Browsing by Keyword "Aluminium"
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Item Effects of Machining Parameters on the Quality in Machining of Aluminium Alloys Thin Plates(2019-09) Del Sol, Irene; Rivero, Asuncion; Gamez, Antonio J.; SGNowadays, the industry looks for sustainable processes to ensure a more environmentally friendly production. For that reason, more and more aeronautical companies are replacing chemical milling in the manufacture of skin panels and thin plates components. This is a challenging operation that requires meeting tight dimensional tolerances and differs from a rigid body machining due to the low stiffness of the part. In order to fill the gap of literature research on this field, this work proposes an experimental study of the effect of the depth of cut, the feed rate and the cutting speed on the quality characteristics of the machined parts and on the cutting forces produced during the process. Whereas surface roughness values meet the specifications for all the machining conditions, an appropriate cutting parameters selection is likely to lead to a reduction of the final thickness deviation by up to 40% and the average cutting forces by up to a 20%, which consequently eases the clamping system and reduces machine consumption. Finally, an experimental model to control the process quality based on monitoring the machine power consumption is proposed.Item Evolution FP7 funded project: body structure design strategies using new composite and aluminium materials and enabled technologies(InderScience, 2018-04-20) Mangino, Enrico; Alcalde, Estibaliz; Maestro, César; Di Paolo, Francesca; DeClaville Christiansen, Jesper; Sanporean, Catalina Gabriela; Deverill, John P.; Cischino, Elena; Elizetxea, Cristina; Lopez, Iratxe; Vuluga, Zina; Kirpluks, Mikelis; Cabulis, PeterisBased on Pininfarina Nido EV concept, EVolution aims to reduce the vehicle weight through new materials and process technologies, focused on five demonstrators: underbody, front crossbeam, mechanical subframe, shotgun system and door. This paper refers to body structure design strategies using new composite, Al materials and enabled technologies, focusing in particular on demonstrators design and manufacturing. The new front crossbeam geometry of the front shell is adapted starting from the Nanotough design, while the rear shell is specific for EVolution. The subframe demonstrator is redesigned to fulfil mechanical requirements of the part and manufacturing feasibility either. The EVolution door concept consists of two semistructural composite skins including a structural Al frame. The underbody is conceived through an integrated approach, optimising each element for its function. The shotgun component is designed to link parts obtained with different manufacturing technologies and several aluminium alloys in one single component: the structural node demonstrator.Item Gas Blowing Ultrasonic Aluminium Degassing Assessment with the Reduced Pressure Test (RPT) Method(2020) Galarraga, Haize; García de Cortázar, Maider; Arregi, E.; Artola, Antxon; Oncala, J.L.; Merchán-Zubieta, Mikel; Tecnalia Research & Innovation; CIRMETALEntrapped gases, solidification shrinkage and non-metallic compound formation are main sources of porosity in aluminium alloy castings. Porosity is detrimental to the mechanical properties of these castings; therefore, its reduction is pursued. Rotary degassing is the method mostly employed in industry to remove dissolved gases from aluminium melts, reducing porosity formation during solidification of the cast part. Recently, ultrasonic degassing has emerged as a promising alternative thanks to a lower dross formation and higher energy efficiency. This work aims to evaluate the efficiency of the ultrasonic degasser and compare it to a conventional rotary degassing technique applied to an AlSi10Mg alloy. Degassing efficiency was evaluated employing the reduced pressure test (RPT), where samples solidified under reduced pressure conditions are analysed. Factors affecting RPT were considered and temperature parameters for the test were established. The influence of ultrasonic degassing process parameters, such as degassing treatment duration and purging gas flow rate were studied, as well as treated aluminium volume and oxide content. Finally, ultrasonic degassing process was contrasted to a conventional rotary degassing technique, comparing their efficiency.Item Hot stamping of aerospace aluminium alloys: Automotive technologies for the aeronautics industry(2022-09) Atxaga, G.; Arroyo, A.; Canflanca, B.; EXTREMAT; PROMETAL; SGThis paper proposes the use of the hot stamping process that provides ready to use parts for the obtention of aircraft components as an alternative manufacturing technology to e.g. machined parts. The development has been focused on the study of the high temperature formability of aluminium alloys. The feasibility of hot forming the AA2198 aluminium‑lithium alloy into complex shapes component has been studied. A wide experimental campaign has been carried out to set up the optimum hot stamping process parameters. In addition, forming trials with different geometries (omega and B-pillar shapes) have also been performed and, after the corresponding heat treatment, material properties have been recovered. Simulations of the hot stamping process have been carried out with Pamstamp® 2G software. These results have been correlated with the ones obtained in the experimental campaign. As a final step of the development, a demonstrator corresponding to a wing rib has been successfully manufactured. Characterization carried out to the prototype indicate specifications are fulfilled.Item Molten aluminium attack on iron based alloys(2017-05-04) Carrera, E. A.; Ramírez-Ramírez, J. H.; Pérez-González, F. A.; González, J. A.; Crespo, I.; Braceras, I.; Martínez-de-la-Pera, I.; Larrañaga, A.; Garza-Montes-de-Oca, N. F.; Pérez-Unzueta, A. J.; Talamantes-Silva, J.; Cavazos, J. L.; Colás, R.; PROMETAL; INGENIERÍA DE SUPERFICIESLiquid aluminium alloys affect the moulds, by formation of intermetallic layers at their surface; such attack is enhanced by the flow of the molten metal on the surface of the tooling. Metal tooling are used to promote high heat transfer rates and increase the solidification rate to enhance mechanical properties in cast pieces, but the damage to their surface affects their quality and increases the production costs due to the need to repair them. This work presents the results of a series of studies conducted to evaluate the attack produced by molten aluminium on samples of iron based materials commonly used in the manufacture of dies and moulds. The studies were conducted in a machine that imposes a rotating movement to experimental specimens to simulate the flow of liquid metal. The damage observed in the samples was compared to that experienced by tooling in the melt shop.Item Rapid simulation models for aluminium furnaces design(2017-07-04) Anglada, Eva; Vicario, Iban; de Landia, Leonor; Mendizabal, Gorka; Toledo, Nagore; CIRMETAL; PROMETALThe minimisation of energy consumption in aluminium metal casting industries requires an appropriate design of the furnaces to reduce as possible the heat losses through the walls. Detailed simulation models have been developed that allow the in-depth study of furnace behaviour, but these models are too complex and slow for some industrial necessities. To make possible a fast evaluation during preliminary phases more agile models are needed. This agility may be achieved by simplified models, but the results could be affected by a lack of accuracy. The work presented hereafter shows how the steady state analysis of the furnace walls with simplified models of finite elements may give sufficiently accurate and fast results. The simulation models have been validated against experimental results, thus confirming their ability to adequately reproduce the thermal behaviour of the walls of several furnaces regardless of their composition or heating system.Item Research on Coatings and Infiltration to Strengthen Ceramic Lost Cores Used in High-Pressure Die Casting Processes(2019-07-15) Merchán, Mikel; García de Cortázar, Maider; Galarraga, Haize; Bárcena, Jorge; Artola, Antxon; CIRMETAL; EXTREMATLost cores used to manufacture complex aluminium components through high-pressure die casting (HPDC) processes need to withstand very high injection velocities and pressures. The conventional sand cores used in other casting processes, such as sand casting or low-pressure die casting, do not support the aggressive process parameters of the HPDC, so advanced ceramic cores must be used. These cores must be strong enough not to get broken during the casting process, but, at the same time, they must have a minimum porosity to be easily removed from the casting to obtain the finished part. Due to this porosity, the aluminium penetrates the core surface during the casting process. So, the criterion here is to find the necessary compromise between strength and porosity and to protect the core surface from the aluminium penetration. In this work, two research lines have been followed to address these challenges. On the one hand, different refractory coatings have been applied to the ceramic core surface with the aim of sealing it. Amongst the coatings analysed, boron nitride-based one has been found to be the most suitable and cost-effective solution to avoid aluminium penetration. On the other hand, silica has been proved to be a suitable infiltration agent to increase the strength of the core.