Enhanced toughness and tear resistance of thin-walled High-Pressure Die-Cast aluminum alloys through Friction stir processing

Samanta, Avik; Lall, Amrita; Das, Hrishikesh; Seffens, Robert J.; Grant, Glenn J.; Jana, Saumyadeep

doi:10.1016/j.matlet.2023.135752

Enhanced toughness and tear resistance of thin-walled High-Pressure Die-Cast aluminum alloys through Friction stir processing

Journal Article · Wed Dec 13 00:00:00 EST 2023 · Materials Letters

DOI:https://doi.org/10.1016/j.matlet.2023.135752· OSTI ID:2337587

^[1]; Lall, Amrita ^[1]; Das, Hrishikesh ^[1]; ^[1]; Grant, Glenn J. ^[1]; Jana, Saumyadeep ^[1]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

In this study, we investigate the toughness and resistance to tear of thin-wall high-pressure die-cast (HPDC) aluminum alloys in two different orientations following the implementation of friction stir processing (FSP). The FSP technique was applied to two different HPDC Al-Si alloys: the recyclable-grade, high iron, A380 alloy and the premium-quality, low iron, Aural-5 alloy. Our findings reveal significant tear resistance and strength enhancements for both alloys after FSP modification. Specifically, FSPed A380 alloy requires 126% higher energy to tear, and it has 49% higher tear strength than the HPDC counterpart. Similarly, the tear energy and tear strength of the Aural-5 alloy witness enhancements of 69% and 21%, respectively. In conclusion, these results highlight the potential of FSP as a viable method for augmenting the mechanical properties of HPDC aluminum alloys, thereby opening up new avenues for their utilization in diverse engineering applications for crack obstruction.

View Accepted Manuscript (DOE)

Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE; USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 2337587

Alternate ID(s):: OSTI ID: 2246672

Report Number(s):: PNNL-SA--191954

Journal Information:: Materials Letters, Journal Name: Materials Letters Vol. 357; ISSN 0167-577X

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
Aluminum alloys
Aural alloy
Friction stir processing
High-pressure die-casting
Tear resistance
Toughness

Enhanced toughness and tear resistance of thin-walled High-Pressure Die-Cast aluminum alloys through Friction stir processing

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