Browse Topic: Casting alloys

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Trace Element Control, Nickel Alloy CastingsAMS2280E (Current)12/9/2025

This specification establishes testing methods and maximum permissible limits for trace elements in nickel alloy castings.

AMS F Corrosion Heat Resistant Alloys Committee
Aluminum Alloy Castings, High Strength 4.5Cu - 0.70Ag - 0.30Mn - 0.25Mg - 0.25Ti (A201.0-T7) Solution Heat Treated and Overaged AMS4229H (Current)12/9/2025
This specification covers an aluminum alloy in the form of sand, permanent mold, and composite mold castings.
AMS D Nonferrous Alloys Committee
Cast Aluminum Alloy Composite 4.6Cu - 3.4Ti - 1.4B - 0.75Ag - 0.27Mg (205.0/TiB2/3p-T7P) Sand Cast, Solution, and Precipitation Heat TreatedAMS4482B (Current)11/25/2025
This specification covers a dilute aluminum/TiB2 metal matrix composite in the form of sand castings.
AMS D Nonferrous Alloys Committee
Cast Aluminum Alloy Composite, 4.6Cu - 3.4Ti - 1.4B - 0.75Ag - 0.27Mg (205.0/TiB2/3p-T7P), Investment Cast, Solution and Precipitation Heat TreatedAMS4471C (Current)11/25/2025
This specification covers a dilute aluminum/TiB2 metal matrix composite in the form of investment castings.
AMS D Nonferrous Alloys Committee
The Chemical Milling ProcessARP1331C (Current)7/15/2021
This practice provides recommendations concerning the chemical milling of aluminum, magnesium, high temperature nickel alloys, titanium alloys, copper alloys, and specialty alloys.
AMS B Finishes Processes and Fluids Committee
Aerospace Information Report on Evaluating Corrosion Testing of Electrical Connectors and Accessories for the Purpose of QualificationAIR4789B (Current)6/22/2021
This SAE Aerospace Information Report (AIR) establishes guidelines for evaluating the effects of corrosion testing and acceptance criteria of aluminum alloy connectors and accessories with plating.
AE-8C1 Connectors Committee
Aluminum Alloy, Castings 5.0Si - 1.2Cu - 0.50Mg (355.0-T51) Precipitation Heat TreatedAMS4210M (Current)4/22/2021
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Cast Aluminum Alloy Composite 4.6Cu - 3.4Ti - 1.4B - 0.75Ag - 0.27Mg (205.0/TiB2/3p-T7P) Investment Cast, Solution and Precipitation Heat TreatedAMS4471B (Historical)4/22/2021
This specification covers a dilute aluminum/TiB2 metal matrix composite in the form of investment castings.
AMS D Nonferrous Alloys Committee
Heat Treatment Nickel Alloy and Cobalt Alloy PartsAMS2774G (Historical)12/10/2020
This specification specifies the engineering requirements for heat treatment, by part fabricators (users) or subcontractors, of parts made of wrought or additively manufactured nickel or cobalt alloys, of raw materials during fabrication, and of fabricated assemblies in which wrought nickel or cobalt alloys are the primary structural components.
AMS F Corrosion Heat Resistant Alloys Committee
Heat Treatment Nickel Alloy and Cobalt Alloy PartsAMS2774F (Historical)5/26/2020
This specification specifies the engineering requirements for heat treatment, by part fabricators (users) or subcontractors, of parts made of wrought or additively manufactured nickel or cobalt alloys, of raw materials during fabrication, and of fabricated assemblies in which wrought nickel or cobalt alloys are the primary structural components.
AMS F Corrosion Heat Resistant Alloys Committee
Rings, Sealing, Cast Leaded-Tin Bronze 80Cu - 16Sn - 5Pb As CastAMS7320G (Current)12/16/2019
This specification covers a cast leaded-tin bronze in the form of sealing rings.
AMS D Nonferrous Alloys Committee
Trace Element Control Nickel Alloy CastingsAMS2280D (Historical)11/5/2019
This specification establishes testing methods and maximum permissible limits for trace elements in nickel alloy castings.
AMS F Corrosion Heat Resistant Alloys Committee
Characterization of AlSi10Mg Alloy Produced by DMLS Process for Automotive Engine Application2019-28-013410/11/2019
Considerable weight of an automobile is constituted by the engine and there is scope for improvement in fuel efficiency and emission control through optimization of weight in the engine. In this work, AlSi10Mg alloy produced by the direct metal laser sintering (DMLS) is suggested for engine application which is a lightweight aluminum alloy. Mechanical properties like tensile strength, compressive strength, and hardness of both cast and DMLS manufactured alloy are compared followed by analysis of SEM images of tensile test fractured surfaces. Reciprocating wear test is carried out for one lakh cycles at 125°C temperature with SAE 40 grade oil as lubricant. Co-efficient of friction (COF), wear rate of the cast and DMLS manufactured samples are compared. Wear patterns are analyzed using SEM images of the wear tracks.
Arun, Kumaran, Aravindh, Kumaran, Raja, Kumar, Naiju, Chooriyaparambil Damodaran, Thrinadh, Emmidi, Ranka, Shreyas
Experimental Investigation of Silicon Carbide Nanoparticles Reinforced Magnesium Alloy (AZ91E) Metal Matrix Composite by Vacuum Stir Casting Method2019-28-016910/11/2019
In the present investigation silicon carbide nanoparticles reinforced magnesium alloy [AZ91E] composites were prepared by vacuum stir casting process in an inert atmosphere. Required amount of silicon carbide nanoparticles with grain size of 50nm was added into AZ91E molten melt with constant stir speed of 600 rpm and vacuum pressure of 1 lpm to obtain magnesium alloy composite containing 0, 5, 7.5 and 10 wt.% SiCp nanoparticles. The prepared composites were subjected to mechanical and microstructure studies. The mechanical properties were found to increase with the addition of silicon nanoparticles compared to unreinforced magnesium alloy. The maximum impact strength, yield strength and tensile strength were found to be 29.13J, 156 MPa and 401.13 MPa respectively. Microstructure studies reveal uniform distribution of silicon carbide in magnesium alloy matrix.
Thangavel, Thirugnana Sambandham, Jeyaseelan, Chandradass, Paramathma, Baskara Sethupathi, Mahadevan, Kannan
Minimizing Stress-Corrosion Cracking in Wrought High-Strength Aluminum Alloy ProductsARP823F (Current)4/17/2019
The purpose of this recommended practice is to provide the aerospace industry with recommendations concerning minimizing stress-corrosion cracking (SCC) in wrought high-strength aluminum alloy products.
AMS D Nonferrous Alloys Committee
Nickel Alloy, Corrosion and Heat-Resistant, Powder for Additive Manufacturing, 47.5Ni - 22Cr - 1.5Co - 9.0Mo - 0.60W - 18.5FeAMS7008 (Current)3/26/2019
This specification covers a corrosion and heat-resistant nickel alloy in the form of pre-alloyed powder.
AMS AM Additive Manufacturing Metals
Washer, Thermal Compensating, Metric SeriesAIR1754B (Current)2/18/2019
The purpose of this document is to define: - compensation washer application requirements - recommended materials - washer thickness determination - dimensioning
E-25 General Standards for Aerospace and Propulsion Systems
Guide for Achieving Plating/Finishing Compatibility with Connectors and Accessories used in Electrical Wiring Interconnect Systems (EWIS)ARP6903A (Current)8/29/2018
The intent of this ARP is to provide guidance to assist users in choosing compatible component finishes/platings to achieve the best corrosion resistance performance for compatible components/couples. This SAE Recommended Practice is intended as a guide toward standard practice and is subject to change to keep pace with experience and technical advances. A galvanic compatibility table is provided to assist with the compatible plating/finish selection. Specific plating performance parameters for each individual plating and each connector/accessory specification have also been provided to assist the product user with compatible plating/finish selection.
AE-8C1 Connectors Committee
Rings, Sealing, Cast Tin Bronze 80Cu - 19Sn As CastAMS7322G (Current)8/22/2018
This specification covers a cast tin bronze in the form of sealing rings.
AMS D Nonferrous Alloys Committee
Nickel Alloy, Corrosion and Heat-Resistant, Powder for Additive Manufacturing, 62Ni - 21.5Cr - 9.0Mo - 3.65NbAMS7001 (Current)6/8/2018
This specification covers a corrosion and heat-resistant nickel alloy in the form of pre-alloyed powder.
AMS AM Additive Manufacturing Metals
Accelerated Corrosion Testing of Automotive Evaporators and Condensers2018-01-00624/3/2018
There is an ongoing effort in the industry to develop an accelerated corrosion test for automotive heat exchangers. This has become even more important as automakers are focusing on corrosion durability of 15 years in the field versus current target of 10 years. To this end an acid immersion test was developed and reported in a previous paper for condensers (1). This paper extends those results to evaporators and establishes the efficacy of the test using these results and those reported in the literature. The paper also discusses variability in corrosion test results as observed in tests such as ASTM G85:A3 Acidified Synthetic Sea Water Test (SWAAT), and its relation to field durability.
Rungta, Ravi, Pandit, Noori
Aluminum Alloys - FundamentalsJ451_201801 (Current)1/10/2018
This information report is intended to give general data on the properties of aluminum and information on working, joining, forming, machining, finishing, and heat treating of aluminum.
Metals Technical Committee
Bearing and Bushing AlloysJ459_201801 (Current)1/10/2018
The bearing performance of steel backed half bearings, bushings, and washers is dependent on the properties and thickness of the lining alloy, the strength and dimensional stability of the steel backing (usually SAE 1010) and the strength of the bond between the lining alloy and the backing. This SAE Information Report is primarily concerned with the properties of the lining alloys used in automotive applications, in particular, the crankshaft bearings of the internal combustion engine.
Metals Technical Committee
General Information - Chemical Compositions, Mechanical and Physical Properties of SAE Aluminum Casting AlloysJ452_201801 (Current)1/10/2018
The SAE Standards for aluminum casting alloys cover a wide range of castings for general and special use, but do not include all the alloys in commercial use. Over the years, aluminum alloys have been identified by many numbering systems as shown in Table 1. Presently, SAE is recommending the use of the UNS Numbering System to identify these materials. The castings are made principally by sand cast, permanent mold, or die cast methods; however, shell molding, investment casting, plaster cast, and other less common foundry methods may also be used. If the alloys listed do not have the desired characteristics, it is recommended that the manufacturers of aluminum castings be consulted.
Metals Technical Committee
Cast Copper AlloysJ462_201801 (Current)1/9/2018
This standard prescribes the chemical and mechanical requirements for a wide range of copper base casting alloys used in the automotive industry. It is not intended to cover ingot. (ASTM B30 is suggested for this purpose.)
Metals Technical Committee
Wrought and Cast Copper AlloysJ461_201801 (Current)1/9/2018
For convenience, this SAE Information Report is presented in two parts as shown below. To avoid repetition, however, data applicable to both wrought and cast alloys is included only in Part 1. Part I—Wrought Copper and Copper Alloys Types of Copper (Table 1) General Characteristics (Table 3) Electrical Conductivity Thermal Conductivity General Mechanical Properties (Table 10) Yield Strength Fatigue Strength Physical Properties (Table 2) General Fabricating Properties (Table 3) Formability Bending Hot Forming Machinability Joining Surface Finishing Color Corrosion Resistance Effect of Temperature Typical Uses (Table 3) Part II—Cast Copper Alloys Types of Casting Alloys Effects of Alloy Elements and Impurities General Characteristics (Table 11) Physical Properties (Table 12) Typical Uses (Table 11)
Metals Technical Committee
Magnesium Wrought AlloysJ466_201801 (Current)1/9/2018
This SAE Standard covers the most common magnesium alloys used in wrought forms, and lists chemical composition and minimum mechanical properties for the various forms. A general indication of the usage of the various materials is also provided.
Metals Technical Committee
Alloy and Temper Designation Systems for AluminumJ993_201801 (Current)1/9/2018
This standard provides systems for designating wrought aluminum and wrought aluminum alloys, aluminum and aluminum alloys in the form of castings and foundry ingot, and the tempers in which aluminum and aluminum alloy wrought products and aluminum alloy castings are produced.
Metals Technical Committee
Bearing Bushing Alloys Chemical Composition of SAE Bearing and Bushing AlloysJ460_201801 (Current)1/9/2018
Compositions apply to the finished bearing or bearing lining, not necessarily to the alloy at an intermediate processing stage. All values not given as ranges are maxima. (See Tables 1 through 5.)
Metals Technical Committee
Magnesium Casting AlloysJ465_201801 (Current)1/9/2018
This document has not changed other than to put it into the new SAE Technical Standards Board Format This SAE Standard covers the most commonly used magnesium alloys suitable for casting by the various commercial processes. The chemical composition limits and minimum mechanical properties are shown. Over the years, magnesium alloys have been identified by many numbering systems, as shown in Table 1. Presently, SAE is recommending the use of the use of the UNS numbering system to identify those materials. Other equally important characteristics such as surface finish and dimensional tolerances are not covered in this standard.
Metals Technical Committee
Influence of Cold Working on Mechanical Properties of Al-Zr and Al-Zr-Mg Alloys2017-36-023911/7/2017
The Hardening by cold work is capable of increasing the mechanical strength of non-ferrous metals. The combination of alloying elements in solid solution and cold working is extremely effective in achieving greater strength for aluminium alloys. However, some alloys may be susceptible to stress corrosion and are notoriously difficult to fabricate during hot and cold work. A requirement for adding the alloy elements in this work will be that the interaction between them will provide hardening by additional cold working, but with no occurrence of chemical interaction between them and not removing them from the solid solution. This paper aims to analyze the effect of cold working on mechanical properties of Al-0.18%Zr, Al-0.18%Zr-2.0%Mg and Al-0.18%Zr-6.0%Mg alloys compared to results obtained without cold working. The alloys were melted in a muffle furnace and cast in a water-cooled Cu mold. Samples were machined to the diameter of 9.5 mm and then were cold worked, obtaining samples with a diameter of 3.0 mm. Tensile test were performed for mechanical characterization. The ultimate tensile strength and elongation of the alloys before and after the cold working were evaluated. The results showed that the increase in Mg content caused grain refiniment. The cold work promoted an increase of almost 100% on the ultimate tensile strength and approximately 90% reduction of the elongation. Al-0.18% Zr-6.0% Mg showed a higher elongation associated with higher strength after cold working, a result of elongation opposite that presented in the alloy without deformation.
Lobato, Mauro Quaresma, Silva, Rafael Assis da, Cunha, Jesus Nazareno Pereira, Fernandes, Everaldo Afonso, Souza, Pedro Henrique Lamarão, Quaresma, José Maria do Vale
Design of As-Cast High Strength Al-Si-Cu-Ni-Sr Alloys Using the Taguchi Method2017-01-50099/30/2017
In the present study, a design of experiment (DOE) technique, the Taguchi method, was used to develop as-cast high strength aluminum alloys with element additions of Si, Cu, Ni and Sr. The Taguchi method uses a special design of orthogonal arrays to study all the designed factors with a minimum of experiments at a relatively low cost. The element factors chosen for this study were Si, Cu, Ni and Sr content in the designed aluminum-based alloys. For each factor, three different levels of weight percentages were selected (Si: 6, 9, 12%, Cu: 3, 5, 7%, Ni: 0.5, 1, 1.5% and Sr: 0.01, 0.02, 0.03%). Tensile properties such as ultimate tensile strength, yield strength and elongation at failure were selected as three individual responses to evaluate the engineering performance of the designed alloys. The results of the factor response analysis were used to derive the optimal level combinations. The alloy with the optimal composition had an average UTS of 267.00 MPa, an elongation at failure of 1.13% and a yield strength of 210.37 MPa under the as-cast condition for a squeeze casting with a section thickness of 25 mm. The contribution of each factor was determined by an analysis of variance.
Fang, Li, Hu, Henry, Nie, Xueyuan, Tjong, Jimi, Zhang, Xuezhi
Starter Motor Light Weighting through Use of Alternate Materials2017-28-19677/10/2017
Global Automotive Industry is mandated with the task of emission reduction and mileage improvements. One of the key areas being looked at from mileage standpoint is light weighting. While Aluminum body is replacing Steel is many vehicular applications, in Starter Motor Aluminum is the key component. Therefore, any attempt at light weighting must consider Aluminum. A Starter motor fits directly on to the engine. Aluminum being the housing material provides structural stability. It also performs the role of heat dissipation being a good thermal conductor and source of electrical ground path. Aluminum constitutes 20 - 25% of Starter motor weight. Any significant weight reduction cannot be achieved unless we look at the components made of Aluminum, namely die cast Housing and End plate. The alternatives considered in this study include engineered plastics, magnesium alloy and composites. The prime reasons for evaluation of these materials include the ones listed above - structural stability and strength, electrical and thermal conductivity. Detailed study was carried out which included material characterization, FEA analysis, thermal studies and finally rigorous physical testing. The results present the comparison of all the various alternate materials. The ultimate deciding factor must include cost as these materials, while scoring over Aluminum in weight (density) cost a premium. The paper will also address the tradeoff - cost vs. benefit, for the car manufactures if they decide to choose the alternative.
Nagapillai Durairaj, Senthil Ram, Ganesan, Thulasirajan, Chakrapani Rao, Praveen
Vibration Analysis on Magnesium Alloy Housing and Analysis of Resonant Frequency on the Housing between Magnesium and Aluminium Alloy2017-28-19697/10/2017
Magnesium alloy current being used for automotive sector and are being significantly used for manufacturing engine block as offering higher power to weight ratio to the vehicle. In this context, the magnesium alloy has been used in the replacement of aluminium alloy for the starter housing which in turn increase the power to weight ratio of the motor. Considering the operation condition of starter motor in the engine of the vehicles, the starter motor is being exposed to the harsh environment, where its system is being tested for Noise, Vibration and Harshness. In this paper, the magnesium alloy housing is used to study the vibration and noise developed in the starter motor and the same is compared with the noise and vibration of the motor when it being used with Aluminium alloy Housing. First, the vibration study is carried out for the housing part alone to capture the resonant frequency of the both housing alloy say, Aluminium and Magnesium. And further to this study, the housings are assembled in the starter motor and being tested for the vibration study as a system. The result will discuss on the vibration analysis of both Magnesium alloy housing and Aluminium alloy housing
Nagapillai Durairaj, Senthil Ram, Ganesan, Thulasirajan, Chakrapani Rao, Praveen
Improved Cast Stainless Steel AlloysTBMG-270646/1/2017
At high temperatures, currently available cast stainless steel alloys used for engine component applications do not have the long-term stability of their original castings, and are lacking in their ability to resist deformation and cracking from extreme temperature changes. There is a need for high-strength, oxidation-resistant, and crack-resistant cast alloys for use in internal combustion engine components such as exhaust manifolds and turbocharger housings, gas-turbine engine components such as combustor housings, and other components that must function in extreme environments for prolonged periods of time.
Fe-Mn-Al-C Alloy Steels – A New Armor Class2017-01-17033/28/2017
Fe-Mn-Al-C steel alloys have been previously studied for their potential as an alternative steel alloy for Rolled Homogeneous Armor (RHA). Prior examination of the material system has shown promise in this capacity due to the high strength and reduced density of Mn steels as compared to RHA. The prior tested materials were both wrought and cast versions but were all less than an inch in thickness. The alloy is once again being examined, but this time in thicker wrought plate. The aim of the current body of work is to develop a Military Specification (MIL-SPEC) for this new class of ballistically capable material. For industry and communities interested in such material development, the purpose of this paper, then, is to provide a summary of the processing parameters, the prior ballistic and dynamic material testing, cutting and welding approaches, and the extent of progress on industrial sized thick plate development.
Howell, Ryan A., Gerth, Richard
Development of High Strength Aluminum Wires for Low-Voltage Automotive Wiring Harnesses2017-01-16443/28/2017
The weight of wire harnesses increases with the growing number of systems used in the vehicle in recent years. For the purpose of reducing the weight of wire harnesses, aluminum instead of the conventional copper is getting popular as a wire conductor. The conventional Al wire, however, is not able to be used for small gauge wires such as the sizes of 0.35mm2 and 0.5mm2 and wires used in the engine compartment due to its insufficient conductor strength. For this reason, we tried to develop a stronger aluminum alloy that has conductor strength equivalent to or stronger than that of copper. For the first time in the industry, we have successfully developed a high-strength aluminum alloy wire. Starting with the application of 0.35mm2 wire for engine wire harnesses, we began mass production in April 2015. This paper reports the development of high-strength aluminum alloy that can be used for small gauge wires and wires used in the engine compartment. The target property of aluminum alloy to be developed was specified as 220MPa tensile strength and 50%IACS conductivity. Based on the age-precipitated 6000 series aluminum alloy, additive elements and their content were specified and the alloy composition was determined. The aging conditions were determined by examining the precipitation status of Mg2Si intermetallic compounds. With this approach, we achieved 250MPa tensile strength and 52%IACS conductivity, both of which are better than the target. We have developed a 0.35mm2 wire that is 53% lighter than the same size copper wire.
Akasofu, Yasuhiro, Taguchi, Kinji, Yoshimoto, Jun, kusakari, Misato
Guide for Achieving Plating/Finish Compatibility with Connectors and Accessories used in Electrical Wiring Interconnect Systems (EWIS)ARP6903 (Historical)3/17/2017
The intent of this ARP is to provide guidance to assist users in choosing compatible component finishes/platings to achieve the best corrosion resistance performance for compatible components/couples. This SAE Recommended Practice is intended as a guide toward standard practice and is subject to change to keep pace with experience and technical advances. A galvanic compatibililty table is provided to assist with the compatible plating/finish selection. Specific plating performance parameters for each individual plating and each connector/accessory specification have also been provided to assist the product user with compatible plating/finish selection.
AE-8C1 Connectors Committee
High Performance Aluminum Casting Alloys for Engine Applications2016-32-001911/8/2016
In the early 1980's, some promising research and development efforts focused on powder metallurgy revealed that aluminum alloys containing 4 wt% cerium exhibit high temperature mechanical properties exceeding those of the best commercial aluminum casting alloys currently in production. Cerium oxide is an abundant rare earth oxide that is often discarded during the refining of more valuable rare earths such as Nd and Dy. Therefore, the economics are compelling for cerium as an alloy additive. In this paper, we report select results obtained during an investigation of the castability of aluminum-cerium alloys and determine compositional modifications that may be required to ensure the compatibility of the alloy with near net shape casting methods such as advanced sand casting, die casting, permanent mold casting and squeeze casting. Al-Ce alloys were cast in binary composition of 6-16 wt% Ce. Commercially pure aluminum ingots were melted and held at approximately 785°C. Ternary and quaternary alloys with Si and Mg additions were also investigated. Test bars were cast to establish mechanical properties and step plates and hot tear molds were used to determine sensitivity to solidification conditions and hot tearing sensitivity respectively. Finally, air cooled engine cylinder heads were cast in sand molds to get a sense of castability in complicated shape castings.
Weiss, David
Powder Reuse and Its Effects on Laser Based Powder Fusion Additive Manufactured Alloy 7182016-01-20719/20/2016
Laser Based Powder Bed Fusion, a specific application of additive manufacturing, has shown promise to replace traditionally fabricated components, including castings and wrought products (and multiple-piece assemblies thereof). In this process, powder is applied, layer by layer, to a build plate, and each layer is fused by a laser to the layers below. Depending on the component, it appears that only 3-5% of the powder charged into the powder bed fusion machine is fused. Honeywell’s initial part qualification efforts have prohibited the reuse of powder. Any unfused powder that exits the dispenser (i.e., surrounds the build or is captured in the overflow) is considered used. In order for the process to be broadly applicable in an economical manner, a methodology should be developed to render the balance of the powder (up to 97% of the initial charge weight) as re-usable. Though multiple manufacturers may be re-using powder, there is no industry standard methodology or practice for powder re-use. The present study (with 10 uses of the same powder lot) shows no appreciable impact on nickel-base superalloy 718 chemistry, powder size / distribution, or mechanical properties, with exception of gradual increase in oxygen content of the powder.
Hann, Brian A.
Fatigue Life Prediction for Adaptable Insert Welds between Sheet Steel and Cast Magnesium Alloy2016-01-03924/5/2016
Joining technology is a key factor to utilize dissimilar materials in vehicle structures. Adaptable insert weld (AIW) technology is developed to join sheet steel (HSLA350) to cast magnesium alloy (AM60) and is constructed by combining riveting technology and electrical resistance spot welding technology. In this project, the AIW joint technology is applied to construct front shock tower structures composed with HSLA350, AM60, and Al6082 and a method is developed to predict the fatigue life of the AIW joints. Lap-shear and cross-tension specimens were constructed and tested to develop the fatigue parameters (load-life curves) of AIW joint. Two FEA modeling techniques for AIW joints were used to model the specimen geometry. These modeling approaches are area contact method (ACM) and TIE contact method. ACM representation was used to calculate forces and moments for the joints and then calculated the structural stresses while TIE contact representation was used to calculate principal stresses for the joints. The load-life curves were used to construct the appropriate S-N curves based on ACM and TIE contact for different specimen configurations. Then both the S-N curves were used to predict fatigue life of AIW joints in the front shock tower structures. The test results and the prediction results were well correlated.
Kang, HongTae, Khosrovaneh, Abolhassan, Su, Xuming, Guo, Mingchao, Lee, Yung-Li, Boorgu, Sai, Jiang, Chonghua
Effect of Thermal Exposure Time on the Relaxation of Residual Stress in High Pressure Die Cast AM602016-01-04234/5/2016
Magnesium alloys are becoming more commonly used for large castings with sections of varying thicknesses. During subsequent processing at elevated temperatures, residual stresses may relax and become a potential mechanism for part distortion. This study was conducted to quantify the effects of thermal exposure on residual stresses and relaxation in a high pressure die cast magnesium (AM60) alloy. The goal was to characterize relaxation of residual stresses at temperatures that are commonly experienced by body components during a typical paint bake cycle. A residual stress test sample design and quench technique developed for relaxation were used and a relaxation study was conducted at two exposure temperatures (140°C and 200°C) over a range of exposure times (0.25 to 24 hours). The results indicate that a significant amount of residual stress relaxation occurred very rapidly during exposure at both exposure temperatures.
Hill, Haley, Zindel, Jacob, Godlewski, Larry
Effect of Humidity on the Very High Cycle Fatigue Behavior of a Cast Aluminum Alloy2016-01-03714/5/2016
In this paper, fatigue tests on a cast aluminum alloy (AS7GU-T64) were performed under different frequencies and humidity levels. Tests conducted under conventional frequency in laboratory air have been compared to tests conducted under ultrasonic frequency in dry air, saturated humidity and in distilled water. It was observed that the highest and lowest fatigue lives correspond to ultrasonic fatigue tests in dry air and in distilled water, respectively. Unlike specimens tested at conventional frequency, all of the specimens tested at ultrasonic frequency presented a large amount of slip facets on the fatigue crack propagation fracture surface.
Li, Wenkai, Engler-Pinto, Carlos, Cui, Haitao, Wen, Weidong, Su, Xuming
Heat Treatment Wrought Nickel Alloy and Cobalt Alloy PartsAMS2774E (Historical)1/13/2016
This specification specifies the engineering requirements for heat treatment, by part fabricators (users) or their vendors or subcontractors, of parts made of wrought nickel or cobalt alloys, of raw materials during fabrication, and of fabricated assemblies in which wrought nickel or cobalt alloys are the primary structural components.
AMS F Corrosion Heat Resistant Alloys Committee
Aircraft Casting AlloyTBMG-2357112/1/2015
IBC Advanced Alloys Corp. Wilmington, MA 855-237-2522
Very High Cycle Fatigue of Cast Aluminum Alloys under Variable Humidity Levels2015-01-05564/14/2015
Ultrasonic fatigue tests (testing frequency around 20 kHz) have been conducted on four different cast aluminum alloys each with a distinct composition, heat treatment, and microstructure. Tests were performed in dry air, laboratory air and submerged in water. For some alloys, the ultrasonic fatigue lives were dramatically affected by the environment humidity. The effects of different factors like material composition, yield strength, secondary dendrite arm spacing and porosity were investigated; it was concluded that the material strength may be the key factor influencing the environmental humidity effect in ultrasonic fatigue testing. Further investigation on the effect of chemical composition, especially copper content, is needed.
Li, Wenkai, Cui, Haitao, Wen, Weidong, Su, Xuming, Engler-Pinto, Carlos
Effect of Strain Level on the Behavior of Intermetallics and Texture of Al-Si-Cu-Mg Alloy Modified with Transition Metals2015-01-05144/14/2015
The uniaxial compression test was used to assess the influence of strain amount on the behavior of precipitates and texture of the Al-7%Si-1%Cu-0.5%Mg alloy, modified with micro-additions of V, Zr and Ti. As revealed through metallographic examinations, fracturing and re-orientation of the second-phase particles increased with increasing compression strain. However, the intermetallic particles experienced substantially more frequent cracking than the eutectic silicon. The crystallographic texture was measured and correlated with deformation behavior of the alloy. The weak texture of 11<211> and 111<110> components, detected after casting transformed to a mixture of 1<110>, 112<110> and 111<110> components after room-temperature compression deformation. The intensity of the texture components depended on the strain amount. It is concluded that the texture formation in the studied alloy is controlled by the precipitates formed during solidification of the alloy.
Shaha, Sugrib K., Czerwinski, Frank, Kasprzak, Wojciech, Friedman, Jacob, Chen, Daolun
THE CHEMICAL MILLING PROCESSARP1331B (Historical)3/5/2015
This recommended practice provides recommendations concerning the chemical milling of aluminum, magnesium, and titanium alloys, and specialty alloys.
AMS B Finishes Processes and Fluids Committee
Advancing the Use of Beryllium Bearing Materials for Unmanned PlatformsTBMG-215022/1/2015
Aerospace and defense platforms are often regarded as the earliest adopters of new materials and processes technologies. Materials test programs provide validations of material supplier property claims, as the physical tests are performed and data is analyzed. Resultant material “design allowables” are developed and compared to the performance envelopes for the intended application(s). The quality of simulation software and the developed knowledge base that design and strength engineering personnel use for analyzing materials in the intended product design and environments have improved dramatically in the last decade. This has primarily been based on the efficiency and availability of computing capacity for complex simulations.
Comparison between Casting and Alloy Rim Pattern on Brake Disk Cooling Using Numerical Simulation2014-01-06174/1/2014
Efficient function of brake system is considered a crucial stage in the vehicle development process. Heat exchange reduction can decrease the operational condition of braking system. Although the rims patterns have a significant role on vehicle aerodynamics, they can also have effect on air flow around the brake disk. So, selecting a rim is vital from both a safety and an aerodynamic point of view. In this paper the effect of air flow around a brake disk for two different types of rims was studied; a steel casting and an aluminum alloy rim. Numerical simulation was used for this analysis. First, the flow field around brake disk with iron casting rim was investigated at different velocities. Second, the flow field around the same brake disk system with an aluminum alloy rim was modeled at the same velocities. Finally, the effect of rim design on flow pattern over brake disk was compared. It was found that changing rim design has significant influence on velocity distribution around brake disc and pads.
Beigmoradi, Sajjad, Jahani, Kambiz, Ravaji, Babak
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