<p> The effect of strain hardening rate and material strength on the development of surface roughness in AA6111 was investigated. No measurable change in the rate of roughening, or in the surface morphology was observed due to altering the strain hardening rate by using different test temperatures. Changing the material strength and strain hardening rate by altering the precipitation state also gave no significant change in either roughening rate or morphology with respect to strain. The development of surface roughness is also independent of strain history. Samples subjected to an intermediate polish after 20% true strain resumed roughening at the same rate regardless of amount of previous tensile strain. The development of surface roughness is dependent on only the strain level to which the sheet is deformed. The surface morphology seems to be controlled by the combination and distribution of texture components on the surface. The rate of roughening is grain size dependent and the surface grain size may provide a key to controlling roughening. </p> / Thesis / Master of Applied Science (MASc)

A model has been developed to predict the yield stress of the aluminum alloy AA6111 after multi-step heat treatments which involve combinations of ambient temperature ageing and high temperature artificial ageing. The model framework follows the internal state variable framework where the two principal state variables are i) the volume fraction of clusters which form at ambient temperature and ii) the volume fraction of metastable phases which form during high temperature ageing. The evolution of the these state variables has modeled using a set of coupled differential equations. The mechanical response (the yield stress) is then formulated in terms of the state variables through an appropriate flow stress addition law. To test the model predictions a series of experiments were conducted which examined two scenarios for multi-step heat treatments. In general, good agreement was observed between the model predictions and the experimental results. However, for the case where a short thermal excursion at 250oC was applied immediately after the solution treatment, the results were not satisfactory. This can be understood in terms of the importance of the temperature dependence for the nucleation density of metastable precipitates.

In this work, we have investigated the internal stress contribution to the flow stress for a commercial 6xxx aluminium alloy (AA6111). In contrast to stresses from forest and precipitation hardening, the internal stress cannot be assessed properly with a uniaxial tensile test. Instead, tension-compression tests have been used to measure the Bauschinger stress and produce a comprehensive study which examines its evolution with i) the precipitation structure and ii) a wide range of applied strain. A large set of ageing conditions was investigated to explore the effect of the precipitation state on the development of internal stress within the material. It is shown that the Bauschinger stress generally increases with the applied strain and critically depends on the precipitate average radius and is thus linked to the shearable/non shearable transition. Further work in the case of non-shearable particles shows that higher strain eventually lead to particle fracture and the Bauschinger stress then rapidly decreases. Following the seminal work of Brown et al, a physically based approach including plastic relaxation and particle fracture is developed to predict the evolution of the internal stress as a function of the applied strain. Knowing the precipitation structure main characteristics –such as the average precipitate radius, length and volume fraction– allows one to estimate accurately the internal stress contribution to the flow stress with this model.

In modern society, car manufactures are actively pursuing vehicle light weighting under both stricter government regulations due to environmental concerns and consumers’ demand for better fuel economy. Under such circumstances, OEMs are using more parts using aluminum alloys to replace parts made with steel. New forming processes are being developed to produce structural components to achieve higher in-service strength using higher strength aluminum alloys. Two of the commonly used high strength aluminum alloys, AA6111 and AA7075, are being considered for elevated temperature sheet forming applications. With more aluminum applications in vehicle and good recyclability of aluminum components, there is a concern of contamination from transition metals such as Fe, Mn and Cr from vehicle end of life scraps getting into aluminum scrap stream. Such impurity elements can have profound impact on aluminum alloy’s mechanical properties, performance and formability at room and elevated temperatures. This study is focused on variants of AA6111 and AA7075 alloys with increased recycling content, and thus higher amounts of the above transition metals. The objective is to investigate the effect of impurity alloying elements on final microstructure, mechanical properties and formability of the above sheet materials. Formability is studied in terms of sheet bendability and elevated temperature forming limit diagrams (FLDs) using a hot gas bulge tester. / Thesis / Master of Applied Science (MASc)

Refill Friction Stir Spot Welding (RFSSW) is a new solid-state joining technology, which is suitable for joining similar and dissimilar overlap sheets connections, particularly in aluminium and magnesium alloys. This welding method is expected to have wide applications in joining of body parts in the automotive industry. In the present study, RFSSW has been used to join 1.0 mm gauge sheets of two material combinations: similar AA6111-T4 automotive aluminium alloy joints and a dissimilar aluminium AA6111-T4 to magnesium AZ31-H24 alloy combinations. The performance of the joints was investigated in terms of the effect of the welding parameters (including tool rotation rate, sleeve plunge depth, and welding time etc.) to improve current understanding and allow optimisation of the process for short welding-cycles when joining similar and dissimilar light alloys. The results of the investigations on similar AA6111 welds showed the ability to use a wide window of process parameters that resulted in joints with a successfully refilled keyhole and flat weld surface, even when using a welding time as short as 0.5 s. The joints in the as-welded condition showed strengths as high as 4.2 kN, when using welding parameters of 1500 rpm, 1.0 mm with a range of welding times from 0.55 to 2.0 s. All joints showed a nugget pull-out failure mode when using a sleeve plunge depth of 0.8 mm or more, as a result of increasing the joint area. The strength of the joints further improved and reached peak loads of 5.15 and 6.43 kN after natural and artificial ageing, respectively, for welds produced using optimised welding parameters of a 2500 rpm tool rotation rate, a 1.5 s welding time and a 1.0 mm plunge. This improvement in strength resulted from the improvement in the local mechanical properties in the HAZ and other regions, which results from a minimal HAZ due to the rapid weld cycle and the re-precipitation of GPZs and clustering on natural ageing, or β on artificial ageing. A modification to the RFSSW process was developed in this project to solve the problems faced when dissimilar welding Mg to Al. This modified process involved adding a final brief pin plunge stage to consolidate refill defects and it was successful in producing nearly defect-free joints with improved mechanical properties, using a wide range of the process parameters. The average peak load of the joints increased with increasing tool rotation rate, to reach a maximum value at 2500 rpm due to eliminating the weld defects by increasing the material plasticity. However, increasing the tool rotation rate further to 2800 rpm led to a decrease in the average peak failure load due to eutectic melting at the weld interface. The optimum welding condition was thus found to be: 2500 rpm, 1.0 s, and 1.0 mm, which gave an average peak failure load of 2.4 kN and average fracture energy of 1.3 kN.mm. These values represent an improvement of about 10 % and 27 %, respectively, compared to welds produced with the conventional RFSSW process, and about 112 % and 78 % of the Mg-Mg similar joints produced using the same welding conditions. A FE model developed in this project was successful in increasing understanding of the behaviour of the RFSSW joints when subjected to lap tensile-shear loading. The stress and strain distribution in the modelled samples showed that the highest concentration occurring in the region of the confluence of the SZ with the two sheets. With increasing extension, these regions of highest stress and strain propagated to the outer surfaces of the two sheets and then annularly around the weld nugget. This annular ring of high strain concentration agreed well with the failure path and results in the full plug pull-out fracture mode shown by the experimentally tested samples. The predicted force-extension curves showed high agreement with the experimental results, especially when including the effect of the hook defect and correction of compliance in the experimental results.