Friction stir processing: A thermomechanical processing tool for high pressure die cast Al-alloys for vehicle light-weighting

Samanta, Avik; Das, Hrishikesh; Grant, Glenn J.; Jana, Saumyadeep

doi:10.1016/j.mfglet.2024.09.061

Title: Friction stir processing: A thermomechanical processing tool for high pressure die cast Al-alloys for vehicle light-weighting

Journal Article · 15 October 2024 · Manufacturing Letters

DOI: https://doi.org/10.1016/j.mfglet.2024.09.061 · OSTI ID:2522680

Samanta, Avik ^[1]; Das, Hrishikesh ^[2]; Grant, Glenn J. ^[2]; Jana, Saumyadeep ^[2]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States); University of South Florida, Tampa, FL (United States)
Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

This study uses friction stir processing (FSP) for thermomechanical processing of high-pressure die-casting (HPDC) to modify microstructure and improve mechanical properties. FSP is carried out on two different HPDC aluminum alloys: (a) general-purpose, high-iron, HPDC A380 alloy and (b) premium quality, low-iron HPDC Aural-5 alloy in thin wall, flat plate geometry. Subsequent mechanical testing shows ~30 % and ~65 % enhancement in yield strength and tensile ductility. In addition, FSP leads to ~10 times improvement in fatigue life for A380 alloy and ~70 % improvement in fracture toughness for Aural-5 alloy. These findings emphasize the capability of FSP to modify the microstructure of HPDC Al-alloys-based structural components so that they can demonstrate a good combination of strength, ductility, fracture toughness, and high fatigue properties for long-term durability and reliability.

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

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

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 2522680

Report Number(s):: PNNL-SA--179890

Journal Information:: Manufacturing Letters, Journal Name: Manufacturing Letters Vol. 41; ISSN 2213-8463

Publisher:: Society of Manufacturing Engineers, ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Title: Friction stir processing: A thermomechanical processing tool for high pressure die cast Al-alloys for vehicle light-weighting

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