore size, obtained by different levels of hydrogen content of the liquid metal, on the fatigue behavior of an Al–7%Si–3%Cu–Mg casting alloy. Three surface conditions have been studied: as-cast rough, as-cast smooth, and standard machined and polished surface. The S–N curves have shown that surface roughness and hydrogen content individually impact fatigue strength. Surprisingly, the fatigue strength of machined and polished samples, which aligns with standard testing practices, is significantly reduced, compared to other conditions. Fatigue cracks have been observed to initiate at the pores just below the as-cast surface or on the machined surfaces. In all cases, pores have been observed to be surrounded by bifilms. Moreover, hydrogen content and roughness of the as-cast surface have been found to interact to determine the fatigue performance. These findings necessitate a re-evaluation of fatigue testing procedures for cast aluminum components.
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| 11. |
- Bogdanoff, Toni, et al.
(författare)
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On the Effectiveness of Rotary Degassing of Recycled Al-Si Alloy Melts : The Effect on Melt Quality and Energy Consumption for Melt Preparation
- 2023
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Ingår i: Sustainability. - : MDPI. - 2071-1050. ; 15:6
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Tidskriftsartikel (refereegranskat)abstract
- The effectiveness of rotary degassing on the defect formation and mechanical properties of the final casting of aluminium alloy EN AC 46000 was investigated, along with its impact on the energy consumption in the casting furnace. In the melt preparation prior to casting, the molten metal is usually transported from the melting furnace to the casting furnace with rotary degassing as a cleaning procedure. Under the conditions of this specific study, negligible degradation was observed in the mechanical properties of the final cast component in an aluminium EN AC 46000 alloy after removing the rotary degassing step in the process. Furthermore, removing the rotary degassing step led to a reduced temperature drop in the melt, thus minimizing the need for reheating (energy consumption) by up to 75% in the casting furnace. The reduced energy consumption was up to 124,000 kWh in yearly production in a 1500 kg casting furnace. The environmental impact showed a similar to 1500 kg reduction in CO2 for one 1500 kg electrical casting furnace in a year.
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| 12. |
- Bogdanoff, Toni, et al.
(författare)
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The complex interaction between microstructural features and crack evolution during cyclic testing in heat-treated Al–Si–Mg–Cu cast alloys
- 2021
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Ingår i: Materials Science & Engineering. - : Elsevier. - 0921-5093 .- 1873-4936. ; 825
-
Tidskriftsartikel (refereegranskat)abstract
- The study aimed to investigate crack initiation and propagation at the micro-scale in heat-treated Al–7Si–Mg cast alloys with different copper (Cu) contents. In-situ cyclic testing in a scanning electron microscope coupled with electron back-scattered diffraction and digital image correlation was used to evaluate the complex interaction between the crack path and the microstructural features. The three-nearest-neighbour distance of secondary particles was a new tool to describe the crack propagation in the alloys. The amount of Cu retained in the α-Al matrix after heat treatment increased with the Cu content in the alloy and enhanced the strength with a slight decrease in elongation. During cyclic testing, the two-dimensional (2D) crack path appeared with a mixed propagation, both trans- and inter-granular, regardless of the Cu content of the alloy. On fracture surfaces, multiple crack initiation points were detected along the thickness of the samples. The debonding of silicon (Si) particles took place during crack propagation in the Cu-free alloy, while cracking of Si particles and intermetallic phases occurred in the alloy with 3.2 wt% Cu. Three-dimensional tomography using focused ion beam revealed that the improved strength of the α-Al matrix changes the number of cracked particles ahead of the propagating crack with Cu concentration above 1.5 wt%.
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| 13. |
- Bogdanoff, Toni
(författare)
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The effect of microstructural features, defects and surface quality on the fatigue performance in Al-Si-Mg Cast alloys
- 2023
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Global warming is driving industry to manufacture lighter components to reduce carbon dioxide (CO2) emissions. Promising candidates for achieving this are aluminium-silicon (Al-Si) cast alloys, which offer a high weight-to-strength ratio, excellent corrosion resistance, and good castability. However, understanding variations in the mechanical properties of these alloys is crucial to producing high-performance parts for critical applications. Defects and oxides are the primary reasons cast components in fatigue applications are rejected, as they negatively impact mechanical properties.A comprehensive understanding of the correlation between fatigue performance and parameters such as the α-aluminium matrix, Al-Si eutectic, surface roughness, porosities, hydrogen content, oxides, and intermetallic phases in Al-Si castings has not been reached.The research presented in this thesis used state-of-the-art experimental techniques to investigate the mechanical properties and crack-initiation and propagation behaviour of Al-Si-Mg cast alloy under cyclic loading. In-situ cyclic testing was conducted using scanning electron microscopy (SEM) combined with electron back-scattered diffraction (EBSD), digital image correlation (DIC), and focused ion beam (FIB) milling. These techniques enabled a comprehensive study of parameters affecting fatigue performance, including hydrogen content, surface roughness, oxides, and intermetallic phases. More specifically, we investigated the effect of melt quality, copper (Cu) content, oxide bifilms, surface quality, and porosity.The increased Cu concentration in heat-treated Al-Si alloys increased the amount of intermetallic phases, which affected the cracking behaviour. Furthermore, oxide bifilms were detected at crack-initiation sites, even in regions far away from the highly strained areas. Si- and Iron (Fe)-rich intermetallics were observed to have precipitated on these bifilms. Due to their very small size, these oxides are generally not detected by non-destructive inspections, but affect mechanical properties because they appear to open at relatively low tensile stresses. Finally, Al-Si alloy casting skins showed an interesting effect in terms of improving fatigue performance, highlighting the negative effect of surface polishing for such alloys.
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| 14. |
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| 15. |
- Bogdanoff, Toni, et al.
(författare)
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The impact of HIP process and heat treatment on the mechanical behavior of an Al-Si-Mg alloy component
- 2023
-
Konferensbidrag (refereegranskat)abstract
- Castings generally contain pores and defects that can have a detrimental impact on mechanical properties. The hot isostatic pressing (HIP) process is usually applied to reduce internal porosities, which improves the mechanical properties because of the closed porosities. Therefore, this study investigates the effect of the HIP process on the mechanical properties of sand casting A356 aluminum alloys. This investigation was performed in collaboration with Unnaryd Modell, Quintus Technologies, and IAC Ankarsrum. Investigation of the complex interaction between the microstructural features on mechanical properties before and after the HIP process was examined using computed tomography scanning, in-situ cyclic testing, and scanning electron microscope. In the absence of large defects, the fatigue performance was improved. However, a significant variation in the result was found between the different conditions, whereas the coarser microstructure with larger porosities before the HIP process showed decreased ultimate tensile strength and elongation to failure. The samples tested under high cycle fatigue showed a reduced fatigue propagation zone in that the coarser microstructure. Moreover, large cleavage areas containing oxides in the fracture surfaces indicated that the HIP process closes all the porosities, but the oxide films are not creating a strong bonding. Furthermore, the samples tested under low cycle fatigue showed a difference in the crack propagation, whereas the coarser microstructure showed large cracks opened up away from the notch that assists the propagation leading to reduced fatigue life.
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| 16. |
- Bogdanoff, Toni, et al.
(författare)
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The impact of HIP process and heat treatment on the mechanical behaviour of an Al–Si–Mg alloy component
- 2024
-
Ingår i: International Journal of metalcasting. - : Springer. - 1939-5981 .- 2163-3193.
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Tidskriftsartikel (refereegranskat)abstract
- This study investigates the effect of hot isostatic pressing (HIPping) on the static and fatigue properties of sand-casting A356 aluminium alloys. HIPping is a method to improve the fatigue properties in aluminium cast material by reducing or eliminating the inner porosities. Investigation of the complex interaction between the microstructural features on mechanical properties before and after the HIPping process was examined using computed tomography and scanning electron microscopy (SEM). Castings generally contain pores and defects that have a detrimental impact on the fatigue properties. The HIPping process closes the porosities in all investigated samples with an increase in density. Without significant defects, the mechanical performance improved in the finer microstructure. However, a considerable variation in the results was found between the different conditions, whereas the coarser microstructure with larger porosities before HIPping showed remarkably reduced results. The high-cycle fatigue-tested samples showed reduced fatigue propagation zone in the coarser microstructure. Moreover, large cleavage areas containing bifilms in the fracture surfaces indicate that the healing process of porosities is inefficient. These porosities are closed but not healed, resulting in a detrimental effect on the static and dynamic properties.
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| 17. |
- Bogdanoff, Toni
(författare)
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The influence of microstructure on the crack initiation and propagation in Al-Si casting alloys
- 2021
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Licentiatavhandling (övrigt vetenskapligt/konstnärligt)abstract
- For reducing the CO2 footprint in many industrial fields, the goal is to produce lighter components. The aluminium-silicon (Al-Si) cast alloys are promising candidates to fulfill these goals with a high weight-to-strength ratio, good corrosion properties, excellent castability, and recyclable material. However, the variations within these components need to be understood to produce high-performance components for critical applications. The main reason for the rejection in these applications is defects and microstructural features that reduce the mechanical properties. The addition of copper (Cu) is one way of increasing the mechanical properties in Al-Si alloys and is commonly used in the automotive industry. Casting defects harm the mechanical properties, and these defects can be reduced by improving the melt quality, the correct design of the component, and the gating system.The study aims to investigate the static mechanical properties and the crack initiation and propagation under cyclic loading in an Al-7Si-Mg cast alloy with state-of-the-art experiments. The main focuses were on the effect of the HIP process and the role of Cu addition. In-situ cyclic testing using a scanning electron microscope coupled with electron back-scattered diffraction, digital image correlation, focused ion beam (FIB) slicing, and computed tomography scanning was used to evaluate the complex interaction between the crack path and the microstructural features.The amount of Cu retained in the α-Al matrix in as-cast and heat-treated conditions significantly influenced the static mechanical properties by increasing yield strength and ultimate tensile strength with a decrease in elongation. The three-nearest-neighbor distance of eutectic Si and Cu-rich particles and crack tortuosity were new tools to describe the crack propagation in the alloys, showing that a reduced distance between the Cu-rich phases is detrimental for the mechanical properties. Three dimensional tomography using a FIB revealed that the alloy with 3.2 wt.% Cu had a significantly increased quantity of cracked Si particles and intermetallic phases ahead of the crack tip than the Cu-free alloy. The effect of Cu and HIP process in this work shows the complex interaction between the microstructural features and the mechanical properties, and this needs to be considered to produce high-performance components.
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| 18. |
- Borkar, Hemant, et al.
(författare)
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Microstructure, texture and mechanical properties of al alloy a380 prepared by directional solidification method
- 2019
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Ingår i: Manufacturing Sciences and Technologies IX. - : Trans Tech Publications. - 9783035713886 - 9783035733884 ; , s. 18-23
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Konferensbidrag (refereegranskat)abstract
- The mechanical properties of Al-Si alloys are affected by several microstructural features such as secondary dendrite arm spacing (SDAS), size and shape of eutectic Si-particles, presence of intermetallics as well as by porosity. In the current study, Al-Si-Cu alloy A380 was prepared by a unique directional solidification method to produce samples with two different SDAS of 9 μm and 27 μm. The lower solidification rate resulted in larger SDAS, larger grain size, larger eutectic Si and larger intermetallics including Fe-rich β phase. The microstructure with higher solidification rate was found to be finer and more homogeneous with smaller eutectic Si and intermetallics. The specimen with larger SDAS exhibited stronger texture than the one with smaller SDAS. The specimen with smaller SDAS showed improved mechanical properties including YS, UTS and ductility.
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| 19. |
- Ceschini, Lorella, et al.
(författare)
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Aluminum and Magnesium Metal Matrix Nanocomposites
- 2017
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Bok (övrigt vetenskapligt/konstnärligt)abstract
- The book looks into the recent advances in the ex-situ production routes and properties of aluminum and magnesium based metal matrix nanocomposites (MMNCs), produced either by liquid or semi-solid state methods. It comprehensively summarizes work done in the last 10 years including the mechanical properties of different matrix/nanoreinforcement systems. The book also addresses future research direction, steps taken and missing developments to achieve the full industrial exploitation of such composites. The content of the book appeals to researchers and industrial practitioners in the area of materials development for metal matrix nanocomposites and its applications.
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| 20. |
- Dini, Hoda, 1984-
(författare)
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As-cast AZ91D magnesium alloy properties : Effects of microstructure and temperature
- 2017
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Today, there is an essential need for lightweight, energy-efficient, environmentally benign engineering systems, and this is the driving force behind the development of a wide range of structural and functional materials for energy generation, energy storage, propulsion, and transportation. These challenges have motivated the use of magnesium alloys for lightweight structural systems. Magnesium has a density of 1.74 g/cm3, which is almost 30% less than that of aluminium, one quarter of steel, and almost identicalto polymers. The ease of recycling magnesium alloys as compared to polymers makes them environmentally attractive, but their poor mechanical performance is the primary reason for the limited adoption of these alloys for structural applications.The Mg-Al-Zn alloy AZ91D exhibits an excellent combination of strength, die-castability, and corrosion resistance. However, its mechanical performance with regard to creep strength, for example, at evaluated temperatures is poor. Moreover, very little is known about the correlation between its mechanical properties and microstructural features. This thesis aims to provide new knowledge regarding the role played by microstructure in the mechanical performance of the magnesium alloy. The properties/performance of the material in relation to process parameters became of great interest during the investigation.An exhaustive characterisation of the grain size, secondary dendrite arm spacing (SDAS) distribution, and fraction of Mg17Al12 was performed using optical and electron backscatter diffraction (EBSD). These microstructural parameters were correlated to the offset yield point (Rp0.2), fracture strength, and elongation to failure of the material. It was proposed that the intermetallic phase, Mg17Al12, plays an important role in determining the mechanical and physical properties of the alloy in a temperature range of room temperature to 190°C by forming a rigid network of intermetallic. The presence of this network was confirmed by studying the thermal expansion behaviour of samples of the alloy containing different amounts of Mg17Al12.A physically based constitutive model with a wide validity range was successfully adapted to describe the flow stress behaviour of AZ91D with various microstructures. The temperature-dependent variables of the model correlated quite well with the underlying physics of the material. The model was validated through comparison with dislocation densities obtained using EBSD.The influence of high-pressure die-cast parameters on the distortion and residual stress of the cast components was studied, as were distortion and residual stress in components after shot peening and painting. Interestingly, it was found that intensification pressure has a major effect on distortion and residual stresses, and that the temperature of the fixed half of the die had a slight influence on the component's distortion and residual stress.
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| 21. |
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| 22. |
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| 23. |
- Dini, Hoda, et al.
(författare)
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Effect of Mg17Al12 Fraction on Mechanical Properties of Mg-9%Al-1%Zn Cast Alloy
- 2016
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Ingår i: Metals. - : MDPI AG. - 2075-4701. ; 6:10
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Tidskriftsartikel (refereegranskat)abstract
- In the current study it was observed that the offset yield point of Mg-9%Al-1%Zn alloy was strongly influenced by the connectivity of Mg17Al12. It was suggested that an increase in the fraction of Mg17Al12 from 8% to 11% could lead to the formation of a Mg17Al12 network which resulted in a higher offset yield point. In addition, it was observed that elongation to failure of the Mg-9%Al-1%Zn alloy strongly depended on the fraction of Mg17Al12. Moreover, the apparent toughness showed a strong inverse relation to the secondary dendrite arm spacing. This approach might be extended to forecast the behavior in other magnesium alloys forming a network of the Mg-Al phase.
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| 24. |
- Dini, Hoda, 1984-, et al.
(författare)
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Effect of Process Parameters on Distortion and Residual Stress in High-Pressure Die Cast AZ91D Components After Clean Blasting and Painting
- 2021
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Ingår i: International Journal of metalcasting. - : Springer. - 1939-5981 .- 2163-3193. ; 15:1, s. 241-258
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Tidskriftsartikel (refereegranskat)abstract
- A high-pressure die-casting process was employed to produce AZ91D components. These cast components were exposed to three different post-treatments: (1) clean blasting, (2) clean blasting and painting, and (3) painting (without clean blasting). The influence of the process parameters first phase injection speed, temperature of fixed half of the die, cooling time, and intensification pressure on distortion and residual stress of the components after each post-treatment were investigated. The results showed that intensification pressure was the most significant factor among the four parameters.
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| 25. |
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| 26. |
- Dini, Hoda, 1984-, et al.
(författare)
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Effect of process parameters on distortion and residual stress of high-pressure die-cast AZ91D components
- 2018
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Ingår i: International Journal of metalcasting. - : Springer. - 1939-5981 .- 2163-3193. ; 12:3, s. 487-497
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Tidskriftsartikel (refereegranskat)abstract
- This paper presents a study of distortion and residual stress within a high-pressure die-cast AZ91D component, cast under different processing conditions. The influence of process parameters, i.e., die temperature, cooling time, intensification pressure and first-phase injection speeds, was examined. Distortions were measured using the in-house standard analog quality control fixture. Residual stress depth profiles were measured using a prism hole-drilling method. It was found that the most important process parameter affecting the distortion was intensification pressure and the second most important was temperature difference between the two die halves (fixed and moving side). Tensile residual stresses were found very near the surface. Increasing the intensification pressure resulted in an increased level of tensile residual stresses.
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| 27. |
- Dini, Hoda, 1984-, et al.
(författare)
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Effects of microstructure on deformation behaviour of AZ91D cast alloy
- 2014
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Ingår i: TMS 2014 Annual Meeting Supplemental Proceedings TMS, The Minerals, Metals & Materials Society, San Diego, February 16-20, 2014. - : John Wiley & Sons. - 9781118889725 ; , s. 565-572
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Konferensbidrag (refereegranskat)abstract
- The deformation behavior of AZ91D cast magnesium alloy was investigated using uniaxial tensile tests from room temperature up to 190°C and strain rates from 0.0001 up to 0.1 1/s. In present work gradient solidification in a Bridgeman furnace was employed to study the effect of initial microstructure on the tensile mechanical response of the AZ91D alloy. The furnace drawing rate was varied from minimum 0.3 to maximum 6 mm/s, which yielded a variation of SDAS from 4.2 up to 25 as well as a variation of the fraction of the γ -phase (Mg17Al12),. The effects of microstructural parameters such as SDAS and γ -phase morphology on the yield strength (YS), ultimate tensile strength (UTS) and hardening were investigated
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| 28. |
- Dini, Hoda, et al.
(författare)
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Microstructural Scale Effects on Thermal Expansion Behaviour of Cast AZ91D
- 2015
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Ingår i: Magnesium Technology 2015 - TMS 2015 144th Annual Meeting and Exhibition, Orlando, March 15-19, 2015. - Hoboken : John Wiley & Sons. - 9781119082439 ; , s. 361-365
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Konferensbidrag (refereegranskat)abstract
- The effect of microstructure on thermal expansion of AZ91D cast alloy was studied. Samples with equiaxed grains and a controlled secondary dendrite arm spacing (SDAS) were fabricated using gradient solidification. SDAS was chosen to represent the range ofmicrostructural scale found in sand castings down to that of high pressure die casting. Optical microscopy and electron backscatter diffraction (EBSD) were used for microstructural characterization. The relation between thermal expansion and microstructuralscale of existing phases precipitated, in particular grain size, SDAS and fraction of Mg17Al12 was analyzed.
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| 29. |
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| 30. |
- Dini, Hoda, 1984-, et al.
(författare)
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Optimization and validation of a dislocation density based constitutive model for as-cast Mg-9%Al-1%Zn
- 2018
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Ingår i: Materials Science & Engineering. - : Elsevier. - 0921-5093 .- 1873-4936. ; 710, s. 17-26
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Tidskriftsartikel (refereegranskat)abstract
- A dislocation density-based constitutive model, including effects of microstructure scale and temperature, was calibrated to predict flow stress of an as-cast AZ91D (Mg-9%Al-1%Zn) alloy. Tensile stress-strain data, for strain rates from 10-4 up to 10-1 s-1 and temperatures from room temperature up to 190 °C were used for model calibration. The used model accounts for the interaction of various microstructure features with dislocations and thereby on the plastic properties. It was shown that the Secondary Dendrite Arm Spacing (SDAS) size was appropriate as an initial characteristic microstructural scale input to the model. However, as strain increased the influence of subcells size and total dislocation density dominated the flow stress. The calibrated temperature-dependent parameters were validated through a correlation between microstructure and the physics of the deforming alloy. The model was validated by comparison with dislocation density obtained by using Electron Backscattered Diffraction (EBSD) technique.
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| 31. |
- Du, Andong, et al.
(författare)
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On the efficient particle dispersion and transfer in the fabrication of SiC-particle-reinforced aluminum matrix composite
- 2023
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Ingår i: Crystals. - : MDPI. - 2073-4352. ; 13:12
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Tidskriftsartikel (refereegranskat)abstract
- Lightweight SiC-particle-reinforced aluminum composites have the potential to replace cast iron in brake discs, especially for electric vehicles. This study investigates the effect of SiC particle size and matrix alloy composition on the resulting transfer efficiency and particle distribution. The performance of a specially designed stirring head was studied using a water model, and the stirring head conditions were assessed to understand the particle transfer and dispersion mechanisms in the molten aluminum. The standard practice of thermal pre-treatment promotes the wetting of the reinforcing particles and commonly causes clustering before the addition to the melt. This early clustering affects the transfer efficiency and particle dispersion, where their interaction with the melt top-surface oxide skin plays an important role. In addition, the transfer efficiency was linked to the particle size and the chemical composition of the matrix alloy. Smaller particles aggravated the degree of clustering, and the addition of rare earth elements as alloying elements in the matrix alloy affected the particle dispersion. The stirring parameters should be selected to ensure cluster disruption when the carbides are added to the melt.
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| 32. |
- Du, A., et al.
(författare)
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On the hardness and elastic modulus of phases in SiC-reinforced Al composite : Role of La and Ce addition
- 2021
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Ingår i: Materials. - : MDPI. - 1996-1944. ; 14:21
-
Tidskriftsartikel (refereegranskat)abstract
- The use of silicon carbide particles (SiCp) as reinforcement in aluminium (Al)-based composites (Al/SiCp) can offer high hardness and high stiffness. The rare-earth elements like lanthanum (La) and cerium (Ce) and transition metals like nickel (Ni) and copper (Cu) were added into the matrix to form intermetallic phases; this is one way to improve the mechanical property of the composite at elevated temperatures. The α-Al15 (Fe,Mn)3 Si2, Al20 (La,Ce)Ti2, and Al11 (La,Ce)3, π-Al8 FeMg3 Si6 phases are formed. Nanoindentation was employed to measure the hardness and elastic modulus of the phases formed in the composite alloys. The rule of mixture was used to predict the modulus of the matrix alloys. The Halpin–Tsai model was applied to calculate the elastic modulus of the particle-reinforced composites. The transition metals (Ni and Cu) and rare-earth elements (La and Ce) determined a 5–15% increase of the elastic modulus of the matrix alloy. The SiC particles increased the elastic modulus of the matrix alloy by 10–15% in composite materials.
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| 33. |
- Du, A., et al.
(författare)
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Role of matrix alloy, reinforcement size and fraction in the sliding wear behaviour of Al-SiCp MMCs against brake pad material
- 2023
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Ingår i: Wear. - : Elsevier. - 0043-1648 .- 1873-2577. ; 530-531
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Tidskriftsartikel (refereegranskat)abstract
- Aluminium metal matrix composites were produced by a newly developed stirring device for stir casting with different matrix alloys, SiC particle fractions and sizes to investigate these parameters' influence on the materials' wear performance. The wear performance of the composites was evaluated with dry sliding pin-on-plate tests against a high-speed train brake pad, and the study of wear surfaces was completed by electron microscopy. The formation of an iron-based tribolayer during wear protected the metal matrix composite from further wear damage. The composite reinforced with 19% SiC particles sized 32 μm showed an increasing coefficient of friction during wear, and the wear surface showed traces of third body wear. The rare earth and transition metal added to the matrix alloy increased the hardness of the composite, and the intermetallic phases reduced the development of the Fe-based tribolayer. The composites with small SiC particles presented the Fe transfer on the exposed aluminium surface, with a lower wear rate and friction coefficient than other composites. The direct comparison of composites produced with different sizes of SiC particles highlighted that the relationship between the wear rate and the coefficient of friction of the composites and the brake pad showed a linear trend.
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| 34. |
- Du, Andong, et al.
(författare)
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The Influence of Ce, La, and SiC Particles Addition on the Formability of an Al-Si-Cu-Mg-Fe SiCp-MMC
- 2022
-
Ingår i: Materials. - : MDPI. - 1996-1944. ; 15:11
-
Tidskriftsartikel (refereegranskat)abstract
- Road transport and the associated fuel consumption plays a primary role in emissions. Weight reduction is critical to reaching the targeted reduction of 34% in 2025. Weight reduction in moving parts, such as pistons and brake disc rotors, provide a high-impact route to achieve this goal. The current study aims to investigate the formability of Al–Si alloys reinforced with different fractions and different sizes of SiCp to create an efficient and lightweight Al-MMC brake disk. Lanthanum (La) and cerium (Ce) were added to strengthen the aluminium matrix alloy and to improve the capability of the Al-MMC brake discs to withstand elevated temperature conditions, such as more extended braking periods. La and Ce formed intermetallic phases that further strengthened the composite. The analysis showed the processability and thermal stability of the different material’s combinations: increased particle sizes and broader size range mixture supported the formation of the SiCp particle interactions, acting as an internal scaffolding. In conclusion, the additions of Ce and La strengthened the softer matrix regions and resulted in a doubled compression peak strength of the material without affecting the formability, as demonstrated by the processing maps.
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| 35. |
- Du, A., et al.
(författare)
-
The influence of la and ce on microstructure and mechanical properties of an al-si-cu-mg-fe alloy at high temperature
- 2021
-
Ingår i: Metals. - : MDPI. - 2075-4701. ; 11:3
-
Tidskriftsartikel (refereegranskat)abstract
- The effect of lanthanum (La)+cerium (Ce) addition on the high-temperature strength of an aluminum (Al)–silicon (Si)–copper (Cu)–magnesium (Mg)–iron (Fe)–manganese (Mn) alloy was investigated. A great number of plate-like intermetallics, Al11 (Ce, La)3-and blocky α-Al15 (Fe, Mn)3Si2-precipitates, were observed. The results showed that the high-temperature mechanical properties depended strongly on the amount and morphology of the intermetallic phases formed. The precipitated tiny Al11 (Ce, La)3 and α-Al15 (Fe, Mn)3Si2 both contributed to the high-temperature mechanical properties, especially at 300◦C and 400◦C. The formation of coarse plate-like Al11 (Ce, La)3, at the highest (Ce-La) additions, reduced the mechanical properties at (≤300) °C and improved the properties at 400 °C. Analysis of the strengthening mechanisms revealed that the load-bearing mechanism was the main contributing mechanism with no contribution from thermal-expansion mismatch effects. Strain hardening had a minor contribution to the tensile strength at high-temperature.
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| 36. |
- Esmaily, Mohsen, 1987, et al.
(författare)
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A new semi-solid casting technique for fabricating SiC-reinforced Mg alloys matrix composites
- 2016
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Ingår i: Composites Part B: Engineering. - : Elsevier BV. - 1359-8368 .- 1879-1069. ; 94, s. 176-189
-
Tidskriftsartikel (refereegranskat)abstract
- The capability of the newly developed rheocasting (RC) technique in combination with the RheoMetal process for producing SiC particulate-reinforced AM50 and AZ91D matrix composites (Mg-based MMCs) was investigated. The quality of the MMCs was studied by analyzing the fraction of casting pores, number density of SiC clusters and the uniformity of SiC particles. Solid fraction, particle size and oxidation of SiC particles had strong impacts on the overall quality of the MMCs. The MMCs produced by 40% solid fraction and oxidized micron-sized SiC particles exhibited an excellent casting quality. A low-quality MMC was obtained when non-oxidized sub-micron sized SiC particles were employed. The results showed the formation of various types intermetallic particles and carbides such as MgO, Mg2Si, Al2MgC2, Mg2C3, Al4C3 as the interfacial reaction products of SiC/Mg alloy's melts. Mg hydride (alpha-MgH2) was also identified in inter-dendritic regions of the MMCs for the first time.
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| 37. |
- Esmaily, Mohsen, 1987, et al.
(författare)
-
Atmospheric Corrosion of Mg Alloy AZ91D Fabricated by aSemi-Solid Casting Technique: The Influence of Microstructure
- 2015
-
Ingår i: Journal of the Electrochemical Society. - : The Electrochemical Society. - 0013-4651 .- 1945-7111. ; 162:7, s. C311-C321
-
Tidskriftsartikel (refereegranskat)abstract
- The atmospheric corrosion behavior of alloy AZ91D produced by a semi-solid metal (SSM) technique and by conventional high pressure die casting (HPDC) was investigated for up to 1176 hours in the laboratory. Alloy AZ91D in the SSM state was fabricated using a rheocasting (RC) technique in which the slurry was prepared by the RheoMetal process. Exposures were performed in 95% RH air at 22 and 4 degrees C. The RC alloy AZ91D exhibited significantly better corrosion resistance than the HPDC material at two temperatures studied. The effect of casting technology on corrosion is explained in terms of the microstructural differences between the materials. For example, the larger number density of cathodic beta phase particles in the HPDC material initially causes relatively rapid corrosion compared to the RC material. During later stages of corrosion, the more network-like beta phase particles in the RC alloy act as a corrosion barrier, further improving the relative corrosion resistance of the RC material.
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| 38. |
- Esmaily, Mohsen, 1987, et al.
(författare)
-
Effect of Rheocasting on Corrosion of AM50 Mg Alloy
- 2015
-
Ingår i: Journal of the Electrochemical Society. - : The Electrochemical Society. - 0013-4651 .- 1945-7111. ; 162:3, s. C85-C95
-
Tidskriftsartikel (refereegranskat)abstract
- The corrosion behavior of magnesium-aluminum (Mg-Al) alloy AM50 produced by a rheocasting (RC) technique was examined in the presence and absence of CO2 at three temperatures -4, 4 and 22 degrees C. The slurry preparation in the RC material was performed with the newly developed RheoMetal process. For reference, 99.97% Mg was included in the corrosion exposures. The influence of the microstructure on the atmospheric corrosion of alloy AM50 produced by RC and high pressure die casting (HPDC) was investigated. The RC AM50 alloy showed better corrosion resistance than HPDC AM50 in all the exposure environments studied. For both materials, there was a strong positive correlation between temperature and the atmospheric corrosion rate. The superior atmospheric corrosion behavior of RC AM50 compared to HPDC AM50 is carefully discussed in relation to differences in the as-cast microstructure. This study demonstrates that producing the alloy AM50 by this type of RC technique opens the door to Mg-Al alloys as a promising candidate for various applications where corrosion resistance is of importance.
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| 39. |
- Esmaily, Mohsen, 1987, et al.
(författare)
-
On the microstructure and corrosion behavior of AZ91/SiC composites produced by rheocasting
- 2016
-
Ingår i: Materials Chemistry and Physics. - : Elsevier BV. - 0254-0584 .- 1879-3312. ; 180, s. 29-37
-
Tidskriftsartikel (refereegranskat)abstract
- The microstructure and atmospheric corrosion behavior of two types of SiC (10 vol%)-reinforced magnesium alloy metal matrix composites (Mg alloy AZ91D-based MMCs) produced by rheocasting (RC) were investigated and compared to the monolithic alloy. Micron-sized and nano-sized SiC particles were used for fabrication of the MMCs. Microstructural studies using a broad range of analytical techniques showed the formation Al carbides and MgO at the alpha-Mg/SiC interface. The higher corrosion rate of the MMCs than RC AZ91D was attributed to a lesser degree of connectivity of the beta phase, the high impurity level of SiC-reinforced MMCs and also the higher fraction of casting pores in the MMCs as compared to the RC alloy.
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| 40. |
- Fourlakidis, Vasilios, et al.
(författare)
-
Fatigue limit and microstructure in lamellar graphite iron
- 2021
-
Ingår i: Materials Science & Engineering. - : Elsevier. - 0921-5093 .- 1873-4936. ; 802
-
Tidskriftsartikel (refereegranskat)abstract
- Demanding environmental legislation and improve performance specifications requires increasing fatigue strength for the engine components that are made of lamellar graphite iron (LGI). Components design, metallurgy and casting conditions define the microstructure formation and mechanical properties. The graphite inclusions embedded in the metallic matrix acting as defects and have a detrimental effect on the fatigue strength of LGI. The cooling conditions determine the coarseness of the microstructure and also have, a great impact on the fatigue resistance. The experimental material was an LGI alloy produced with three different solidification times. A fully reversed fatigue test was performed, and various microstructure features were quantitatively estimated by utilizing the Gumbel's statistics of extremes. The stereological parameter of Hydraulic Diameter of the Inter-dendritic Phase and the graphite Feret size found to be the most suitable microstructure parameters to be correlated with the fatigue limit. The results also indicate the sizeable effect of the solidification time on the fatigue limit. Several other microstructure features that have been reported to influence the tensile strength were also found to be related to the fatigue limit. The obtained endurance ratio ranges from 0.25 to 0.30, a value that is in line with previous investigations.
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| 41. |
- Ghasemi, Rohollah, 1983-, et al.
(författare)
-
Abrasion resistance of lamellar graphite iron : Interaction between microstructure and abrasive particles
- 2018
-
Ingår i: Tribology International. - : Elsevier BV. - 0301-679X .- 1879-2464. ; 120, s. 465-475
-
Tidskriftsartikel (refereegranskat)abstract
- This study focuses on abrasion resistance of Lamellar Graphite Iron (LGI) using microscratch test under constant and progressive load conditions. The interactions between a semi-spherical abrasive particle, cast iron matrix and graphite lamellas were physically simulated using a sphero-conical indenter. The produced scratches were analysed using LOM and SEM to scrutinise the effect of normal load on resulting scratch depth, width, frictional force, friction coefficient and deformation mechanism of matrix during scratching. Results showed a significant matrix deformation, and change both in frictional force and friction coefficient by increase of scratch load. Furthermore, it was shown how abrasive particles might produce deep scratches with severe matrix deformation which could result in graphite lamella's coverage and thereby deteriorate LGI's abrasion resistance.
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| 42. |
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| 43. |
- Ghasemi, Rohollah, 1983-, et al.
(författare)
-
Load effect on scratch micro-mechanisms of solution strengthened Compacted Graphite Irons
- 2019
-
Ingår i: Tribology International. - : Elsevier. - 0301-679X .- 1879-2464. ; 133, s. 182-192
-
Tidskriftsartikel (refereegranskat)abstract
- This study investigates the scratch load effect, from 100 to 2000 mN, on micro-mechanisms involved during scratching. A pearlitic and three ferritic Compacted Graphite Irons (CGI) solution strengthened through addition of 3.66, 4.09, and 4.59 Si wt% were investigated. Good correlation was observed between hardness measurements, tensile testing, and scratch results explaining the influence of matrix characteristics on scratch behaviour for investigated alloys. A significant matrix deformation, change in frictional force and scratch coefficient of friction was observed by increase in scratch load. In all cases, microscratch depth and width increased significantly with load increasing, however pearlitic CGI showed most profound deformation, while the maximum and minimum scratch resistances were observed for high-Si ferritic and pearlitic CGI alloys, respectively.
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| 44. |
- Ghasemi, Rohollah, et al.
(författare)
-
Mechanical properties of Solid Solution-Strengthened CGI
- 2016
-
Ingår i: International Journal of Cast Metals Research. - : Taylor and Francis Ltd.. - 1364-0461 .- 1743-1336. ; 29:1-2, s. 98-105
-
Tidskriftsartikel (refereegranskat)abstract
- Despite the increased usage of pearlitic compacted graphite iron (CGI) in heavy vehicle engines, poor machinability of this material remains as one of the main technical challenges as compared to conventional lamellar iron. To minimise the machining cost, it is believed that solution-strengthened CGI material with a ferritic matrix could bring an advantage. The present study focuses on the effect of solution strengthening of silicon and section thickness on tensile, microstructure and hardness properties of high-Si CGI materials. To do so, plates with thicknesses from 7 to 75 mm were cast with three different target silicon levels 3.7, 4.0 and 4.5 wt%. For all Si levels, the microstructure was ferritic with a very limited pearlite content. The highest nodularity was observed in 7 and 15 mm plate sections, respectively, however, it decreased as the plate thickness increased. Moreover, increasing Si content to 4.5 wt% resulted in substantial improvement up to 65 and 50% in proof stress and tensile strength, respectively, as compared to pearlitic CGI. However, adding up Si content to such a high level remarkably deteriorated elongation to failure. For each Si level, results showed that the Young’s modulus and tensile strength are fairly independent of the plate thickness (30–75 mm), however, a significant increase was observed for thin section plates, particularly 7 mm plate due to the higher nodularity in these sections.
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| 45. |
- Ghasemi, Rohollah, 1983-, et al.
(författare)
-
Mechanical properties of solid solution strengthened CGI
- 2014
-
Ingår i: 10th International Symposium on the Science and Processing of Cast Iron Proceedings.
-
Konferensbidrag (refereegranskat)abstract
- The development of high-performing components is crucial in applications such as heavy vehicle automotive powertrains. In these applications, strength, weight and thermal conductivity is essential properties. Key materials that may fulfil these requirements include cast irons of different grades where in terms of manufacturability and in particular machinability pearlitic grades are difficult due to hardness variation, where a fully ferritic matrix would provide an advantage. To achieve maximum strength a fully ferritic and solid solution strengthened compacted graphite iron (CGI) would provide an interesting alternative to the automotive industry. In the current study, the effect of Si level on mechanical properties in a fully ferritic material was investigated. The influence of section thickness on tensile properties and hardness was investigated. The resulting material was fully ferritic with limited pearlite content. Section thickness influence on nodularity and hence the mechanical properties were also investigated.
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| 46. |
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| 47. |
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| 48. |
- Ghasemi, Rohollah, et al.
(författare)
-
Modelling and simulation of local mechanical properties of high silicon solution-strengthened ferritic compacted graphite iron
- 2017
-
Ingår i: International Journal of Cast Metals Research. - : Taylor & Francis Group. - 1364-0461 .- 1743-1336. ; 30:3, s. 125-132
-
Tidskriftsartikel (refereegranskat)abstract
- This study focuses on the modelling and simulation of local mechanical properties of compacted graphite iron cast at different section thicknesses and three different levels of silicon, ranging from about 3.6% up to 4.6%. The relationship between tensile properties and microstructure is investigated using microstructural analysis and statistical evaluation. Models are generated using response surface methodology, which reveal that silicon level and nodularity mainly affect tensile strength and 0.2% offset yield strength, while Young′s modulus is primarily affected by nodularity. Increase in Si content improves both the yield and tensile strength, while reduces elongation to failure. Furthermore, mechanical properties enhance substantially in thinner section due to the high nodularity. The obtained models have been implemented into a casting process simulation, which enables prediction of local mechanical properties of castings with complex geometries. Very good agreement is observed between the measured and predicted microstructures and mechanical properties, particularly for thinner sections.
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| 49. |
- Ghasemi, Rohollah, 1983-, et al.
(författare)
-
Scratch behaviour of silicon solid solution strengthened ferritic compacted graphite iron (CGI)
- 2018
-
Ingår i: Materials Science Forum. - : Trans Tech Publications. - 0255-5476 .- 1662-9752. - 9783035710557 ; 925, s. 318-325
-
Tidskriftsartikel (refereegranskat)abstract
- The present study focuses on scratch behaviour of a conventional pearlitic and a number of solid solution strengthened ferritic Compacted Graphite Iron (CGI) alloys. This was done by employing a single-pass microscratch test using a sphero-conical diamond indenter under different constant normal load conditions. Matrix solution hardening was made by alloying with different contents of Si; (3.66, 4.09 and 4.59 wt%. Si) which are named as low-Si, medium-Si and high-Si ferritic CGI alloys, respectively. A good correlation between the tensile and scratch test results was observed explaining the influence of CGI’s matrix characteristics on scratch behaviour both for pearlitic and fully ferritic solution strengthened ones. Both the scratch depth and scratch width showed strong tendency to increase with increasing the normal load, however the pearlitic one showed more profound deformation compared to the solution strengthened CGI alloys. Among the investigated alloys, the maximum and minimum scratch resistance were observed for high-Si ferritic CGI and pearlitic alloys, respectively. It was confirmed by the scratched surfaces analysed using Scanning Electron Microscopy (SEM) as well. In addition, the indenter’s depth of penetration value (scratch depth) was found as a suitable measure to ascertain the scratch resistance of CGI alloys.
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| 50. |
- Ghasemi, Rohollah
(författare)
-
The influence of microstructure on mechanical and tribological properties of lamellar and compacted irons in engine applications
- 2016
-
Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Lamellar graphite iron (LGI) is commonly used in diesel engine applications such as piston rings–cylinder liner where an excellent combination of physical and tribological properties is essential to avoid scuffing and bore polishing issues. The excellent tribological behaviour of LGI alloys is related to the graphite lamellas, which act as solid lubricant agents by feeding onto the tribosurfaces under sliding conditions. However, increasingly tighter emissions and fuel economy legislations and the higher demands on enhanced power and durability have encouraged both engine designers and manufacturers to introduce pearlitic compacted graphite irons (CGI) as an alternative material replacing LGI, although the poor machinability of pearlitic CGI alloys compared to the LGI remains a challenge.The focus of this study is placed on investigating how the microstructure of LGI and CGI alloys affects their mechanical and tribological properties. This was initially undertaken by investigating representative, worn lamellar cast iron piston rings taken from a two-stroke large-bore heavy-duty diesel engine. As known that it is tribologically essential to keep the graphite open under sliding conditions, in particular under starved lubrication regimes or unlubricated conditions to avoid scuffing issues; however, this study revealed the closure of a majority of graphite lamellas; profoundly for those lamellas that were parallel to sliding direction; due to the severe matrix deformation caused by abrasion. Both microindentation and microscratch testing, which were used to crudely simulate the abrasion under starved lubricated condition in combustion chamber, suggested a novel mechanism of activating the graphite lamellas to serve as lubricating agents in which the matrix deformation adjacent to the graphite initially resulted in fracturing and then extrusion of the graphite lamellas.Additionally, in order to investigate the relation between matrix constituents, mechanical properties and machinability of cast iron materials, solution-strengthened CGI alloys were produced with different levels of silicon and section thicknesses. The results showed significant improvements in mechanical properties and machinability while deteriorating the ductility. Moreover, multiple regression analysis, based on chemical composition and microstructural characteristics was used to model the local mechanical properties of high Si ferritic CGI alloys, followed by implementing the derived models into a casting process simulation which enables the local mechanical properties of castings with complex geometries. Very good agreement was observed between the measured and predicted microstructure and mechanical properties.
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