Examples of Aluminium Fractography

Slides:



Advertisements
Similar presentations
Fractography Resource - 1 Examples of Steel Fractography Professor M Neil James Department of Mechanical &
Advertisements

CHE 333 Class 18 Fracture of Materials.
Mohammad Irfan, David Schwam (CWRU) Andy Karve, Randy Ryder (Neemak) Mike Cox, John Kubisch (GM) February, 2009.
Metallurgy of Welding.
MatSE 259 Exam 1 Review Session 1.Exam structure – 25 questions, 1 mark each 2.Do NOT forget to write your student I.D. on the answer sheet 3.Exams are.
LECTURER5 Fracture Brittle Fracture Ductile Fracture Fatigue Fracture
3 – Fracture of Materials
ME 240: Introduction to Engineering Materials Chapter 8. Failure 8.1 CHAPTER 8.
NEEP 541 – Creep Fall 2002 Jake Blanchard.
CHE 333 Class 20 Fracture continued.
Continuum Mechanics Mohsen Malayjerdi. » Strain : intensity of deformation strain = change in length/original length » Stress : intensity of force Stress.
BMFB 4283 NDT & FAILURE ANALYSIS
INTRODUCTION M.N. Tamin, UTM SME 4133 Failure of Engineering Components and Structures MODULE 1 INTRODUCTION SKMM 4133 Failure of Engineering Components.
Strengthening Mechanisms Metallurgy for the Non-Metallurgist.
Deformation & Strengthening Mechanisms of Materials
Welding Metallurgy 2. Lesson Objectives When you finish this lesson you will understand: The various region of the weld where liquid does not form Mechanisms.
Fractography Resource - 1 Examples of Fractography in Other Materials Professor M Neil James Department of.
PART 2 : HEAT TREATMENT. ALLOY SYSTEMS STEELS ALUMINUM ALLOYS TITANIUM ALLOYS NICKEL BASE SUPERALLOYS.
Basic Mechanisms of Fracture in Metals
The American University in Cairo Mechanical Engineering Department MENG 426: Metals, Alloys & Composites Interactive MENG 426 Lab Tutorials Experiment.
Mechanical & Aerospace Engineering West Virginia University Strengthening by Phase Transformation.
Chapter 3 Structure and Manufacturing Properties of Metals
Welding Metallurgy 2.
LECTURER6 Factors Affecting Mechanical Properties
Annealing Processes All the structural changes obtained by hardening and tempering may be eliminated by annealing. to relieve stresses to increase softness,
Aluminum 7075 Microstructure and Current Research through the use of In-situ X-ray Diffraction By: Jay Schuren.
Fracture Toughness & Fatigue
Low Cycle Fatigue (LCF) High Cycle Fatigue (HCF)
INTRODUCTION The ultimate goal of a manufacturing engineer is to produce steel/metal components with required geometrical shape and structurally optimized.
Early structural concepts  Some of the structures in earlier have endured for ages.  Materials used were brittle type like bricks, stones, mortar: poor.
Queen’s University Belfast Crest; Coat of Arms; Emblem.
Precipitation, microstructure and mechanical properties of maraging steels Wei SHA Professor of Materials Science
Evaluation of the Susceptibility of Simulated Welds In HSLA-100 and HY-100 Steels to Hydrogen Induced Cracking R. E. Ricker, M. R. Stoudt, and D. J. Pitchure.
Fatigue Fatigue is the lowering of strength or the failure of a material due to repetitive stress, which may be above or below the yield strength. Many.
Solidification, Lecture 2
FRACTURE MECHANICS MENG 486 BY DR. O. PHILLIPS AGBOOLA.
FATIGUE Fatigue of Materials (Cambridge Solid State Science Series) S. Suresh Cambridge University Press, Cambridge (1998)
FATIGUE Fatigue of Materials (Cambridge Solid State Science Series) S. Suresh Cambridge University Press, Cambridge (1998) MATERIALS SCIENCE &ENGINEERING.
B. Titanium-based Alloys Titanium is hcp at room temperature – and transform to the bcc structure on heating to 883 o C. Alloying elements are added to.
1. Introduction Assoc.Prof.Dr. Ahmet Zafer Şenalp Mechanical Engineering Department Gebze Technical.
Identification of most promising candidate alloys for fuel cladding and core internal structures SCWR Information Meeting - April 29-30, 2003 UW-Madison.
Hardness testing - localized deformation Brinell Vickers Knoop Rockwell Hardness/tensile strength correlation Impact testing - energy absorbed upon fracture.
Welding Inspection and Metallurgy
Jiangyu Li, University of Washington Yielding and Failure Criteria Plasticity Fracture Fatigue Jiangyu Li University of Washington Mechanics of Materials.
Silicon Pure aluminium melts at 660.4° C it is not suitable for casting and is only used for electrical applications (where high conductivity is essential),
Numbering and Classification of Non-ferrous metals
Lecture 7 Review of Difficult Topics MATLS 4L04: Aluminum Section.
Plastic deformation Extension of solid under stress becomes
FAILURE ANALYSISOF WELDED COMPONENTS
MatSE 259 Exam 1 Review Session 1.Exam structure – 25 questions, 1 mark each 2.Do NOT forget to write your student I.D. on the answer sheet 3.Exams are.
ENT 487 FRACTURE MECHANISMS IN METALS
Materials Science Metals and alloys.
A Seminar Report On Fracture Mechanism In Design And Failure Analysis
SHUBHAM VERMA. Fracture Mechanism In Design And Failure Analysis PREPARED BY SHUBHAM VERMA ME-2 nd Roll No.:BT/ME/1601/020.
Examples of Wheel Failures
What is cast iron? Alloys of iron and carbon with more than 2.11% carbon are called cast irons.
Noteworthy advantages of using aluminum alloys
Effect of Tunneling Defect in Friction Stir Welding of Al-Mg Alloys
ENT 487 FRACTURE MECHANISMS IN METALS
Materials Engineering
© 2016 Cengage Learning Engineering. All Rights Reserved.
CHE 333 Class 20 Fracture continued.
Chapter 2 Material and Manufacturing Properties
Behavior of Materials in Service
FATIGUE FATIGUE Dr. Mohammed Abdulrazzaq
CAMS 2018 Advancing Materials and Manufacturing November 27-29, University of Wollongong, NSW AUSTRALIA The 6th Conference of the Combined Australian.
DR. AL EMRAN ISMAIL FRACTURE MECHANISMS.
CHE 333 Class 18 Fracture of Materials.
Table 1. Chemical Composition of Base Aluminium Alloys
Presentation transcript:

Examples of Aluminium Fractography Professor M Neil James mjames@plymouth.ac.uk Department of Mechanical & Marine Engineering University of Plymouth Drake Circus, Plymouth PL4 8AA ENGLAND Fractography Resource - mjames@plymouth.ac.uk

Contents – Use the hyperlinks to navigate around this resource Bend fatigue of 6261-T6 alloy Torsion fatigue of 6061-T6 alloy Ductile fracture of 6061-T6 alloy Fatigue of 8090-T8511 Al-Li alloy Ductile fracture of 8090-T8511 Al-Li alloy Bend fatigue of friction stir welded 5383-H321 alloy Ductile fracture of 5383-H321 alloy Defects in an aluminium-silicon-magnesium casting alloy Fractography Resource - mjames@plymouth.ac.uk

Bend fatigue of 6261-T6 alloy Al 0.74Mg 0.63Si 0.19Fe 0.26Cu 0.025Zn 0.020Ti Peak aged - PS = 282 MPa – Parent Plate (I-beam flange) Linear growth rate regime ~ 10-4 mm/cycle Arrows indicate grain boundaries Original magnification 80x Fractography Resource - mjames@plymouth.ac.uk

Bend fatigue of 6261-T6 alloy Al 0.74Mg 0.63Si 0.19Fe 0.26Cu 0.025Zn 0.020Ti Peak aged - PS = 282 MPa – Crack at weld toe of cover plate Linear growth rate regime ~ 10-4 mm/cycle The HAZ appears to be embrittled, and cleavage facets are present Original magnification 20x Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Torsion fatigue of 6061-T6 alloy Al 0.8-1.0Mg 0.4-0.8Si 0.70Fe 0.15-0.40Cu 0.25Zn 0.15Ti 0.15Mn Peak aged - PS = 312 MPa – extruded rod Crack initiation region Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Torsion fatigue of 6061-T6 alloy Al 0.8-1.0Mg 0.4-0.8Si 0.70Fe 0.15-0.40Cu 0.25Zn 0.15Ti 0.15Mn Peak aged - PS = 312 MPa – extruded rod Crack initiation region – smooth areas of slip band cracking are present Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Torsion fatigue of 6061-T6 alloy Al 0.8-1.0Mg 0.4-0.8Si 0.70Fe 0.15-0.40Cu 0.25Zn 0.15Ti 0.15Mn Peak aged - PS = 312 MPa – extruded rod Crack growth appears to have a component of MVC Original magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Ductile fracture of 6061-T6 alloy Al 0.8-1.0Mg 0.4-0.8Si 0.70Fe 0.15-0.40Cu 0.25Zn 0.15Ti 0.15Mn Peak aged - PS = 312 MPa – extruded rod Precipitate particles are present at the bottom of voids Original magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Fatigue of 8090-T8511 Al-Li alloy Al 2.37Li 1.19Cu 0.82Mg 0.11Zr Peak aged - PS = 300 MPa – large extrusion 120 mm by 100 mm Heat treatment leads to grain boundary precipitation of Al2CuMg, which affects crack growth IG regions are often present Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Fatigue of 8090-T8511 Al-Li alloy Al 2.37Li 1.19Cu 0.82Mg 0.11Zr Peak aged - PS = 300 MPa – large extrusion 120 mm by 100 mm Heat treatment leads to grain boundary precipitation of Al2CuMg, which affects crack growth IG regions are often present Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Fatigue of 8090-T8511 Al-Li alloy Al 2.37Li 1.19Cu 0.82Mg 0.11Zr Peak aged - PS = 300 MPa – large extrusion 120 mm by 100 mm Heat treatment leads to grain boundary precipitation of Al2CuMg, which affects crack growth Typical IG region at high magnification Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Fatigue of 8090-T8511 Al-Li alloy Al 2.37Li 1.19Cu 0.82Mg 0.11Zr Peak aged - PS = 300 MPa – large extrusion 120 mm by 100 mm Heat treatment leads to grain boundary precipitation of Al2CuMg, which affects crack growth 'Blocky' striated fatigue also occurs Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Fatigue of 8090-T8511 Al-Li alloy Al 2.37Li 1.19Cu 0.82Mg 0.11Zr Peak aged - PS = 300 MPa – large extrusion 120 mm by 100 mm Heat treatment leads to grain boundary precipitation of Al2CuMg, which affects crack growth Regions of 'normal' striated fatigue also occur Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Fatigue of 8090-T8511 Al-Li alloy Al 2.37Li 1.19Cu 0.82Mg 0.11Zr Peak aged - PS = 300 MPa – large extrusion 120 mm by 100 mm Interface between ductile fast fracture (MVC) and fatigue is shown here Original magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Ductile fracture of 8090-T8511 Al-Li alloy Al 2.37Li 1.19Cu 0.82Mg 0.11Zr Peak aged - PS = 300 MPa – large extrusion 120 mm by 100 mm Typical MVC is shown here Original magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Bend Fatigue of 5383-H321 alloy Al 4.43Mg 0.78Mn 0.12Si 0.21Zn 0.09Fe 0.09Cu 0.09Cr Strain hardened – quarter hard - PS = 272 MPa – single pass friction stir welded Crack initiation is from tool travel marks Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Bend Fatigue of 5383-H321 alloy Al 4.43Mg 0.78Mn 0.12Si 0.21Zn 0.09Fe 0.09Cu 0.09Cr Strain hardened – quarter hard - PS = 272 MPa – single pass friction stir welded High cycle fatigue shows signs of the underlying microstructure Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Bend Fatigue of 5383-H321 alloy Al 4.43Mg 0.78Mn 0.12Si 0.21Zn 0.09Fe 0.09Cu 0.09Cr Strain hardened – quarter hard - PS = 272 MPa – single pass friction stir welded Low cycle fatigue appears more generally ductile striated growth Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Bend Fatigue of 5383-H321 alloy Al 4.43Mg 0.78Mn 0.12Si 0.21Zn 0.09Fe 0.09Cu 0.09Cr Strain hardened – quarter hard - PS = 272 MPa – single pass friction stir welded Low cycle fatigue shows clear striations at high magnification Original magnification given by micron marker Fractography Resource - mjames@plymouth.ac.uk

Bend Fatigue of 5383-H321 alloy Al 4.43Mg 0.78Mn 0.12Si 0.21Zn 0.09Fe 0.09Cu 0.09Cr Strain hardened – quarter hard - PS = 272 MPa – single pass friction stir welded SP FSW can lead to partial-fusion defects in the weld nugget (also called 'kissing' bonds) Original magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Ductile Fracture of 5383-H321 alloy Al 4.43Mg 0.78Mn 0.12Si 0.21Zn 0.09Fe 0.09Cu 0.09Cr Strain hardened – quarter hard - PS = 272 MPa – single pass friction stir welded MVC in this alloy Original magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Defects in welded Al-Si-Mg casting alloy Intergranular-interdendritic hot cracking Magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Defects in welded Al-Si-Mg casting alloy Wormhole porosity Magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Defects in welded Al-Si-Mg casting alloy Possible layer porosity Magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Defects in welded Al-Si-Mg casting alloy Illustration of the formation of layer porosity during solidification of an aluminium alloy where the freezing range is large and/or the temperature gradient is low (i.e. solidification occurs over an extended time). Magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Defects in welded Al-Si-Mg casting alloy HC+UC Fatigue crack (F) which has been initiated by a region of hot cracking and undercut/slag inclusion (HC+UC). Magnification given by micron marker Back to Contents F Fractography Resource - mjames@plymouth.ac.uk

Defects in welded Al-Si-Mg casting alloy Increasing the size of the image reveals faint striation-like markings whose spacing indicate a fast growth rate of ~ 1x10-3 mm/cycle of load at this point. Magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Defects in welded Al-Si-Mg casting alloy Illustrative crack growth rate curve for an Al alloy; a crack growth rate of 1x10-3 mm/cycle of load lies in Region III of the curve. Magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk

Defects in welded Al-Si-Mg casting alloy Parts of both the fatigue and the brittle fracture surfaces, as well as some regions of porosity show the presence of needles, which EDS indicated are likely to be the iron-rich β-phase, Al5FeSi. This phase is known to detrimentally influence the mechanical properties of Al-Si-Mg alloys. Magnification given by micron marker Back to Contents Fractography Resource - mjames@plymouth.ac.uk