• Corrosion Science and Technology
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• v.6 no.4
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• pp.206-210
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• 2007

Aerospace aluminum alloys such as Al alloy 2024-T3 and 7075-T6 are subject to localized corrosion due the existence of intermetallics containing Cu, Mg or Zn. Chromate is currently widely used in the aerospace industry as the corrosion inhibitor for these alloys. However, chromate needs to be replaced due to its strong carcinogenicity. In this study, an extensive pigment screening has been performed to find replacements for chromates. Different categories of inhibitors were evaluated by immersion tests, DC polarization tests and other methods. Phosphates, zinc salts, cerium salts, vanadates and benzotriazole were found to be effective inhibitors for AA7075. Among those inhibitors, zinc phosphate was found to be the most effective in our novel, silane-based, one-step aqueous primer system. The performance of this primer is comparable to that of currently used chromate primers in accelerated corrosion tests, while it is completely chromate-free and its VOC is about 80% less than that of current primers. Studies by SEM/EDS showed that the unique structure of the superprimer accounts for the strong anti-corrosion performance of the zinc phosphate pigment. The self-assembled stratified double-layer structure of the superprimer is characterized by a less-penetrable hydrophobic layer at the top and a hydrophilic layer accommodating the inhibitors underneath. The top layer functions as the physical barrier against water ingress, while the lower layer functions as a reservoirfor the inhibitor, which is leached out only if the coating is damaged by a scratch or scribe. The presence of a silane in the primer further improves the adhesion and anti-corrosion performance of the primer.

• International Journal of Ocean System Engineering
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• v.2 no.2
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• pp.106-115
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• 2012

In the present study, TiN and CrN films were coated by arc ion plating equipment onto aluminum alloy substrate, A2024. The film thickness was about 4.65 ${\mu}m$. TiN and CrN films were analyzed by X-ray diffraction and energy dispersive X-ray equipments. The Young's modulus and the micro-Vickers hardness of aluminum substrate were modified by the ceramic film coatings. The difference in Young's modulus between substrate and coating film would affect on the wear resistance. The critical load, Lc, was 75.8 N for TiN and 85.5 N for CrN. It indicated from the observation of optical micrographs for TiN and CrN films that lots of cracks widely propagated toward the both sides of scratch track in the early stage of MODE I. TiN film began to delaminate completely at MODE II stage. The substrate was finally glittered at MODE III stage. For CrN film, a few crack can be observed at MODE I stage. The delamination of film was not still occurred at MODE II and then was happened at MODE III. This agrees with critical load measurement which the adhesive strength was greater for CrN film than for TiN film. Consequently, it was difficult for CrN to delaminate because the adhesive strength was excellent against Al substrate. The wear process, which the film adheres and the ball transfers, could be enhanced because of the increase in loading. The wear weight of ball was less for CrN than for TiN. This means that the wear damage of ball was greater for TiN than for CrN film. It is also obvious that it was difficult to delaminate because the CrN coating film has high toughness. The coefficient of friction was less for CrN coating film than for TiN film.

• Progress in Superconductivity and Cryogenics
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• v.25 no.4
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• pp.70-74
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• 2023

The Small Punch Test (SPT) was developed to evaluate the softening and embrittlement of materials such as power plants and nuclear fusion reactors by taking samples in the field. Specimens used in the SPT are very thin and small disk-shaped compared to specimens for general tensile test, and thus have economic advantages in terms of miniaturization and repeatability of the test. The cryogenic SPT can also be miniaturized and has a significantly lower heat capacity than conventional universal test machines. This leads to reduced cooling and warm-up times. In this study, the cryogenic SPT was developed by modifying the existing room temperature SPT to be cooled by liquid nitrogen using a super bellows and a thermal insulation structure. Since the cryogenic SPT was first developed, basic experiments were conducted to verify the effectiveness of it. For the validation, aluminum alloy 6061- T6 specimens were tested for mechanical properties at room and cryogenic temperature. The results of the corrected tensile properties from the SPT experiment results were compared with known room temperature and cryogenic properties. Based on the correction results, the effectiveness of the cryogenic SPT test was confirmed, and the surface fracture characteristics of the material were analyzed using a 3d image scanner. In the future, we plan to conduct property evaluation according to the development of various alloy materials.

• Journal of Welding and Joining
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• v.14 no.3
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• pp.93-104
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• 1996

This study evaluated relative hot cracking susceptibility of commercial aluminum alloy welds, and then suggested possible mechanisms operated in the weld fusion zone and in the heat affected zone based on the observed cracking morphologies, fractography and microstructural features. The fusion zone solidification cracking was found to be mainly due to a microsegregation of Cu, Si, and Mg in grain boundaries, while liquation cracking in the HAZ was by the incipient melting of the segregated grain boundaries and the consitutional liquation of large aging precipitates and intermetallic compounds in the partially melted zone adjacent to the fusion line which experienced a rapid thermal excursion during welding.

• Structural Engineering and Mechanics
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• v.18 no.3
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• pp.277-286
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• 2004

Defective metallic components and structures are being repaired with bonded composite patches to improve overall mechanical and fatigue properties. In this study, fatigue crack growth tests were conducted on pre-cracked 7075/T6 Aluminum substrates with and without bonded Boron/epoxy patches. A considerable increase in the fatigue life and a decrease in the stress intensity factor (SIF) were observed as the number of patch plies increased. The experimental results demonstrate that the patch configurations and patch thickness can enhance fatigue life by order of magnitude. Quantitative comparisons between analytical and experimental data were made, and the analytical model based on a modified Rose's analytical solution appears to best estimate the fatigue life.

• Proceedings of the KSME Conference
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• 2003.04a
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• pp.1118-1123
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• 2003

Based on the design requirements(size, strength, structure, weight, and etc.) for the rubber-tired AGT vehicle, carbody made of aluminum alloy is designed. The analysis of strength and stiffness is performed in the designed carbody, which results in the modification for optimal shapes and structures. It consists of a under frame, side frame, roof frame, end frame and forehead frame. After the carbody manufactured, tests are performed, which are vertical load test, longitudinal compressive load test, twisting load test, twisting natural frequency measurement, bending natural frequency measurement and 3 points supporting test. Results of them can guarantee a structural safety.

• Proceedings of the KSR Conference
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• 2003.10c
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• pp.59-64
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• 2003

This paper describes the result of structure analysis and load test of body structure. The purpose of the analysis and test is to evaluate an safety which body structure shall be considered fully sufficient rigidity so as to satisfy proper system function under maximum load and operating condition. Material of body structure applied an aluminum alloy. This strength test is based on 'Performance Test Standard for Electrical Multiple Unit, noticed by Ministry of Construction & Transportation, in 2000' and reference code is JIS E 7105

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.2
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• pp.59-66
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• 2015

The production of high value-added products requires efficient processing and this constant demand for complex shape processing has led to the need for hybrid processing. In this study, the surface characteristics of hybrid machining, which combines wire-cut E.D.M and vibration, are examined. The selected experimental parameters are verticality, waveform, amplitude, peak current and frequency. The experimental results provide a guideline for selecting reasonable machining parameters. Surface roughness was improved by increasing the amplitude of the vibration.

• Transactions of the Korean Society of Automotive Engineers
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• v.2 no.2
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• pp.95-102
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• 1994

Aluminum sheet application to automobile body panels has now become an important objective to meet the requirements of automobile weight reduction. As the Mg content in Al-Mg based alloys increased up to 7.19%, the strength and elongation increased. For instance. Al-7.19Mg alloy had a high strength of 305MPa and a high elongation of 35%. A study was also made to investigate the interrelation between grain size and tensile properties with varying the contents of Mg, Ti and Zr elements and annealing conditions. The yield stress decreased as the grain size increased, which increased the uniform elongation. The strain hardening exponents n increased as the Mg content increased, which depended on the increasing difficulties of the cross slip of dislocation.

• Transactions of Materials Processing
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• v.23 no.5
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• pp.289-296
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• 2014

Uniaxial tensile tests were conducted to accurately evaluate the in-plane mechanical properties of fiber metal laminates (FMLs). The FMLs in the current study are comprised of a layer of self-reinforced polypropylene (SRPP) sandwiched between two layers of aluminum alloy 5052-H34. The nonlinear tensile behavior of the FMLs under in-plane loading conditions was investigated using both numerical simulations and a theoretical analysis. The numerical simulation was based on finite element modeling using the ABAQUS/Explicit code and the theoretical constitutive model was based on the volume fraction approach using the rule of mixture and a modification of the classical lamination theory, which incorporates the elastic-plastic behavior of the aluminum alloy and the SRPP. The simulations and the model are used to predict the inplane mechanical properties such as stress-strain response and deformation behavior of the FMLs. In addition, a post-stretching process is used to reduce the thermal residual stresses before uniaxial tensile testing of the FMLs. Through comparison of both the numerical simulations and the theoretical analysis with the experimental results, it is concluded that the numerical simulation model and the theoretical approach can describe with sufficient accuracy the actual tensile stress-strain behavior of the FMLs.