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Development of Mg-Al-Sn and Mg-Al-Sn-Si Alloys and Optimization of Super Vacuum Die Casting Process for Lightweight Applications

Klarner, Andrew Daniel
http://orcid.org/0000-0003-2824-478X
http://rave.ohiolink.edu/etdc/view?acc_num=osu1515083355012541

Abstract Details

2018, Doctor of Philosophy, Ohio State University, Materials Science and Engineering.
The development of new magnesium alloys with improved mechanical properties is important for lightweighting applications, since the current high pressure die cast (HPDC) magnesium alloys, i.e. AM50/60 (Mg-5/6wt.%Al-0.2wt.%Mn) and AZ91 (Mg-9wt.%Al-1wt.%Zn), have limited mechanical properties. Two magnesium alloy systems, Mg-Al-Sn (AT) and Mg-Al-Sn-Si (ATS), were investigated for potential automotive applications. A CALPHAD (CALculation of PHAse Diagrams) approach was used in the development of AT and ATS alloys and to aid in the design of heat treatment schedules. Scanning electron microscopy (SEM), energy dispersive x-ray spectroscopy (EDS), high-angle annular dark field scanning transmission electron microscopy (HAADF-STEM), and transmission electron microscopy (TEM) techniques were used to characterize the microstructure of the alloys in the as-cast and heat treated conditions. Mechanical testing was performed on cast specimens, as well as samples cut from thin-wall HPDC components to compare the strength and ductility of these alloys to currently used magnesium alloys. To expand the applications of HPDC components in the transportation industries, further development and optimization of the process is needed. The development of super vacuum die casting (SVDC) process for aluminum and magnesium thin-wall castings were explored using process simulation and experimental validation. Two experimental dies, i.e., a test specimen die and a fluidity die, were designed to evaluate the castability of several new aluminum alloys and optimize process parameters for these alloys. The process conditions were successfully validated in industrial castings such as an automotive door inner and a side impact beam.
Alan Luo (Advisor)
Michael Mills (Committee Member)
Glenn Daehn (Committee Member)
Gary Kennedy (Committee Member)
201 p.
Materials Science
alloy development; lightweighting; magnesium; aluminum; HPDC; die casting; high pressure die casting; CALPHAD; SVDC; heat treatment

Recommended Citations

Citations

  • Klarner, A. D. (2018). Development of Mg-Al-Sn and Mg-Al-Sn-Si Alloys and Optimization of Super Vacuum Die Casting Process for Lightweight Applications [Doctoral dissertation, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1515083355012541

    APA Style (7th edition)

  • Klarner, Andrew. Development of Mg-Al-Sn and Mg-Al-Sn-Si Alloys and Optimization of Super Vacuum Die Casting Process for Lightweight Applications. 2018. Ohio State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1515083355012541.

    MLA Style (8th edition)

  • Klarner, Andrew. "Development of Mg-Al-Sn and Mg-Al-Sn-Si Alloys and Optimization of Super Vacuum Die Casting Process for Lightweight Applications." Doctoral dissertation, Ohio State University, 2018. http://rave.ohiolink.edu/etdc/view?acc_num=osu1515083355012541

    Chicago Manual of Style (17th edition)

osu1515083355012541
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This open access ETD is published by The Ohio State University and OhioLINK.
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