This project was funded by Automotive Partnership Canada (APC), an initiative created by the Government of Canada in an attempt to support significant, collaborative R&D activities in order to benefit the entire Canadian automotive industry. / High strength Al-Zn-Mg-Cu alloys have been increasingly employed in the transportation industry due to the increased demands for light structural components. However, their applications have been limited to relatively expensive wrought products. Application of the shape cast Al-Zn-Mg-Cu parts has never been the focus of attention due to their poor castability and mechanical properties. Improving the casting quality is expected to increase their utilization within the automotive industry. The poor castability and mechanical properties of some alloys in this family may be effectively improved through optimized chemistry control and melt treatment including grain refinement. The primary objective of this project is to optimize the chemistry and heat treatment of the Al-Zn-Mg-Cu alloy family that results in improved strength with acceptable level of ductility and casting quality relative to other shape cast Al alloys.
The Taguchi experimental design method was used to narrow down the number of required casting experiments required to meet the research objective. Three levels across four elements yielded a total of 9 Al-Zn-Mg-Cu alloys, which were cast using a tilt pour permanent mold process. The effect of each major alloying element on the microstructure, and mechanical properties was investigated. Tensile measurements were made on the 9 alloys subjected to two steps solution treatments. Mechanical properties such as yield strength (YS), ultimate tensile strength (UTS), and elongation at fracture (El.%) were experimentally measured and statistically analyzed.
An ANOVA analysis was employed to quantify the percentage contribution of the alloying elements on the material properties. Grain refinement was found to play a significant role in improving the hot tearing resistance and, thereby ameliorating quality. The alloying element that affected the YS and UTS to the greatest extent was Cu, followed by Zn. In contrast, the effect of Mg and Ti on YS and UTS was insignificant. Moreover, a decrease in Mg content had the greatest effect in enhancing the El.%.
A regression analysis was used to obtain statistical relationships (models) correlating the material properties with the variations in the content of the major alloying elements. The R-square values of YS, UTS, and El.% were 99.7 %, 98 %, and 90 %, respectively, showing that the models replicated the experimental results. Verification measurements made on shape cast Al-6Zn-2Mg-2Cu alloy revealed that the material property model predictions were in agreement with the experimentally measured values.
The results show that secondary and over ageing treatments of the shape cast Al-Zn-Mg-Cu alloys lead to superior combination of YS and El.%. The ongoing advances in shape casting of Al-Zn-Mg-Cu alloys with high will make them suitable choices for commercial load-bearing automotive components, when it comes to the selection of a material meeting the minimum requirements for strength, damage tolerance, cost and weight. / Thesis / Master of Applied Science (MASc)
| Identifer | oai:union.ndltd.org:mcmaster.ca/oai:macsphere.mcmaster.ca:11375/20552 |
| Date | January 2016 |
| Creators | Mazahery, Ali |
| Contributors | Kish, Joseph, McDermid, Joe, Shankar, Sumanth, Mechanical Engineering |
| Source Sets | McMaster University |
| Language | en_US |
| Detected Language | English |
| Type | Thesis |
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