In this project forging of aluminum alloy Al 6026 T9 has been performed in the temperature range of 400 °C – 470 °C. The alloy which was in the shape of a cylindrical billet was formed in a press with the aim of analyzing the effect of different forging temperatures and required press load for optimal die filling. The component’s dimensions were later measured and compared to a reference piece. To ease the flow of material a lubricant was used between the billet and the die. This was demonstrated by compressing the billet with and without any lubricant.The performed experiments show that the lubricant reduces friction and makes it easier for the material to flow into the die. Higher billet temperature than 450 °C is deemed unnecessary as it does not give any significant improvement in filling the die. The experiments also conclude that a press load of at least 280 tons is required for these conditions.

<p>The present work has been carried out in order to investigate Al-Mg-Si alloys that are deformed at moderate temperatures. These temperatures are in the range between 200 C and 300 C. Also some experiments are performed at room temperatures. Two deformation models have been applied in the experiments: material deformation by compression testing and by forward extrusion. </p><p>The investigated alloys are AA6063, AA6082 and an alloy that is named “Alloy R” in this work. The latter alloy is the industrial alloy AA6082 without the Mn-addition (0.56wt%Mn in the AA6082). The “R” denotes the recrystallized microstructure in the material after hot forming operations.</p><p>The investigations show the effect of changing the temperature in the given temperature interval on the stress-strain relationship for each alloy. From the compression testing, it is found that none of the alloys AA6063 or Alloy “R” reaches a steady state condition as true strain approaches 0.8 for deformation temperatures between 200 C and 250 C. At compression testing performance at 300 C, the alloy “R” reaches a steady state condition at a true strain equal to 0.4.</p><p>As true stress-true strain relationship has been investigated for the “Alloy R” and the AA6063 at comparable deformation parameters, it is shown that the alloy “R”, with the highest Si-content, requires the highest true stress for a given true strain value (AA6063: 0.45wt%Si, Alloy “R”: 0.87wt%Si).</p><p>From the compression testing, the effect of Mn on the material properties in the AA6082-alloy has been determined. For the Alloy “R” and the AA6082, the true stress reached the same value after a certain amount of deformation. As deformation temperature increases, this common value of true stress corresponds to a decrease in true strain.</p><p>The AA6082 and Alloy “R” are also compared in experiments performed in forward extrusion. One observes that for the same deformation temperature and at identical die diameters, the ram force is identical. It is worth noticing that these alloys did not show the same relationship during the compression testing at low values of true strain (<0.8). On a microscopic scale, one concludes that Mn has no significant effect on the stress-strain relationship for the applied deformation parameters in the forward extrusion equipment.</p><p>Hardness measurements indicate that the age hardening potential in the extruded test specimen decreases as the deformation temperature increases. The hardness data is similar for both the AA6082 and the Alloy R, thus indicating that the Mn content has no significant effect on the strength of the material.</p><p>The deformed material has been annealed in order to investigate the recrystallization process in the AA6082 and the Alloy “R”. The recrystallization grain size in the Alloy “R” is significantly larger than in the AA6082 at comparable deformation parameters after annealing at 530 C for 15 minutes. This result is due to the effect of Mn-containing dispersoids in the AA6082. The recrystallization grain size in the Alloy “R” seems to be unaffected by the deformation temperature after annealing for 15 minutes. The observation of the AA6082 is quite different. A small increase in grain size is observed for both reduction ratios as the deformation temperature is elevated from 20C to 200 C and further to 250 C. At extrusion temperatures of 300 C the recrystallization grains are significantly larger.</p><p>Annealing experiments performed at 430 C on the AA6082 indicates that a change in the deformation temperature from 200 C to 250 C does not affect the amount of stored energy in the material significantly.</p><p>The Forge2 programme has been used to perform numeric simulations of the forward extrusion experiment. From this the temperature distribution, strain rate variation and true strain development in the test piece had been investigated. As the simulated true strain values are compared to the grain size in the annealed material, the recrystallization grain size is related to the amount of stored energy in the material in a very convincing way. It is also shown that the recrystallization grain diameter is related to the amount stored energy as the grain diameter is investigated in the radial and the extrusion direction separately.</p>

The present work has been carried out in order to investigate Al-Mg-Si alloys that are deformed at moderate temperatures. These temperatures are in the range between 200 C and 300 C. Also some experiments are performed at room temperatures. Two deformation models have been applied in the experiments: material deformation by compression testing and by forward extrusion. The investigated alloys are AA6063, AA6082 and an alloy that is named “Alloy R” in this work. The latter alloy is the industrial alloy AA6082 without the Mn-addition (0.56wt%Mn in the AA6082). The “R” denotes the recrystallized microstructure in the material after hot forming operations. The investigations show the effect of changing the temperature in the given temperature interval on the stress-strain relationship for each alloy. From the compression testing, it is found that none of the alloys AA6063 or Alloy “R” reaches a steady state condition as true strain approaches 0.8 for deformation temperatures between 200 C and 250 C. At compression testing performance at 300 C, the alloy “R” reaches a steady state condition at a true strain equal to 0.4. As true stress-true strain relationship has been investigated for the “Alloy R” and the AA6063 at comparable deformation parameters, it is shown that the alloy “R”, with the highest Si-content, requires the highest true stress for a given true strain value (AA6063: 0.45wt%Si, Alloy “R”: 0.87wt%Si). From the compression testing, the effect of Mn on the material properties in the AA6082-alloy has been determined. For the Alloy “R” and the AA6082, the true stress reached the same value after a certain amount of deformation. As deformation temperature increases, this common value of true stress corresponds to a decrease in true strain. The AA6082 and Alloy “R” are also compared in experiments performed in forward extrusion. One observes that for the same deformation temperature and at identical die diameters, the ram force is identical. It is worth noticing that these alloys did not show the same relationship during the compression testing at low values of true strain (&lt;0.8). On a microscopic scale, one concludes that Mn has no significant effect on the stress-strain relationship for the applied deformation parameters in the forward extrusion equipment. Hardness measurements indicate that the age hardening potential in the extruded test specimen decreases as the deformation temperature increases. The hardness data is similar for both the AA6082 and the Alloy R, thus indicating that the Mn content has no significant effect on the strength of the material. The deformed material has been annealed in order to investigate the recrystallization process in the AA6082 and the Alloy “R”. The recrystallization grain size in the Alloy “R” is significantly larger than in the AA6082 at comparable deformation parameters after annealing at 530 C for 15 minutes. This result is due to the effect of Mn-containing dispersoids in the AA6082. The recrystallization grain size in the Alloy “R” seems to be unaffected by the deformation temperature after annealing for 15 minutes. The observation of the AA6082 is quite different. A small increase in grain size is observed for both reduction ratios as the deformation temperature is elevated from 20C to 200 C and further to 250 C. At extrusion temperatures of 300 C the recrystallization grains are significantly larger. Annealing experiments performed at 430 C on the AA6082 indicates that a change in the deformation temperature from 200 C to 250 C does not affect the amount of stored energy in the material significantly. The Forge2 programme has been used to perform numeric simulations of the forward extrusion experiment. From this the temperature distribution, strain rate variation and true strain development in the test piece had been investigated. As the simulated true strain values are compared to the grain size in the annealed material, the recrystallization grain size is related to the amount of stored energy in the material in a very convincing way. It is also shown that the recrystallization grain diameter is related to the amount stored energy as the grain diameter is investigated in the radial and the extrusion direction separately.

Saab Surveillance in Järfä̈lla constructs complex products, such as radars and electronic support measures. Saab sees an advantage in manufacturing details with additive manufacturing as it enables a high level of complexity. Additive manufacturing is relatively new in the industry and consequently there are uncertainties regarding the process. The purpose of this bachelor thesis was to improve the knowledge of the repeatability of additive manufactured parts as well as compare additive manufactured test rods in two different directions, horizontally and vertically, to subtractive manufactured test rods with a vibration test. The vibration test was conducted to simulate the operative environment where the additive manufactured parts might be implemented in the future. Before the vibration test could be performed, the test rods were designed in a 3D-modeling program and analysed with a finite element method to achieve the required natural frequency range of 100 - 200 Hz and a maximal bending stress of 60 - 80 MPa in the notched area of the test rod. It was concluded that the subtractive manufactured test rods had the highest repeatability. The horizontally additive manufactured test rods had a higher repeatability than the vertically additive manufactured test rods, but the vertically additive manufactured test rods had the highest overall strength. It was also concluded that more studies are needed to ensure that additive manufactured parts can be produced with high repeatability while maintaining the structural integrity. / Saab Surveillance i Järfä̈lla konstruerar komplexa försvarsprodukter som till exempel radarsystem. Additiv tillverkning i metall möjliggör tillverkning av produkter med hög komplexitet, men då tillverkningsprocessen är relativt ny i industrin finns det en stor osäkerhet kring processen. Syftet med detta kandidatexamensarbete var att få en bättre förståelse för repeterbarheten hos additivt tillverkade delar samt att jämföra additivt tillverkade provstavar konstruerade i två olika riktningar, horisontellt och vertikalt, med svarvade provstavar med hjälp av ett vibrationstest. Vibrationstestet genomfördes för att simulera den operativa miljön där de additivt tillverkade detaljerna skulle kunna implementeras i framtiden. Innan vibrationstestet kunde utföras simulerades provstavarnas design i en mjukvara för 3D-modellering. En finit element-analys utfördes även fö̈r att få en egenfrekvens inom intervallet 100 - 200 Hz och en maximal böjspänning mellan 60 - 80 MPa i anvisningen på provstaven. Slutsatsen drogs att de traditionellt bearbetade stavarna hade den högsta repeterbarheten. De horisontellt additivt tillverkade stavarna hade högre repeterbarhet än de vertikalt additivt tillverkade stavarna, men att de vertikalt additivt tillverkade stavarna hade ett längre utmattningsliv. Det kunde även konstateras att fler studier inom ämnet behövs för att kunna säkerställa repeterbarheten hos additivt tillverkade delar utan att behöva kompromissa med hållfastheten.

Today’s transportation highly depends on hydrocarbon fuels, and reducing the weight could help a lot in reducing the air pollutants and carbon footprints in the environment to comply with the strict regulations set by reputable standard organizations in the world. Utilizing lightweight materials in automobile parts is one of the key factors to succeed in meeting the goals defined in the standards. Replacing the conventional single material component with a multi-material component having the same geometry but lighter weight could help the automakers to achieve these goals. Compound casting is one of the methods to produce such components. The aluminum alloy/ductile iron bimetal component produced by compound casting was investigated. During the production of the experimental sample of the compound casting, component two parameters were considered, melt-to-solid volume ratio and pre-heat temperature of the solid insert. The results showed that the increasing melt-to-solid volume ratio caused the formation of a stronger metallurgical bond between the two materials compared to the lower melt-to-solid volume ratio. However, pre-heating the solid insert under the atmospheric condition caused the formation of iron oxide layers on the surface, and as a result, no metallurgical bonding was formed, no matter which melt-to-solid volume ratio was used during the production process. So, inspired by AlFin process, the solid inserts were first dipped inside the aluminum alloy bath with the target temperature of 750 °C for two extended periods, 15 minutes and 30 minutes, to ensure that the preliminary metallurgical bonds were formed at the interface surfaces without disturbance by the surrounding atmosphere. To make the experimental components and to develop the metallurgical bonds, the aluminized inserts were then quickly placed inside the sand molds, and the cast alloy was poured inside the molds and around the inserts immediately after placement. In this way, although the formation of the aluminum oxide layer was unavoidable on the surfaces of the aluminized inserts, there was still liquid aluminum alloy melt underneath, which could be easily washed away during the pouring of the cast alloy.Nevertheless, the metallurgical bonds in the compound casting products having a lower melt-to-solid volume ratio didn’t withstand the shear loads and only the product having a higher melt-to-solid volume ratio with the aluminized insert dipped for a longer time could resist against the loads. In addition to the mechanical strength of the experimental products, their metallurgical bonds were specified and characterized using microscopic examination and EDS analysis. The successful results of the experimental product were then proposed to modify the design of a model from the automobile industry, called the truck wheel hub. / Dagens transport beror starkt på kolvätebränslen, och att minska vikten kan hjälpa mycket att minska luftföroreningar och kolavtryck i miljön för att följa de strikta regler som ställts av ansedda standardorganisationer i världen. Att använda lätta material i bildelar är en av de viktigaste faktorerna för att lyckas uppfylla de mål som fastställs i standarderna. Att ersätta den konventionella komponenten med enstaka material med en komponent med flera material som har samma geometri men lättare vikt kan hjälpa biltillverkarna att uppnå dessa mål. Gjutning av föreningar är en av metoderna för att producera sådana komponenter. Aluminiumlegeringen / segjärn-bimetalkomponenten framställd genom sammansatt gjutning undersöktes. Under framställningen av det experimentella provet av gjutning av föreningen beaktades komponent två parametrar, volymförhållandet smält till fast material och förvärmningstemperaturen för det fasta insatsen. Resultaten visade att det ökande smält-till-fasta volymförhållandet orsakade bildandet av en starkare metallurgisk bindning mellan de två materialen jämfört med det lägre förhållandet mellan smält och fast volym. Förvärmning av den fasta insatsen under atmosfäriskt tillstånd orsakade emellertid bildningen av järnoxidskikt på ytan, och som ett resultat bildades ingen metallurgisk bindning, oavsett vilket smält-till-fast volymförhållande användes under produktionsprocessen . Så, inspirerad av AlFin-processen, doppades de fasta insatserna först in i aluminiumlegeringsbadet med måttemperaturen 750 ° C under två långa perioder, 15 minuter och 30 minuter, för att säkerställa att de preliminära metallurgiska bindningarna bildades vid gränsytans ytor utan störningar av den omgivande atmosfären. För att tillverka de experimentella komponenterna och för att utveckla de metallurgiska bindningarna placerades sedan de aluminiumiserade skärmen snabbt inuti sandformarna, och den gjutna legeringen hälldes in i formarna och runt insatserna omedelbart efter placering. På detta sätt, även om bildningen av aluminiumoxidskiktet var oundvikligt på ytorna på de aluminiumförsedda insatserna, fanns det fortfarande flytande aluminiumlegeringssmälta under, vilket lätt kunde tvättas bort under hällningen av den gjutna legeringen.Icke desto mindre tål de metallurgiska bindningarna i de sammansatta gjutprodukterna med ett lägre volym-till-fast volymförhållande inte skjuvbelastningarna och endast produkten med ett högre smält-till-fast volymförhållande med den aluminiumiserade insatsen doppades under en längre tid kunde motstå mot lasterna. Förutom de experimentella produkternas mekaniska styrka specificerades och karakteriserades deras metallurgiska bindningar med mikroskopisk undersökning och EDS-analys. De framgångsrika resultaten av den experimentella produkten föreslogs sedan att modifiera utformningen av en modell från bilindustrin, kallad truckhjulnavet.