• Journal of the Korean Society of Manufacturing Process Engineers
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• v.9 no.6
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• pp.29-35
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• 2010

Recently the industry high-speed machining has been applied to the automotive, aircraft, electronics parts machining because the effect of cost savings, machining time reduction and productivity improvement. In this study recently the aircraft structural aluminum alloy 7075 used in cutting the ball end-mill on the surface roughness terms most affect the parameters of the spindle speed and feed rate on the surface roughness of the work-piece according to the cutting depth is to investigate. Cutting depth at 0.3 mm has the lowest surface roughness.

• Proceedings of the Korean Society of Marine Engineers Conference
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• 2005.06a
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• pp.331-338
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• 2005

The grain structure, dislocation density and second phase particles in various regions including the stir zone(SZ), thermo-mechanically affected zone(TMAZ), and heat affected zone(HAZ) of a friction stir weld 6.35mm thick aluminum 7075-T651 alloy were investigated and compared with the base metal. The microstruectures of nugget zone were compared according to tool rotation speeds and tool transition speeds. The hardness profiles of nugget zone were increased, while decreasing rotation speed and increasing welding speed. The optimal microstructure was gained at the low rotation speed 800rpm and th high welding speed 124mm/min. The nugget microstructures of fracture surface, transgranular dimple and quasicleavage type were showed different fracture type with the HAZ, shear fracture type.

• Journal of Powder Materials
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• v.30 no.3
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• pp.203-209
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• 2023

Aluminum alloy-based additive manufacturing (AM) has emerged as a popular manufacturing process for the fabrication of complex parts in the automotive and aerospace industries. The addition of an inoculant to aluminum alloy powder has been demonstrated to effectively reduce cracking by promoting the formation of equiaxed grains. However, the optimization of the AM process parameters remains challenging owing to their variability. In this study, the response surface methodology (RSM) was used to predict the crack density of AM-processed Al alloy samples. RSM was performed by setting the process parameters and equiaxed grain ratio, which influence crack propagation, as independent variables and designating crack density as a response variable. The RSM-based quadratic polynomial models for crack-density prediction were found to be highly accurate. The relationship among the process parameters, crack density, and equiaxed grain fraction was also investigated using RSM. The findings of this study highlight the efficacy of RSM as a reliable approach for optimizing the properties of AM-processed parts with limited experimental data. These results can contribute to the development of robust AM processing strategies for the fabrication of high-quality Al alloy components for various applications.

• Journal of the Korean Society for Heat Treatment
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• v.34 no.4
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• pp.185-190
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• 2021

The extrusion experiments using the 7075 aluminum billet have been performed to investigate the effects of die cooling and ram speed on the occurrence of surface defects on the extrudate. The purpose of die cooling was to suppress overheating of the extrudate at the moment of extrusion. In the present die cooling system, liquid nitrogen has been injected in to the die and sprayed to the surface of extrudate. Ram speed was either kept or varied in the range of 1.1~1.7 mm/sec. throughout one extrusion shot to check the occurrence of surface defects. Every extrusion started at a ram speed of 1.25 mm/sec. The temperature of extrudate was measured using a laser thermometer. The 7075 billet of 180 mm in diameter and 550 mm in length was preheated at 390℃ and extruded to get a single plate of 8000 mm in length, 150 mm in width and 10 mm in thickness. Each extrudate was checked by eye to find the surface defects. The microstructures were obtained in the specimen cut from each corner of the extrudate using the EBSD micrographs.

• Journal of the Korean Society for Heat Treatment
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• v.35 no.6
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• pp.319-326
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• 2022

Direct extrusions of an aluminum 7075 alloy were carried out using 1500 ton machine with and without die cooling system. Cooling of extrusion die has been performed by the flow of liquid nitrogen and controlled by laser thermometer. Billet was 180 mm in diameter and 500 mm in length. The preheating temperatures of billet, container and die were 390℃, 400℃ and 450℃, respectively. Ram speed was kept with 1.25 mm/sec first. The change of ram speed was carried out during extrusion according to the observation of surface defects such as crack or tearing. Extrudates of 8.3 m in length, 100 mm in width and 15 mm in thickness were obtained to observe and analyze surface defects by optical microscopy and EBSD (Electron BackScattered Diffraction). In case of extrusion without die cooling cracks on the surface and tearing in the corner of extrudate occurred in the middle stage and developed in size and frequency during the late stage of extrusion. At the extrusion with die cooling the occurrence of defects could be suppressed on the most part of extrudate. EBSD micrographs showed that cracks and tearings have been resulted from the same origin. Surface defects were generated at the boundaries of grains formed by secondary recrystallization due to surface overheating during extrusion.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.12 no.4
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• pp.1552-1558
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• 2011

In this paper, the automotive beam using aluminium foam is designed and the impact analysis is carried out. The analysis model is the beam of actual size with B- type section structure. At the frontal crash of low speed, ANSYS AUTODYN is used by predicting the behavior of deformation and its internal energy. By the use of 7075-T6 aluminum alloy, the weight is reduced as much as 55% than steel. The deformation at the bumper foam of aluminum is similar with that of steel and the impact energy reduction at aluminum is more than steel. The foam filled with aluminum as much as 50 % has more impact energy absorption than the completely filled aluminum foam.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.350-353
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• 2005

Microstructures according to experimental conditions (pouring temperature, stirring current and stirring time) and hardness according to aging time were investigated for A356 cast aluminum alloy and 7075 wrought aluminum alloy. In pouring temperature control, grains became larger and non-uniform at high temperature, however dendritic shapes were shown at lower temperature. In stirring current control, dendritic grains were not destroyed enough at lower current, however fine grains were agglomerated at higher current. And, in stirring time control, grains were more globular but grew larger and larger with the stirring time increasing.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.35 no.10
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• pp.1229-1235
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• 2011

Fatigue tests were conducted on the aluminum alloy, A7075-T6 to determine the most reliable fretting fatigue damage parameter. Specimens with grooves were used, so that either fretting fatigue crack at the pad/specimen interface or plain fatigue crack at the groove could be nucleated, depending on the pad pressure. Both the crack nucleation location and initial crack orientation were examined using optical microscopy, and the results were used to assess the reliability of the various fretting fatigue damage parameters that have been most commonly used in the literature. Finite element analysis was employed to obtain the stress and strain data of the specimen, which were needed to estimate the parameter values and the orientation of the critical plane. It was revealed that both the Fatemi.Socie and McDiarmid parameters, which assume shear-mode fatigue cracking, are the most reliable.

• Transactions of the Korean Society of Mechanical Engineers
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• v.9 no.4
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• pp.395-402
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• 1985

The apparent activation energy Q$_{c}$ and the applied stress exponent n have been determined during creep of Al 7075 alloy over the temperature range of 90.deg. C to 320.deg. C (0.4-0.65T$_{m}$) and stress range of 1.85 kgf/mm$^{2}$ to 21 kgf/mm$^{2}$, respectively in order to investigate the creep behavior. Constant load creep tests were carried out in the experiment. At round the temperature of 200.deg. C-240.deg. C and under the stress level 8.13-9.55kgf/mm$^{2}$ and again at around the temperature of 280.deg. C-320.deg. C and under the stress level of 1.85-2.55kgf/mm$^{2}$, the creep behavior obeyed for the creep deformation was nearly equal to that of the volume self diffusion of pure aluminum (34kcal/mole). But at around the temperature of 90.deg. C and under the stress level of 10-21kgf/mm$^{2}$, the creep behavior did not obey a simple power-law relation and the apparent activation enrgy, Q$_{c}$ was 26.01 kcal/mole. From the above facts, at around the temperature of 200.deg. C-240.deg. C and 280.deg. C-320.deg. C, the creep deformation for Al 7075 alloy seemed to be controlled by dislocation climb but at 90.deg. C, by cross slip over the range of experimental stress conditions.tions.

• Structural Engineering and Mechanics
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• v.55 no.4
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• pp.857-869
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• 2015

The aluminum 7075-T6 is known as an alloy widely used in aircraft structural applications, which does not exhibit strain rate sensitivity during dynamic compressive tests. Despite mechanical importance of the material, there is not enough attention to determine appropriate sample dimensions such as a sample diameter relative to the device bar diameter and sample length to diameter (L/D) ratio for dynamic tests and how these two parameters can change mechanical behaviors of the sample under dynamic loading condition. In this study, various samples which have different diameters of 31.8, 25.4, 15.9, and 9.5 mm and sample L/D ratios of 2.0, 1.5, 1.0, 0.5, and 0.25 were tested using Split Hopkinson Pressure Bar (SHPB), as this testing device is proper to characterize mechanical behaviors of solid materials at high strain rates. The mechanical behavior of this alloy was examined under ${\sim}200-5,500s^{-1}$ dynamic strain rate. Aluminum samples of 2.0, 1.5 and 1.0 of L/D ratios were well fitted into the stress-strain curve, Madison and Green's diagram, regardless of the sample diameters. Also, the 0.5 and 0.25 L/D ratio samples having the diameter of 31.8 and 25.4 mm followed the stress-strain curve. As results, larger samples (31.8 and 25.4 mm) in diameters followed the stress-strain curve regardless of the L/D ratios, whereas the 0.5 and 0.25 L/D ratios of small diameter sample (15.9 and 9.5 mm) did not follow the stress-strain diagram but significantly deviate from the diagram. Our results indicate that the L/D ratio is important determinant in stress-strain responses under the SHPB test when the sample diameter is small relative to the test bar diameter (31.8 mm), but when sample diameter is close to the bar diameter, L/D ratio does not significantly affect the stress-strain responses. This suggests that the areal mismatch (non-contact area of the testing bar) between the sample and the bar can misrepresent mechanical behaviors of the aluminum 7075-T6 at the dynamic loading condition.