Tribocorrosion properties of friction stir welded and laser welded titanium alloy
- Authors: Davoren, Brandon Hilton
- Date: 2017
- Subjects: Chemistry, Technical -- Research Materials -- Mechanical properties , Aluminum alloys
- Language: English
- Type: Thesis , Masters , MSc
- Identifier: http://hdl.handle.net/10948/33250 , vital:32605
- Description: Titanium alloy Ti6Al4V has extensive uses in aerospace, dentistry and the biomedical industry. When used in these applications there is often a need to weld two or more pieces of titanium alloy together. This can be done by either friction stir weld or laser weld methods. These welded regions are often exposed to corrosive environments in addition to factors such as induced additional mechanical wear. Thus to accurately report on the viability of the material in a specific application, the corrosion, wear and their synergistic effects need to be studied. Friction stir welding, which is a well-suited method for joining plates of Ti6Al4V, creates regions in the material that are affected differently. These regions can be described as the parent material, advancing side, retreating side and the weld zone. The tribological properties of the different friction stir weld regions were analysed in air using different loads, frequencies, experimental duration and surrounding environments. When the applied load was increased some of the weld regions showed an increase in the specific wear rate. For example, the weld zone region showed a decrease when compared to the parent material. In this tribology study the effect of the counter material was evaluated. E52100, Si3N4, SS 316 and alumina counter materials were used in the test procedure which was conducted in air on the weld regions. The parent material was found to have the highest average specific wear rates with the four counter materials when compared to the weld zone samples. The regions affected by the friction stir weld process all showed, on average, lower specific wear rates than the parent material. For the various tested samples, the coefficient of friction and material compatibility that was found to be the most stable, was the alumina ball. Owing to this as well as its chemical stability, alumina was determined to be the best material for further tribocorrosion studies. The friction stir welded samples, that were cut from a cross section of a friction stir weld plate, were analyzed in 3.5% NaCl and dilute Harrison’s solution respectively. The effect of wear on the electrochemical properties was studied under open circuit voltage (OCV) and fixed 0.2 V and 0.4 V applied potential conditions respectively. The effect of wear on the corrosion properties was studied using potentiodynamic polarization. From analyzing the friction stir weld regions in both a wear and wear-free environment, the synergistic properties, namely the effect of wear on corrosion and the effect of corrosion on wear, were able to be calculated. The first electrochemical study was performed under OCV conditions. In the presence of applied wear, the open circuit potential of the friction stir weld samples, in both 3.5% NaCl and dilute Harrison’s solution, was found to decrease from the initial stabilized value. Of interest was the rate at which the OCV recovered. It was found to follow a second order repassivation growth model which was explained in terms of an initial film growth stage, followed by a film thickening stage that results in a new OCV. The second synergized electrochemical-wear study was under fixed 0.2 V and 0.4 V applied potential conditions. In both solutions, 3.5% NaCl and dilute Harrison’s solution, a large increase in the current was observed during the applied wear experiment. The samples submerged in 3.5% NaCl were found to have higher average currents during the wear experiment than those in dilute Harrison’s solution. The rapid decrease in the current, after the applied wear ceased, was found to also follow the second order repassivation model. The electrochemical-wear synergism was done by using potentiodynamic polarization tests. The friction stir weld regions as well as the laser samples were analysed in a wear as well as a wear-free environment in order to determine the effect that wear had on the corrosion properties. In both 3.5% NaCl and dilute Harrison’s solution the corrosion rates were found to increase by 100-fold when the wear was present. The effect of the wear process on corrosion could also be described by synergistic factor, where values close to 1 would imply that applied wear had little effect on the corrosion properties and vice versa. The synergistic factors showed that the corrosion rate was greatly affected by the presence of wear with corrosion synergistic factors of 20 and upward for the friction stir welded samples. The results showed that the weld zone region had a lower corrosion rate than the parent material. This implied that the main weld zone was shown to have the least effect of wear on corrosion and would therefore show the lowest likelihood of failure due to corrosion when compared to the parent material. The wear synergistic factor was found to be between 1 and 1.6 for the friction stir weld regions. This implied that the wear rates of the friction stir welded samples were slightly affected by the presence of a corrosive environment and that the wear properties of the laser welded samples were enhanced by the presence of a corrosive environment. Similar studies performed on laser welded samples showed unusually different results due to the small nature of the laser weld region, with inconclusive results when compared to the friction stir welded samples.
- Full Text:
- Date Issued: 2017
- Authors: Davoren, Brandon Hilton
- Date: 2017
- Subjects: Chemistry, Technical -- Research Materials -- Mechanical properties , Aluminum alloys
- Language: English
- Type: Thesis , Masters , MSc
- Identifier: http://hdl.handle.net/10948/33250 , vital:32605
- Description: Titanium alloy Ti6Al4V has extensive uses in aerospace, dentistry and the biomedical industry. When used in these applications there is often a need to weld two or more pieces of titanium alloy together. This can be done by either friction stir weld or laser weld methods. These welded regions are often exposed to corrosive environments in addition to factors such as induced additional mechanical wear. Thus to accurately report on the viability of the material in a specific application, the corrosion, wear and their synergistic effects need to be studied. Friction stir welding, which is a well-suited method for joining plates of Ti6Al4V, creates regions in the material that are affected differently. These regions can be described as the parent material, advancing side, retreating side and the weld zone. The tribological properties of the different friction stir weld regions were analysed in air using different loads, frequencies, experimental duration and surrounding environments. When the applied load was increased some of the weld regions showed an increase in the specific wear rate. For example, the weld zone region showed a decrease when compared to the parent material. In this tribology study the effect of the counter material was evaluated. E52100, Si3N4, SS 316 and alumina counter materials were used in the test procedure which was conducted in air on the weld regions. The parent material was found to have the highest average specific wear rates with the four counter materials when compared to the weld zone samples. The regions affected by the friction stir weld process all showed, on average, lower specific wear rates than the parent material. For the various tested samples, the coefficient of friction and material compatibility that was found to be the most stable, was the alumina ball. Owing to this as well as its chemical stability, alumina was determined to be the best material for further tribocorrosion studies. The friction stir welded samples, that were cut from a cross section of a friction stir weld plate, were analyzed in 3.5% NaCl and dilute Harrison’s solution respectively. The effect of wear on the electrochemical properties was studied under open circuit voltage (OCV) and fixed 0.2 V and 0.4 V applied potential conditions respectively. The effect of wear on the corrosion properties was studied using potentiodynamic polarization. From analyzing the friction stir weld regions in both a wear and wear-free environment, the synergistic properties, namely the effect of wear on corrosion and the effect of corrosion on wear, were able to be calculated. The first electrochemical study was performed under OCV conditions. In the presence of applied wear, the open circuit potential of the friction stir weld samples, in both 3.5% NaCl and dilute Harrison’s solution, was found to decrease from the initial stabilized value. Of interest was the rate at which the OCV recovered. It was found to follow a second order repassivation growth model which was explained in terms of an initial film growth stage, followed by a film thickening stage that results in a new OCV. The second synergized electrochemical-wear study was under fixed 0.2 V and 0.4 V applied potential conditions. In both solutions, 3.5% NaCl and dilute Harrison’s solution, a large increase in the current was observed during the applied wear experiment. The samples submerged in 3.5% NaCl were found to have higher average currents during the wear experiment than those in dilute Harrison’s solution. The rapid decrease in the current, after the applied wear ceased, was found to also follow the second order repassivation model. The electrochemical-wear synergism was done by using potentiodynamic polarization tests. The friction stir weld regions as well as the laser samples were analysed in a wear as well as a wear-free environment in order to determine the effect that wear had on the corrosion properties. In both 3.5% NaCl and dilute Harrison’s solution the corrosion rates were found to increase by 100-fold when the wear was present. The effect of the wear process on corrosion could also be described by synergistic factor, where values close to 1 would imply that applied wear had little effect on the corrosion properties and vice versa. The synergistic factors showed that the corrosion rate was greatly affected by the presence of wear with corrosion synergistic factors of 20 and upward for the friction stir welded samples. The results showed that the weld zone region had a lower corrosion rate than the parent material. This implied that the main weld zone was shown to have the least effect of wear on corrosion and would therefore show the lowest likelihood of failure due to corrosion when compared to the parent material. The wear synergistic factor was found to be between 1 and 1.6 for the friction stir weld regions. This implied that the wear rates of the friction stir welded samples were slightly affected by the presence of a corrosive environment and that the wear properties of the laser welded samples were enhanced by the presence of a corrosive environment. Similar studies performed on laser welded samples showed unusually different results due to the small nature of the laser weld region, with inconclusive results when compared to the friction stir welded samples.
- Full Text:
- Date Issued: 2017
Optical diamond turning of rapidly solidified aluminium alloy grade - 431
- Authors: Oyekunle, Funsho Adekunle
- Date: 2020
- Subjects: Aluminum alloys
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/46860 , vital:39670
- Description: The high demand for ultraprecision machining systems is increasing day by day. The technology leads to increased productivity and quality manufactured products, with an excellent surface finish. Therefore, these products are in demand in many industrial fields such as space, national defence, the medical industry and other high-tech industries. Single point diamond turning (SPDT) is the core technology of ultraprecision machining, which makes use of single-point crystalline diamond as a cutting tool. This technique is used for machining an extensive selection of complex optical surfaces and other engineering products with a quality surface finish. SPDT can achieve dimensional tolerances in order of 0.01um and surface roughness in order of 1nm. SPDT is not restricted, but mostly applicable, to non-ferrous alloys; due to their reflective properties and microstructure that discourages tool wear. The focus of this study is the development of predictive optimisation models, used to analyse the influence of machining parameters (speed, feed, and depth of cut) on surface roughness. Moreover, the study aims to obtain the optimal machining parameters that would lead to minimum surface roughness during the diamond turning of Rapidly Solidified Aluminium (RSA) 431. In this study, Precitech Nanoform 250 Ultra grind machine was used to perform two experiments on RSA 431. The first machining process, experiment 1, was carried out using pressurized kerosene mist; while experiment 2 was carried out with water as the cutting fluid. In each experiment, machine parameters were varied at intervals and the surface roughness of the workpiece was measured at each variation. The measurements were taken through a contact method using Taylor Hobson PGI Dimension XL surface Profilometer. Acoustic emission (AE) was employed as a precision sensing technique – to optimize the machining quality process and provide indications of the expected surface roughness. The results obtained revealed that better surface roughness can be generated when RSA 431 is diamond-turned using water as a cutting fluid, rather than kerosene mist. Predictive models for surface roughness were developed for each experiment, using response surface methodology (RSM) and artificial neural networks (ANN). Moreover, RSM was used for optimisation. Time domain features acquired from AE signals, together with the three cutting parameters, were used as input parameters in the ANN design. The results of the predictive models show a close relationship between the predicted values and the experimental values for surface roughness. The developed models have been compared in terms of accuracy and cost of computation - using the mean absolute percentage error (MAPE).
- Full Text:
- Date Issued: 2020
- Authors: Oyekunle, Funsho Adekunle
- Date: 2020
- Subjects: Aluminum alloys
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/46860 , vital:39670
- Description: The high demand for ultraprecision machining systems is increasing day by day. The technology leads to increased productivity and quality manufactured products, with an excellent surface finish. Therefore, these products are in demand in many industrial fields such as space, national defence, the medical industry and other high-tech industries. Single point diamond turning (SPDT) is the core technology of ultraprecision machining, which makes use of single-point crystalline diamond as a cutting tool. This technique is used for machining an extensive selection of complex optical surfaces and other engineering products with a quality surface finish. SPDT can achieve dimensional tolerances in order of 0.01um and surface roughness in order of 1nm. SPDT is not restricted, but mostly applicable, to non-ferrous alloys; due to their reflective properties and microstructure that discourages tool wear. The focus of this study is the development of predictive optimisation models, used to analyse the influence of machining parameters (speed, feed, and depth of cut) on surface roughness. Moreover, the study aims to obtain the optimal machining parameters that would lead to minimum surface roughness during the diamond turning of Rapidly Solidified Aluminium (RSA) 431. In this study, Precitech Nanoform 250 Ultra grind machine was used to perform two experiments on RSA 431. The first machining process, experiment 1, was carried out using pressurized kerosene mist; while experiment 2 was carried out with water as the cutting fluid. In each experiment, machine parameters were varied at intervals and the surface roughness of the workpiece was measured at each variation. The measurements were taken through a contact method using Taylor Hobson PGI Dimension XL surface Profilometer. Acoustic emission (AE) was employed as a precision sensing technique – to optimize the machining quality process and provide indications of the expected surface roughness. The results obtained revealed that better surface roughness can be generated when RSA 431 is diamond-turned using water as a cutting fluid, rather than kerosene mist. Predictive models for surface roughness were developed for each experiment, using response surface methodology (RSM) and artificial neural networks (ANN). Moreover, RSM was used for optimisation. Time domain features acquired from AE signals, together with the three cutting parameters, were used as input parameters in the ANN design. The results of the predictive models show a close relationship between the predicted values and the experimental values for surface roughness. The developed models have been compared in terms of accuracy and cost of computation - using the mean absolute percentage error (MAPE).
- Full Text:
- Date Issued: 2020
Optimisation of cold rolling process parameters to improve surface quality of the AA 3003-H22 treadbright coils
- Authors: Makhanya, Lehlohonolo
- Subjects: Aluminum alloys
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9611 , http://hdl.handle.net/10948/554 , Aluminum alloys
- Description: The main objective of this dissertation was to investigate how cold rolling process parameters could be optimised to improve surface quality of the AA 3003 H22 treadbright coils. This treadbright product is one of Hulett Aluminium’s main products and is exported mainly to the North American market. One of its critical requirements is a defect-free bright surface. The literature review was conducted with particular focus on the effects of selected parameters or settings with respect to surface quality and a chapter outlining these aspects has been included. It was clear from the literature review that selected parameters do affect the surface quality and if adjusted accordingly can improve surface quality on treadbright coils. Subsequent chapters after the literature review outline how the tests were conducted, procedures followed and equipments used from the cold rolling machine to laboratories. Surface appearance results after each parameter was adjusted, showed that the surface quality did improve and even got better when other parameters like the colouring roll angle and percentage reduction were adjusted. Correct working limits within which each parameter would yield acceptable surface quality were also established. All experiments conducted had no influence on the microstructure of the metal as it remained the same throughout each experiment. The same has been found with the mechanical properties as percentage reductions experiments led to no change in tensile strength, proof strength and percentage elongation. In conclusion, this research has proved that cold rolling process parameters selected did affect the product surface quality. If controlled they can be used to optimise the surface quality on the treadbright product as required by Hulett Aluminium and its customers.
- Full Text:
- Authors: Makhanya, Lehlohonolo
- Subjects: Aluminum alloys
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9611 , http://hdl.handle.net/10948/554 , Aluminum alloys
- Description: The main objective of this dissertation was to investigate how cold rolling process parameters could be optimised to improve surface quality of the AA 3003 H22 treadbright coils. This treadbright product is one of Hulett Aluminium’s main products and is exported mainly to the North American market. One of its critical requirements is a defect-free bright surface. The literature review was conducted with particular focus on the effects of selected parameters or settings with respect to surface quality and a chapter outlining these aspects has been included. It was clear from the literature review that selected parameters do affect the surface quality and if adjusted accordingly can improve surface quality on treadbright coils. Subsequent chapters after the literature review outline how the tests were conducted, procedures followed and equipments used from the cold rolling machine to laboratories. Surface appearance results after each parameter was adjusted, showed that the surface quality did improve and even got better when other parameters like the colouring roll angle and percentage reduction were adjusted. Correct working limits within which each parameter would yield acceptable surface quality were also established. All experiments conducted had no influence on the microstructure of the metal as it remained the same throughout each experiment. The same has been found with the mechanical properties as percentage reductions experiments led to no change in tensile strength, proof strength and percentage elongation. In conclusion, this research has proved that cold rolling process parameters selected did affect the product surface quality. If controlled they can be used to optimise the surface quality on the treadbright product as required by Hulett Aluminium and its customers.
- Full Text:
Machinability of rapidly solidified aluminium alloy for optical applications
- Authors: Abbas, Abdalla Abbas Said
- Date: 2020
- Subjects: Aluminum alloys , Mechatronics
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/45975 , vital:39402
- Description: The production of metal mirrors and critical components for optical devices and aerospace application requires extreme high accuracy and outstanding surface quality. Thus, to achieve such high dimensional accuracies, they are being mainly produced through ultra-high precision machining. Aluminium alloys have been used in the production of components for optics application as well as spaceborne for so many years but with the advancement in technology and demands for a superior material, a new modified grade of aluminium was developed by a rapid solidification process. These grades exhibit a much better mechanical and physical properties while having a finer microstructure. The only downside is the limited research in the correlation of surface roughness and reflectance when single point diamond turned. In this study, rapidly solidified aluminium RSA 905 were used to investigate the effect of varying the cutting parameters on the machined surface finish and its corresponding surface reflectance. The cutting parameters were cutting speed, feed rate and depth of cut. The surface roughness was measured using Taylor Hopson PGI Profilometer while the reflectance factor was measured by using VERTEX 80v Spectrometer. The results were used to develop two predictive models namely; response surface and artificial neural network which have indicated a very high accuracy to the experimental measurements. Finally, the results were very promising for the diamond turning of RSA 905 where it has achieved a very low values of surface roughness and high reflectance in the visual range without the need of any additional production/fabrication steps and to ensure that bi-metallic binding does not take place in extreme low temperatures. Therefore, RSA 905 is a very promising material for optical applications in the visual spectrum.
- Full Text:
- Date Issued: 2020
- Authors: Abbas, Abdalla Abbas Said
- Date: 2020
- Subjects: Aluminum alloys , Mechatronics
- Language: English
- Type: Thesis , Masters , MEng
- Identifier: http://hdl.handle.net/10948/45975 , vital:39402
- Description: The production of metal mirrors and critical components for optical devices and aerospace application requires extreme high accuracy and outstanding surface quality. Thus, to achieve such high dimensional accuracies, they are being mainly produced through ultra-high precision machining. Aluminium alloys have been used in the production of components for optics application as well as spaceborne for so many years but with the advancement in technology and demands for a superior material, a new modified grade of aluminium was developed by a rapid solidification process. These grades exhibit a much better mechanical and physical properties while having a finer microstructure. The only downside is the limited research in the correlation of surface roughness and reflectance when single point diamond turned. In this study, rapidly solidified aluminium RSA 905 were used to investigate the effect of varying the cutting parameters on the machined surface finish and its corresponding surface reflectance. The cutting parameters were cutting speed, feed rate and depth of cut. The surface roughness was measured using Taylor Hopson PGI Profilometer while the reflectance factor was measured by using VERTEX 80v Spectrometer. The results were used to develop two predictive models namely; response surface and artificial neural network which have indicated a very high accuracy to the experimental measurements. Finally, the results were very promising for the diamond turning of RSA 905 where it has achieved a very low values of surface roughness and high reflectance in the visual range without the need of any additional production/fabrication steps and to ensure that bi-metallic binding does not take place in extreme low temperatures. Therefore, RSA 905 is a very promising material for optical applications in the visual spectrum.
- Full Text:
- Date Issued: 2020
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