Technical Sessions – Details of all abstracts
ABSTRACT 03
Automatic and Contactless Inspection of Machined Aluminum Parts Surface Finish
René Kamguem
Antoine Souheil Tahan
Victor Songmene
Department of Mechanical Engineering, École de technologie supérieure, Québec, Canada
Surface roughness/texture requirements are important for mechanical parts. Crack initiation and part/structure reliability relate directly to surface quality. Techniques are presented for non-contact inspection of machined parts directly at the machining station. Machining parameters, tool geometry and coating, and workpiece materials influences on milling part surface quality are analysed. Models assess roughness in real time using captured image characteristics. Roughness parameters can be estimated using features from images/models without prior knowledge of machining parameters used to generate the surface. Results obtained using a vision system compare to those obtained with conventional stylus measuring surface roughness systems, and could contribute to on-line surface roughness monitoring, reducing product manufacturing costs.
ABSTRACT 04
Subject Area: New Product Design and Construction
5 Dimensional CFD Simulation and Optimisation of Ventilation for Smelter Process Applications
Edmund Baltuch
Member CQRDA
Siegmar Baltuch
Air-Therm Inc., Montréal, Québec, Canada
CFD simulation allows the optimised application of thermodynamic and aerodynamic engineering in the design and fabrication of natural green ventilation solutions. Derivative to this analysis, we have undertaken a study and applied the results to use this technique to optimise the design of aluminium extrusions and light-gauge aluminium sheet metal, improve performance, optimise fabrication processes, and increase safety for the fabricating team. Our research has developed a system and methodology that can be applied to a large number of non-ferrous design, development and fabrication processes.
ABSTRACT 05
Subject Area: Processes
Casting a Very Unconventional Aluminium Alloy in Low Pressure Permanent Mould (LPPM)
Nicolas Giguère Ph.D.
Research Engineer
Franco Chiesa
Chief Scientist
Centre de Métallurgie du Québec, Trois-Rivières, Québec, Canada
During A356-T6 aluminium battery cover production using the low pressure permanent mould process (LPPM), the casting sticking to the mould made ejection increasingly difficult. This project casts high-iron alloy A380 using LPPM to reduce die sticking of cast parts to the mould. Air tightness of the casting was met; solution heat treatment of 10h at 540°C needed for alloy A356 was eliminated, along with subsequent straightening of the castings. A380 0.79% iron content drastically reduced soldering problems, enabling increased injections before mould disassembly. Casting strength and ductility is reduced using A380; however, yield strength and elongation sufficiently achieved part functionality.
ABSTRACT 07
Effects of Lubricating Conditions on Machinability of AA6061-T6
Jules Kouam
Victor Songmene
École de Technologie Supérieure (ETS), Montréal, Québec, Canada
Marek Balazinski
École Polytechnique de Montréal, Montreal, Québec, Canada
Patrick Hendrick
Université Libre de Bruxelles, Brussels, Belgium
Machining industries seek alternative solutions to wet machining due to costs, environmental effects and impacts on occupational health and safety. Dry machining is proposed, but in most conditions the cutting tool wears out quickly, leading to part quality deterioration and increased machining costs. MQL machining is proposed to maintain reasonable tool life and limited cost compared to flood or wet machining. MQL and dry machining methods are susceptible to generating aerosols containing metallic particles that can seriously harm occupational health and safety. Investigations are presented to improve machinability and effects of lubrication (dry, MQL and wet) during turning of 6061-T6 aluminium alloy. Performance indexes include surface roughness, tool wear, chip thickness, and aerosol generation.
ABSTRACT 08
Subject Area: Processes
Modeling the Formation of Transverse Weld in Billet-to-Billet Extrusion using Finite Element Method
Yahya Mahmoodkhani Ph.D.
Candidate, MME
Mary Wells
Professor , MME
University of Waterloo, Waterloo, Ontario, Canada
Nick Parson
Senior Scientist
Arvida Research and Development Centre, Rio Tinto Alcan, Jonquière, Québec, Canada
A comprehensive mathematical model of the hot extrusion process for aluminium alloys is developed and validated. Reflecting complex thermomechanical changes in alloys during extrusion, the model incorporates heat flow and plastic deformation. The plasticity module uses finite element package DEFORM #61650, a 2-D transient Lagrangian model, coupling thermal and deformation phenomena. Model validation against industrial data predicts pressure and temperature during extrusion. Finite element results for velocity fields calculated surface cladding thickness feeding one billet after another through the die (transverse weld). The mathematical model assessed feeder dimension changes effects on shape, thickness and extent of transverse weld during extrusion.
ABSTRACT 09
Subject Area: Emerging Technologies
Process Optimisation of a Friction Stir Lap Welded 5456 Aluminium Alloy
Mohammad Jahazi
Professor, Department of Mechanical Engineering
Ecole de technologie supérieure, Montréal, Québec, Canada
Emad Salari
Student
Alireza Khdabandeh
Professor
IAU-University, Department of Materials Engineering, IAU-S&R Branch, Tehran, Iran
Tool geometry and rotational speed influences on macrostructure, microstructure and mechanical properties of friction stir lap welded 5456 aluminium alloy plates with different thicknesses and temper conditions were investigated using a new pin design. Rotational speeds, 300rpm/600rpm/800rpm, were used to study heat input influence on weld joint quality. Welded joint mechanical properties were evaluated as a function of FSW processing conditions. The SZ exhibited higher average hardness; tensile strength of FSW plates was similar, but elongation was lower than the base metal. Tool geometry and processing condition influences on microstructure evolution and mechanical properties, and optimum conditions are discussed.
ABSTRACT 10
Subject Area: Emerging Technologies
The Development of AA3065 – an Extrudable Alloy with Improved Mechanical Properties for Heavy-Duty Heat Transfer Applications
Nick Parson
Senior Scientist
Alexandre Maltais
R&D Engineer
Raynald Guay
R&D Technologist
Arvida Research and Development Centre, Rio Tinto Alcan, Jonquière, Quebec, Canada
Aluminium extruded tubes are widely used in mobile and stationary heavy-duty heat transfer applications for diesel engine charge air coolers, oil coolers and radiators. This product has the advantage that the profile cross section can be internally enhanced to assist heat transfer, or wall thickness can be locally modified to increase damage resistance. AA3003 is the most widely available "strong" 3xxx extrusion alloy that is readily brazeable. However, material is demanded with increased strength at ambient and elevated temperatures to allow weight reduction and meet increased service temperature challenges. Development of AA3065 extrusion alloy to meet these requirements is presented.
ABSTRACT 12
Subject Area: Emerging Technologies, Structural Design
A Streamlined Approach to the Flexural Strength of Aluminium Members
Randy Kissell
The TGB Partnership, Hillborough, North Carolina, USA
Flexural strength may be governed by several limit states: tensile yielding, tensile rupture, compressive yielding, local buckling, and lateral-torsional buckling. Structural design specifications for aluminium and steel have dealt with these limit states in various ways, usually as a function of the cross section (for example, I-beam, tube, or rectangular bar). Given the great variety of aluminium member cross sections, however, engineers designing aluminium flexural members would benefit from a more general approach. Such an approach is being considered for the "2015 Specification for Aluminum Structures," published by the Aluminum Association, and is the subject of this presentation.
ABSTRACT 13
Subject Area: Market Sectors
Design for Fastener Tension and Pull-Out from Tapped Aluminium
James C. LaBelle
Computerized Structural Design, S.C., Milwaukee, Wisconsin, USA
Tanya A. Dolby
Engineer
Kawneer Company, Inc., Norcross, Georgia, USA
Designs are presented for tension-loaded aluminium, carbon steel and stainless steel fasteners installed in tapped holes in aluminium components. Allowable tension is the least of: fastener, internal thread and external thread strengths. Fastener strength is determined using ultimate stress and cross-section tensile area. Internal-thread strength is based on AA specification's pull-out equations for thin, thick and transition behaviour regions. Equations are solved for minimum thickness as a function of allowable tension. Tables show allowable values for fastener materials, grades, diameters, and thicknesses. A prior Dewalt/Mack study testing threaded 2024-T4 aluminium rods is re-interpreted using tensile areas instead of root areas.
ABSTRACT 14
Subject Area: Processes
Structural Behaviour of Aluminium Bolt-Channel Joint: Calibration of Numerical Models on Testing Results
Vincenzo Macillo
Luigi Fiorino,
Federico M. Mazzolani
University of Naples "Federico II", Naples, Italy
The variety of cross-sectional extruded shapes enables new joining solutions for aluminium profiles to compete with conventional solutions using rapid execution, optimisation of parent material, treatments, and machining reduction. Structural behaviour for this joint typology is presented. Bolt channel joints commonly used in building applications and transportation structures are one possibility when joining aluminium extrusions. The system's track or channel holds a bolt head, nuts or plates with threaded holes. Experiments evaluate bolt-channel joint structural behaviour. Two cross-sections corresponding to different bolt diameters were selected and three load directions were considered. Experimental results are used to calibrate non-linear numerical models.
ABSTRACT 15
Structural Design for Manufacturing with Aluminium
Alexandre de la Chevrotière, P.Eng.
President
Simon Lacasse, M. Eng.
MAADI Group Inc., Montreal, QC, Canada
Key structural design aspects of aluminium are presented. Design for: manufacturing, production, assembly, recycling/disposal, life cycle, and prototyping. Aluminium extrusions and castings are powerful tools for structural design, improving functionality and optimizing aluminium products at reduced cost. Well-designed aluminium products may reduce fabrication costs and offset the higher metal price per weight. Aluminium increases product life cycle, reduces total cost of ownership and reduces environmental footprint via recycling. New structural design approaches are presented that enable success from engineering design to manufacturability. To demonstrate improved manufacturability during the design phase, MAADI project experience presents a modular aluminium pedestrian bridge example that illustrates the design for manufacturing concept.
ABSTRACT 16
Reinforcement and characterization of XTiO2 composites modified A500-type Al-Mg-Si alloy matrix
O. S. I. Fayomi
A. P .I. Popoola
O.M Popoola
Faculty of Engineering and the Built Environment,
Tshwane University of Technology, P.M.B. X680, Pretoria, South Africa.
The possibility of increasing the mechanical properties of aluminum upon inoculation of a sand cast XTiO2-modified A500-type Al-Mg-Si alloy was studied. The influence of XTiO2 on the structural and mechanical properties of an Al-Mg-Si alloy has been investigated using scanning electron microscope and microhardness measurement. The alloying composition was determined with energy dispersive spectroscopy (EDX). The surface morphology of the alloyed sample using (SEM) showed that Ti particles were dispatched along the interface which led to the precipitation and better crystallization within the intermediates.
ABSTRACT 17
Subject Area: Processes
Effect of High-Speed Machining on Surface Integrity of 7075-T651 Aluminium Alloy
Walid Jomaa
Victor Songmene
Philippe Bocher
Professor
École de technologie supérieure, ETS, University of Québec, Montréal, Québec, Canada
Aluminium alloys such as 7075-T651 are widely used for fabricated aerospace and automotive structural components due to their high strength-to-weight ratios compared to other metals. Machined parts' fatigue life and performance depend strongly on their surface integrity after machining operations. To improve manufactured component durability, parts were produced with or without limited surface and subsurface alterations. To better understand surface alteration by sequential machining operations and how surface integrity is affected by machining, accumulated damage effects are presented on residual stresses induced by sequential high-speed machining of Al7075-T651 alloy. Correlations between cutting mechanisms, plastic deformation and residual stresses are investigated.
ABSTRACT 18
Subject Area: Processes
Screwed Joint for Aluminium Extrusions: Experimental and Numerical Investigation
Vincenzo Macillo
Luigi Fiorino,
Federico M. Mazzolani
University of Naples "Federico II", Naples, Italy
Extrusion technology provides many possibilities to join aluminium profiles. Special joint systems may use mechanical fasteners inside semi-hollow parts of aluminium extruded shapes for easiness, simplicity, rapid execution, optimisation of parent material, treatments, and reduced machining. Screw-groove joints, a screw engaged in an open slot of an extruded profile, are used in structural and non-structural applications under low and moderate loads for façades, doors and windows. Experiments assess pull-out behaviour of screw-groove connections. Screw location, aluminium alloy type, and the screw threads, diameter and embedment length were investigated. Non-linear finite element models were developed and calibrated based on experiment results.
ABSTRACT 19
Subject Area: Processes
Effect of Feeder Pocket Geometry on the Streaking Tendency of 6xxx Extrusions
Jean-François Béland
National Research Council, Saugenay, Québec, Canada
Christopher W. Jowett
Nick Parson
Alexandre Maltais
Rio Tinto Alcan, Québec, Canada
The best extruded surface finishes, as required for bright trim AA6463 profiles, can generally be produced with flat dies that do not incorporate any welding chamber. One explanation for this is that feeder pocket dead zones are dynamic, and are partly composed of previously extruded billets. Material from successive billets is gradually released into the profile surface and is a potential source of mill finish or post-anodised streaks. Dead zone dynamics are examined via tracers, looking at the effect of feeder pocket geometry on the accumulation and release of material into the product surface over a series of billets.
ABSTRACT 22
Subject Area: Market Sectors
A Step for Aluminium Global Market Growth
Aku Canice
Canice Maritime
Canice Maritime Alutec, Banjul, Gambia
Aluminium for construction, office and home furniture stands a better chance to outdo other metals and non-metals in the same usage with an aluminium welding machine. Manufacturers should modernize aluminium welding machines to consume less energy. Alternatively, aluminium profile manufacturers must reduce the element in aluminium compounds that requires more energy during welding, thus enabling diversified aluminium usage. Rivets and plastic angles used for joining aluminium are limiting aluminium use for other purposes. Aluminium use for doors globally has not been maximised. Producing universal size aluminium plate is suggested to enable aluminium use in doors to exceed other door materials.
ABSTRACT 23
Particle Emission and Dispersion during Dry Machining of Aluminium Alloys
Abdelhakim Djebara
Ali Bahloul
Institut Robert-Sauvé en santé et sécurité du travail, Montréal, Québec, Canada
Victor Songmene
École de Technologie Supérieure, Montréal, Québec, Canada
In metal cutting, two major concerns are associated with cutting fluids: costs and health hazard. Dry machining process dust impacts worker health. Clean machining must be cost effective and comply with shop floor occupational safety. Research aims to understand and reduce harmful impacts of the machining process on the environment and occupational safety. Experiments were conducted during milling of 2024-T351, 6061-T6 and 7075-T6 aluminium alloys in dry conditions. Cutting conditions significantly influenced dust generation. Cutting speed was a determinant factor for dust emission and control. Thus, it is possible to machine parts at very high speeds to ensure high productivity and good parts quality without producing harmful dust.
ABSTRACT 24
Dissimilar Metal Welding Using Electron Beam Process to Join Aluminium and Other Metals
Michinori OKUBO
Toshiyuki HASEGAWA
Department of Mechanical Engineering, College of Industrial Technology, Nihon University, Chiba, Japan
Dissimilar metal welding using high-quality electron beam process takes advantage of high-level controllability of the heat source. Welded quality of dissimilar 5mm-thick metal by electron beam welding equipment and process parameters were investigated using hardness and tensile tests, observing imperfections and microstructure. This study clarifies the properties for dissimilar welds and behaviour of inter-metallic compounds, rate of dilution, and mechanical properties in dissimilar welded joints. Weld metal compositions are controlled by off-center beam position. Partial modification on internal thread of Al-Zn-Mg wrought alloy and Al-Si-Mg casting were investigated by gas tungsten arc heat source using copper alloying process. Tensile strength improvements for internal thread are admitted by suitable process parameter.
ABSTRACT 26
Subject Area: Emerging Technologies
Welding Training with an Interactive 3D Technology
Claude Choquet
123 Certification Inc., Montréal, Québec, Canada
Simplify welding training and online certification for industry training centers by implementing a simulator that creates real-world experiences, training today's students with tomorrow's tools. Six years of apprenticeship and test results are presented. The simulator replicates workplace environment, welding machine and welding motion. The 100% virtual Arc+ system simulates the GTAW welding process commonly used in the aluminium industry: a 3D weld bead with motion tracking action, smoke, sparks, metal projections, and sounds, offering ultra-quick setups for multiple welding applications. The built-in Learning Content Management System enables self-directed practice and learning, instant replays, learner feedback, and detailed reports for instructors.
ABSTRACT 27
Structural Application of Perforated Aluminium Plates in a Footbridge Canopy
B.W.E.M. (Dianne) van Hove
F. (Frans) Soetens
Eindhoven University of Technology, Faculty of Architecture, Building and Planning, Unit Structural Design, Eindhoven, The Netherlands
A recently designed footbridge canopy covering a concrete bridge at the Eindhoven University of Technology campus is built up by aluminium plates containing perforations. The perforations differ in concentrations, diameter and pattern. The aluminium structure was adapted to improve global behaviour, especially in relation to deformation requirements. Further experimental and numerical research was carried out to investigate the failure behaviour of perforated plates loaded by compression. It is concluded that the failure behaviour of relatively thin aluminium plates in compression is very complex, even for non-perforated plates. Further fundamental research is needed to investigate failure models and failure loads of the perforated plates.
ABSTRACT 28
Optimisation of Aluminium Stressed Skin Panels in Offshore Applications
B.W.E.M. (Dianne) van Hove
F. (Frans) Soetens
Eindhoven University of Technology, Faculty of Architecture, Building and Planning, Unit Structural Design, Eindhoven, The Netherlands
Since introducing Eurocode 9, specific design rules for calculating aluminium stressed skin panels are available. These design rules are used to optimise two extrusions: one governing explosions and wind loading; and one governing explosions and floor loading. The optimised extrusions fulfill class 3 section properties, leading to weight reductions up to 25% of regularly used shear panel sections. Design based on class 4 section properties may yield more weight reduction. Failure mode depends on hat stiffeners height. For areas using relatively high sections, Eurocode 9 design rules and numerical calculations show good agreement. For sections using relatively low hat stiffeners, failure is introduced by global buckling. For such cross sections, Eurocode 9 gives rather conservative results.
ABSTRACT 29
Subject Area: Emerging Technologies
Turning Post-Consumer Scrap into Wrought Alloy
Frans Bijlhouwer
Ing., Director, Quality Consultants VOF
Heusden, the Netherlands
State-of-the-art aluminium scrap sorting and recycling technologies installed in our Greenfield operation are described including automated magnet sorters, eddy current separators, x-ray, and processing post-consumer scrap from scrap yards, incinerators and drosses, melting scrap via a tilting rotary furnace. Through holding furnaces, molten metal becomes ingots in a fully-automatic, robotised casting machine to produce die cast parts like automotive gear boxes, pistons and engine blocks. Analysis measures sorting effectiveness as input and output. With this sorting installation and post-consumer scrap, Mg and Ni purchases were reduced; treated scrap eventually becomes base material for aluminium master alloy and wrought alloy production.
ABSTRACT 30
Subject Area: Emerging Technologies
The Use and Misuse of Aluminium in Packaging
Frans Bijlhouwer
Ing., Director, Quality Consultants VOF
Heusden, the Netherlands
The key to aluminium use is to assure that unique material characteristics are optimised. Aluminium's modern look and appearance allow for use, but corrosion resistance, light weight, heat transfer and other factors are key application criteria. Importantly, the metal is recycled after use in large quantities, e.g., in consumer product packaging. Aluminium is easily used for certain packaging, while little thought is given to recycling. Examples demonstrate where designers clearly envision recycling and aluminium's carbon footprint, and how careless design pollutes with packaging that recycles on too small a scale. Increased awareness of aluminium use and recycling solutions are presented.
ABSTRACT 31
Subject Area: Processes
New Generation Surface Pretreatment Methods for Adhesive Bonding of AA6061-T6 Alloys
Noormohammed Saleema
Danick Gallant
National Research Council Canada, Saguenay, Québec, Canada
Dilip K. Sarkar
University of Québec at Chicoutimi (UQAC), Québec, Canada
Inadequate adherent surface preparation may result in inadequate surface wetting and poor mechanical interlocking of the adhesive. Since surface preparation is important in obtaining excellent adhesive joints, AA6061-T6 alloy surface pretreatments for adhesive bonding are reported including chemical, mechanical and plasma methods. Lap shear joints prepared using two-component epoxy adhesive were used under pristine conditions without degradation, and under environmental test conditions (degraded) to evaluate joint stability and environmental durability. Surface pretreatment method effects on joint stability were investigated using surface analysis: IRRAS, SEM/EDX for chemical and morphological analysis, contact angle goniometer for wettability studies, and crystallographic studies using XRD.
ABSTRACT 32
Subject Area: Processes
Retrogression Heat Treatment of Aluminium Extrusions and Rolled Products to Facilitate Forming and Joining in Structures
Joseph C. Benedyk
Illinois Institute of Technology, Chicago, Illinois, USA
Retrogression heat treatment (RHT) successfully forms and joins aluminium extrusions and rolled products for structural applications. Specialized RHT involves rapid heat treatment of 6xxx/7xxx alloy products via localized induction heating to the solutionised condition, quenching to approach a highly ductile state. Aluminium extrusions and rolled products in various tempers locally receive RHT in seconds, synchronised with forming operations to achieve significant plastic strains in forming with hardness and strength recovery in local regions of extrusions or rolled products. Localized RHT helps create compression fit joints without welding, facilitating commercial application in automotive vehicles, and suggested applications in bridges and buildings.
ABSTRACT 33
Subject Area: Emerging Technologies
High-Temperature Forming Processes for the Manufacturing of Complex Components using Aluminium Alloy Sheets
Guillaume D'Amours
Jean-François Béland
Ehab Samuel
National Research Council Canada, Saguenay, Québec, Canada
Aluminium yields low formability at room temperature, especially in high-performance alloys with several alloying elements. Increased forming temperature improves material flow by activating different deformation mechanisms, depending on alloy composition and microstructure. High-temperature aluminium alloy forming process reduces forming loads, lowers springback and improves surface finish. Hot forming capabilities of commercial-grade aluminium alloys are evaluated in terms of formability, forming time and manufacturing. Aluminium sheet forming processes of varying complexity and speeds are reviewed. Wrought 2xxx, 5xxx and 7xxx alloys are investigated. Effects of grain size, alloying elements and strain rates on formability and key process improvements are discussed.
ABSTRACT 34
Deburring and Edge Finishing of Aluminium Alloys: A Review
Seyed Ali Niknam
Victor Songmene
Aluminium Research Centre – REGAL, École de technologie supérieure (ETS), Montréal, Québec, Canada
Burr formation is one of the most common and undesirable phenomenon occurring in machining operations, reducing assembly and machined part quality. To remove burrs, a costly and non-value-added process known as deburring is required for post-processing and edge finishing. A basic burr formation and removal overview is presented. Due to vast applications of aluminium alloys in sectors such as the automotive and aerospace industries, the most highly used deburring and edge finishing on aluminium machined parts is described. The main advantages, disadvantages, limitations, part quality, and precision of these operations are presented. This can be beneficial for an adequate selection of deburring methods, cost reduction and production rate improvement.
ABSTRACT 35
Subject Area: Emerging Technologies, Surface Treatment, New Product Design & Development
Structural Studies of Electrochemically Deposited Conducting Polymer Polypyrrole on Aluminium Substrates
Dr. Ashoka Siddaramanna
Prof. D.K. Sarkar
University of Québec at Chicoutimi (UQAC), Québec, Canada
Energy storage materials play an important role in clean, efficient energy. Using a conductive polymer like polypyrrole (Ppy) offers high energy storage capacity, low density, good electrical conductivity, low cost synthesis, and environmental stability. Rational synthesis of Ppy on aluminium and copper-modified aluminium substrates via electrochemical technique are presented. Infrared studies confirming Ppy formation are highlighted. X-ray diffraction (XRD) pattern of Ppy on copper-modified aluminium surfaces are highly crystalline with sharp, intense peaks; no XRD peaks of Ppy are found on the aluminium substrates. Corrosion-resistance properties and morphological differences between Ppy on bare aluminium and copper-modified aluminium substrates are discussed.
ABSTRACT 37
Subject Area: Emerging Technologies
Development of Aluminium High Stiffness Panels
Masaya Takahashi
Sumitomo Light Metal Industries, Ltd., Nagoya, Japan
Nobuyuki Ohtaki
Sumikei-Engineering Co., Ltd., Japan
Aluminium honeycomb sandwich panels with large second moment of area are used when lightweight panels require high bending stiffness. We developed and manufactured honeycomb sandwich panels for railways, SHINKANSEN high-speed rail, and buildings, TOKYO SKYTREE communication tower. Manufacturing panel cost is high; using honeycomb sandwich panels in large production requires reduced price. Corrugated sheet lightweight panels for mass production have anisotropic bending stiffness. To solve this, convex-concave shapes were developed with large second moment of area in arbitrary cross sections. FEM and experimental results indicated that developed patterns could reduce flat sheet weight by half under equivalent bending stiffness condition.
ABSTRACT 39
Aluminium Bridge Decks – A New Development by Bayards
Dick de Klujver
Commercial Director at Bayards Aluminium Constructie B.V., Nieuw Lekkerland, The Netherlands
One major challenge in replacing bridge decks is finding a better solution than the initial concept, perfectly tailored to fit the existing structure. Finding a long-lasting solution requires true engineering innovation. Our aluminium solutions are tailored to customer needs, engineered and built in accordance with the latest international safety regulations and highest quality standards. When combined with aluminium’s natural advantages, this partnership delivers advanced, viable solutions. With over 50 years of experience working with aluminium in major projects across the globe, we developed new knowledge working with aluminium, significantly reducing its limitations. All available options for bridge deck replacement are discussed, presenting our findings.
ABSTRACT 41
Subject Area: Processes
Modelling Surface Grain Structure Evolution in AA6082 Hot Direct Extrusion
Wojciech Z. Misiolek
Nabeel H. Alharthi
Lehigh University, Bethlehem, Pennsylvania, USA
Ahmet Güzel
Andreas Jäger
TU Dortmund
A. Erman Tekkaya
A new surface dynamic recrystallisation (DRX) model for aluminum alloys, considering continuous dynamic recrystallisation (CDRX) and geometric dynamic recrystallisation (GDRX), was proposed for AA6xxx, verified by hot-torsion testing and hot-rolling reduction schedules of AA6061; applicability to AA6082 hot-direct extrusion is verified. Finite element modelling of hot-direct extrusion using DEFORM™ 3D software predicted localised-state variables, temperature, strain, strain rate, and stress, which were incorporated into the DRX model to predict grain structure evolution near the extruded surface. The DRX model was verified by analysing the experimentally extruded profile's surface region. Recrystallised grain structure evolution near the extrusion surface was accurately predicted.
ABSTRACT 42
Subject Area: Market Sectors
Vibration Characterization of a Modular Aluminium Pedestrian Bridge
Scott Walbridge
Professor
Sriram Narasimhan
Associate Professor
Ann Sychterz
Master's Candidate
University of Waterloo, Waterloo, Ontario, Canada
Specific design rules for aluminium pedestrian bridges currently don't exist; designers must refer to general standards, CAN/CSA S6-06 or AASHTO LRFD Guide Specifications. A vibrational characterisation study of an aluminium pedestrian bridge aims to: learn about natural frequencies, damping and mode shapes associated with these structures; determine if structural behaviour is predictable using available standards. The study uses a proprietary modular bridge system with variable span and fixed width, instrumented with accelerometers, strain gauges, and load cells. An innovative signal separation method extracts natural frequencies, damping, and mode shapes. A finite element model will compare experimental results to predicted values.
ABSTRACT 43
Subject Area: Market Sectors
Aluminium Use in Vehicular Bridge Applications: A State-of-the-Art Review
Scott Walbridge
Professor
University of Waterloo, Waterloo, Ontario, Canada
Alexandre de la Chevrotière
President
MAADI Group Inc., Montréal, Québec, Canada
High bridge maintenance costs, recent bridge collapses, user delay costs, and environmental impacts associated with deterioration of bridge infrastructure are noted. Increased aluminium use in vehicular bridge applications and aluminium's potential role in addressing the industry's maintenance challenges are reviewed and assessed. Experiences and new applications that exploit the attributes of aluminium alloys (light weight, high corrosion resistance and extrudability) are highlighted, including: deck replacement, deck widening, sidewalk/bike path additions, and rapid bridge replacement projects. Barriers inhibiting increased use of aluminium in vehicular bridge applications are identified. Recommendations on future research and industry initiatives to overcome these barriers are made.
ABSTRACT 44
Preventing Molten Aluminium Explosions
Alex W. Lowery
Wise Chem LLC, Pittsburgh, Pennsylvania, USA
Molten aluminium explosions occur, resulting in numerous worker injuries and deaths. Industry and government studies into root causes of explosions are explored. Fifteen years ago the Aluminum Association and the U.S. Department of Energy reinvestigated root causes of molten aluminium water explosions, finding that a specific organic coating (e.g., Wise Chem E 212F) prevented molten metal explosions; whereas some specific organic coatings (safety pit coating) initiated explosions. Ignoring such studies risks worker safety; when aluminium plants delay or forgo maintenance on safety pit coatings, explosion risk increases. Properly applied and maintained safety pit coatings can protect workers from molten aluminium explosions.
ABSTRACT 45
Boralcan™, an Advanced Cast Aluminium Product for Nuclear Application
Pierre Marchand
Rio Tinto Alcan, Head Office, Montréal, Québec, Canada
Jean-Alain Laurin
Rio Tinto Alcan, Arvida Research and Development Centre, Saguenay, Québec, Canada
Mario Roux
Rio Tinto Alcan, Dubuc Works, Saguenay, Québec, Canada
X. Grant Chen
NSERC/RTA Industrial Research Chair in Metallurgy of Aluminium Transformation, University of Québec at Chicoutimi, Saguenay, Québec, Canada
Rio Tinto Alcan (RTA) recently developed Boralcan™, a metal matrix composite containing nuclear-grade boron-carbide powder for application in spent fuel nuclear containers for dry and wet storage. This process may apply to various aluminium matrix and B4C concentrations, which can be cast, extruded or rolled to any size and shape to meet customer specifications. The process for manufacturing Boralcan™ is presented. Boralcan™ products having typical mechanical and material properties are introduced for structural and non-structural applications. Neutron absorption results based on neutron transmission testing show that delivered materials in the entire batch have satisfactory neutron absorbing capacity. The patented RTA process breakthrough produces superior quality products at their Dubuc Works.
ABSTRACT 48
Subject Area: Processes
Increased Robustness in Three-Dimensional Friction Stir Welding using Force and Temperature Feedback
Jeroen De Backer
Gunnar Bolmsjö
University West, Trollhattan, Sweden
Friction Stir Welding (FSW) on 3D joints requires multi-axial robots, advanced heat input control, and in-process adaptation of welding parameters. A newly-developed temperature measurement method for industrial FSW is presented, allowing quick FSW-tool exchanges without human interference. Temperature measurement is implemented on a robot system, combined with force sensor measurements. Heat input is controlled by combining temperature and force feedback into a cascade controller, where rotational speed and downforce are controlled during welding. FSW experiment results in AA6082-T6 aluminium on various 2D and 3D geometries are described. Weld properties are compared for different temperatures, with and without a temperature controller.
ABSTRACT 49
THE EFFECT OF ERBIUM ADDITIONS ON GRAIN GROWTH BEHAVIOR IN AL-MG ALLOYS
Bamidele Akinrinlola
McGill University, Canada
ABSTRACT 50
Fabrication of Bicycle Frame of A356 Aluminium Alloys by using Sand Casting
Suyitno
U.A. Salim
S. Saragih
Casting And Solidification (CASTEC) Groups, Department of Mechanical and Industrial Engineering, Faculty of Engineering, Gadjah Mada University, Yogyakarta, Indonesia
Bicycle frames are generally made from welded pipe by big companies that require forming technology of raw materials for pipe production and complex welding technologies. To reduce dependence on raw materials and pipe welding processes, alternative casting technology is investigated for bicycle frame manufacturing. Limited quantity production of cast bicycle frames is possible, and is achievable by redesigning the bicycle frame to make it suitable for the casting process. Prototypes and the first bike in the testing phase are presented. The initially heavier bicycle (7 kg) achieves design optimisation, reducing to a light, strong frame that weighs 3.74 kg. The frame prototype was succesfully cast using the sand casting method.
ABSTRACT 51
Subject Area: Emerging Technologies
Selection of Spectrographic Certified Reference Material for the Analysis of Aluminium Alloys
Jean-François Archambault
Ph.D., Chemistry, Principal Research Scientist
Pierre Bégin
Physicist, Principal Research Scientist
Robert Hark
Technical Services Manager, Analytical Technologies
Arvida Research and Development Centre, Rio Tinto Alcan, Jonquière, Québec, Canada
Spark atomic emission spectroscopy or Optical Emission Spectroscopy (OES) is the standard method for analysing and certifying alloy chemical compositions made in the cast house. Selecting spectroscopic certified reference materials (CRM) for each alloy becomes essential to meet product chemical specification conformity. Composition limits combined with spectroscopic CRM availability constraints require structured selection methodology. CRM selection methodology for aluminium alloy analysis is described, accounting for factors such as spectral interferences and matrix effects within the plasma created during sample sparking. Spectroscopic CRM selection is discussed through practical examples, illustrating work that must be accomplished to inform clients before product delivery.
ABSTRACT 52
FATIGUE ANALYSIS OF A STRUCTURAL JOINT OF AN ALUMINIUM ROADSTER FRAME
William Rouge
Université de Sherbrooke, Canada
ABSTRACT 53
A New Heating System for Refractory used in the Aluminium Industry
Sylvain Tremblay
Michael Bouchard
Engineer
Jens Bouchard,
Engineer
Pyrotek Inc., Chicoutimi, Québec, Canada
Refractory parts such as troughs or CFF boxes have to be preheated in order to minimise thermal shock and heat sink at the cast start-up. Typical methods used such as natural gas burners or electrical heating panels have several limitations. The methods are not user-friendly and they lead often to high production costs. The presented new heating method consists of heating the refractory from inside-out, while at the same time minimising the heating time and cost. Examples of this new technology used in the field are presented.
ABSTRACT 54
Subject Area: Processes
The Use of Promag NI as Refining Agent in Molten Aluminium Treatment
Sylvain Tremblay
Jens Bouchard
Engineer
Pyrotek Inc., Chicoutimi, Québec, Canada
Aluminium producers moved from chlorine gas to fused refining agents to treat the melt in furnaces. Two fused refining agents, Promag RI and SI, contain 40% and 60% MgCl2, respectively. The second binary fused flux ingredient is potassium chloride, mainly used in fertilising applications, which suffered significant price increases. To avoid price fluctuations, a new binary refining agent, Promag NI, is made of sodium chloride and magnesium chloride. Promag NI used at two plants is presented; Promag use in the last three years is summarised. The new refining agent's effect on alkalis removal, CFF efficiency and process variables is detailed.
ABSTRACT 58
RAPID SINTERING OF NANOSTRUCTURED AND CONVENTIONAL ALUMINIUM POWDERS
Prof. Mathieu Brochu
McGill University, Canada
ABSTRACT 59
Subject Area: Emerging Technologies
Effect of Grain Shapes of the Microstructure on the Mechanical Properties of the Binary Aluminium Alloy
Sharifi Hamid
Larouche Daniel
Professor
Laval University, Québec, Canada
Numerical simulation of granular structure was used to study thermo-mechanical behaviour variation of binary aluminium copper alloys pertaining to their microstructure, grain shapes/sizes. Different granular microstructures are created selecting suitable basic grain shapes; the modelled microstructure exhibits a realistic aluminium alloy microstructure, adaptable to a particular cooling condition or heat treatment process. Granular models are automatically converted to a finite element model. The finite element method with Abaqus was used to analyse models subjected to various loading conditions. Resulting effects of grain shapes and sizes on the variation of elastic modulus and plasticity of such a heterogeneous domain was investigated.
ABSTRACT 61
Subject Area: Market Sectors
Strategic Management of Innovation to Improve Competitive Advantages of Middle East Primary Aluminium Industries
Hadi Fanisalek
Marzban Petro Energy (MPE), Tehran, Iran
Primary aluminium production in industrial scale is a hundred-years-old industry. Progress was slow compared to other industries, but research and development is moving faster recently. To have better conditions for the Middle Eastern primary aluminium industry compared to developed and pioneer countries, we need a strategic plan to enable export of high-quality products. This will not occur unless we have a long-term strategic plan for research and development, technology improvement and technology transfer. The fundamental factor to reach the target is investing financially, making an easily understood plan and an updated, well-organized strategy for continuous innovation in primary aluminium industry.
ABSTRACT 62
Subject Area: Processes
Fracture Study of a Welded Aluminium Cylinder Containing Longitudinal Crack and Subjected to Combined Residual Stress and Internal Pressure
M.R.M. Aliha
H. Gharehbaghi
Welding and Joining Research Center, Iran University of Science and Technology, Narmak, Tehran, Iran
R. Ghafoori Ahangar
Department of Mechanical Engineering, Ecole Polytechnique of Montréal, Montréal, Québec, Canada
Simulated gas tungsten-arc welding of a thin AA6061-T6 cylinder uses 3-D finite element modelling, obtaining residual stress distribution. Temperature dependent thermo-mechanical properties are considered for the aluminium alloy and for simulating the heat source of tungsten-arc welding. Finite element results show high residual stresses around the weld line and HAZ area, increasing crack initiation/propagation risks in the weldment zone. A longitudinal semi-elliptical crack is considered in the internally-pressurized aluminium cylinder wall; mode I stress intensity factor (KI) is determined numerically for different crack geometries. Residual stress field and internal pressure influences are taken into account on the KI value.
ABSTRACT 63
Designing Efficient and Cost Effective Structures Utilising Aluminium Extrusions
Craig R. Werner
Werner Extrusion Solutions, LLC, Lake Forest, Illinois, USA
IBIS Associates, strategic material selection experts, evaluated Photovoltaic (PV) and Concentrated Solar Power (CSP) mounting structures based on aluminium extrusions or steel components. While the $/pound cost of aluminium is higher, aluminum extrusion’s superior strength-to-weight ratio, design flexibility and other contributing factors proved that they offer the optimal design solution for these applications, when considering the total installed costs. These analyses are presented, and structural design solutions are highlighted, using PV and CSP examples. Utilising the key advantages of aluminium and the extrusion process to drive creative new extrusion uses is discussed. Tools are provided to effectively communicate with designers, engineers, architects, and extrusion customers.
ABSTRACT 65
Influence of Column Axial Load and Heat Affected Zone on the Strength of Aluminium Column Web in Tension
Gianfranco De Matteis
Gianluca Sarracco
Giuseppe Brando
Department of Engineering and Geology, University “G. d’Annunzio” of Chieti-Pescara, Pescara, Italy
Federico Massimo Mazzolani
Department of Structure for Engineering and Architecture, University “Federico II” of Naples, Naples, Italy
The component method for aluminium joints has been introduced in some codes and guidelines, but still needs development and improvement; in some cases it was obtained by adapting existing formulations that are valid for steel. The main outcomes are presented of a parametric analysis carried out using FE numerical models for determining the influence of both column axial load and heat affected zone, in case of welded details, on the structural response of the column web in tension component. The proposed study integrates the authors’ previous research where the influence of the assumed alloy was investigated and interpreted by corrective parameters expressed as a function of both material strain hardening and ductility.
ABSTRACT 66
Subject Area: Processes
Optimisation of Friction Stir Welding Tool Advance Speed – Monte-Carlo Simulation of Non-Linear Finite Difference Heat Transfer Algorithm for Friction Stir Welding
Kirk A. Fraser
Dr. Laszlo Kiss
Dr. Lyne St-Georges
GRIPS, University of Québec at Chicoutimi, Chicoutimi, Québec, Canada
Friction stir welding (FSW) availability for structural fabrications requires highest speed of advance to be used without causing welding defects. A numerical solution to transient two-dimensional heat diffusion equation for FSW is presented. A non-linear heat generation term based on a piecewise linear friction model as a function of temperature is solved for temperature distribution in AA6061-T6 workpieces. The Finite Difference solution is used to perform Monte-Carlo simulation (MCS), constructing a polynomial response surface from MCS results, determining optimum tool speed of advance and rotational speed. Exterior Penalty method finds highest speed of advance and rotational tool speed for FSW.
ABSTRACT 67
Research on 1100/7075/1100 Three-Layer Composite Sheet Fabricated by Hot Roll Bonding
Zejun Chen
Hong Qin
Guangjie Huang
Qing Liu
College of Materials Science and Engineering, Chongqing University, Chongqing, China
The 1100/7075/1100 three-layer composite sheet was fabricated by hot roll bonding (HRB) technology. The deformation histories of each layer of metal thickness are investigated during the hot roll bonding process. The characterisation of the bonding interface of 1100/7075 was executed by SEM. The diffusion of interfacial structures is investigated after heat treatment. The effect of annealing technology on the thickness of the diffusion layer of composite sheet is researched. Research results offer guides and references for controlling the thickness of bonding interface, optimising the annealing process, and improving the mechanical properties of 1100/7075/1100 composite sheet.
ABSTRACT 68
ÉTUDE DE LA FIABILITÉ THERMOMÉCANIQUE DE DISQUE FREIN
Dr. Mrad Hatem
Université du Québec à Chicoutimi, Québec, Canada
ABSTRACT 69
Système de Renforcement in Situ d’un Portique de Signalisation Aérienne en Aluminium
Marcel Vallières, ing. M. Sc.
Direction des structures, Ministère des Transports du Québec, Québec, Canada
Bruno Massicotte
Professeur titulaire, Groupe de recherche de génie des structures, École Polytechnique de Montréal, Montréal, Québec, Canada
Aluminium overhead truss structures are commonly used by the Ministry of Transportation of Québec (MTQ) to support large highway signs. To improve its complex maintenance and repair methods, MTQ designed an in-situ reinforcement system for truss beams using a variable-geometry telescopic member. The design allows length and inclination angle adjustments, varying from 45° to almost 90°. A three-step research program verifies the capacity of different components in the reinforcement system. All components designed and fabricated by MTQ were submitted for tests. The final program step verified the real capacity of a truss beam reinforced at one end by two telescopic members installed at 45°. Experimental program results are presented.
ABSTRACT 70
Creativity in Design: Aluminium Can Gain Market; a Different Approach is Required
Dick de Klujver
Commercial Director at Bayards Aluminium Constructie B.V., Nieuw Lekkerland, The Netherlands
Constructing offshore platform/vessel parts in aluminium saves up to 60% in weight compared to steel, but replacing steel with full aluminium structures is not entirely feasible. Aluminium construction requires considering valuable benefits such as aluminium’s behaviour in harsh, highly corrosive seawater environments. Aluminium alloys in offshore construction corrode 100 times more slowly than steel. During the first year, steel corrodes at 120mm/year, while aluminium at only 1mm/year with little to no maintenance, resulting in a durable structure with a very low cost of ownership. Many presumptions exist around aluminium construction material, such as its behaviour in fire, complexity of welding and price; these assumptions are explained and shown to be false.
ABSTRACT 72
Influence of Iron Intermetallic Phases on the Mechanical Properties of Heat Treated Al-Si-Mg Alloys
Ehab A. Elsharkawi
Agnes M. Samuel
Fawzy H. Samuel
Département des Sciences Appliquées, Université du Québec à Chicoutimi, Chicoutimi, Québec, Canada
Al-7Si-Mg alloys typically contain small amounts of iron impurities, forming two different intermetallic compounds during solidification: β-Al5FeSi and π-Al8FeMg3Si6, known for their detrimental effects on alloy ductility and strength. The impact and tensile properties of heat-treated Al-7Si-0.55Mg-0.1Fe (357 type) alloy samples were investigated, seeking a correlation between said properties and changes occurring in microconstituents with prolonged solution treatment, carried out at 540°C for 2 to 100 hours, then quenching in water at 60°C, and artificial aging at 155°C for 5 hours. Results after solution treatment are presented; fracture behaviour is controlled mainly by the eutectic Si morphology. The π-phase particles act as crack initiation sites, facilitating crack propagation in as-cast and heat-treated alloys.
ABSTRACT 73
Introduction to Explosion Bonded Bimetals and Transition Joints Concept from DMC Nobelclad
Stéphane Pauly
Business Development Manager, Dynamic Materials Corporation, DMC Nobelclad, Rivesaltes, France
Structural designers must select sound structural materials that minimise weight within a reasonable budget. Various metals are typically employed throughout the structure, selecting appropriate properties for each specific component. Many dissimilar metals cannot be welded, and are mechanically joined by bolting or riveting. Explosion welded bi-metal transition components can provide mechanical, thermal or electrical solutions. Combining metallic aluminium and steel structures is possible using intermediate transition joints specifically designed to resist static, dynamic stresses and external constraints, and solves the complexity of standard riveting or bolting by removing insulation systems, reducing maintenance costs and accelerating or simplifying production routes. Transition joints used in shipbuilding, cryogenic plants, and the rolling stock industry with bimetallic constructions are described.
ABSTRACT 74
Subject Area: Market sectors
Design Considerations for Aluminium Products
François Racine
Reza Bihamta
Yves Aarchambault
Petrino Buzatu
Alain Chapdelaine
Alcoa Innovation, Montréal, Québec, Canada
Aluminium alloys provide top product selections in criteria like high resistance over density ratio, corrosion resistance, thermal and electrical conductivity, ductility, and unlimited recyclability; however, aluminium applications need special design considerations. Technical considerations are presented, including: welded joint design; extrusion profile design; permanent joining methods for aluminium products; contact of an aluminium part with steel; and corrosion resistance in aluminium products. For each consideration, examples of Alcoa Innovation projects yielding successful results with respect to these points are presented. Results and experiences confirm that using aluminium with enough technical data and information can lead to better and more economical products.
ABSTRACT 75
NON-DESTRUCTIVE INSPECTION OF ADHESIVELY BONDED ALUMINIUM JOINTS SUBMITTED TO AN ENVIRONMENT SIMULATING THE EFFECT OF DE-ICING SALTS
FRANCIS BRETON
Centre de recherche et de développement Arvida, Rio Tinto Alcan, Jonquière, Québec, Canada
JEAN CRÉPEAU
Montréal Office, Rio Tinto Alcan, Montréal, Québec, Canada
ABSTRACT 76
CONDITIONS MITIGATING ABNORMAL GRAIN GROWTH IN FRICTION-STIR WELDS RELATED TO HOT FORMING APPLICATIONS
François Nadeau
CTA, Canada
ABSTRACT 77
Rio Tinto Alcan CastProTM Advanced Compact Filtration (ACF):
Industrial Operation Feedback and Commercial Availability
Francis Breton
Arvida Research and Development Centre, Rio Tinto Alcan, Jonquière, Québec, Canada
Jean Crépeau
Montréal Office, Rio Tinto Alcan, Montréal, Québec, Canada
Advanced compact filter (ACF) technology is the solution to a highly productive value-added product casthouse. ACF redefines economically viable batch sizes for high-quality filtered aluminium cast products. Deep bed filters’ (DBF) economical batch sizes are over 1000 tonnes, due to: residual hot metal in the bed between casts; associated cost of preparation and media; and incompatibility to handle on-the-go alloy changes. ACF enables the production of furnace size batches of highly filtered metal to qualities typically achieved by DBF. Due to its operation reliability and performance, the ACF has proven ability to meet users’ stringent quality requirements for a variety of alloys. Using ACF technology improves productivity, flexibility, and casthouse operating costs.
ABSTRACT 78
INNOVATIVE USE OF ALUMINIUM IN THE OIL SANDS INDUSTRY
Jennifer L. Kirby
AMEC, Alberta, Canada
