Application of neutron diffraction in analysis of residual stress profiles in the cylinder web region of an as-cast V6 Al engine block with cast-in Fe liners

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Proceedings titleTMS Annual Meeting
ConferenceTMS 2011 - 140th Annual Meeting and Exhibition, 27 February 2011 through 3 March 2011, San Diego, CA
Pages299308; # of pages: 10
Subject319 aluminum alloy; Al alloys; As-cast; Axial orientations; Cast components; Cooling rates; Critical factors; Engine block; Engine blocks; Gasoline engines; Hardness measurement; Heat treatment process; Hooke's Law; Light weight alloys; Manufacturing technologies; Residual stress profiles; Sand casting; Service properties; Strain mapping; Aluminum; Automobile engine manufacture; Automotive industry; Engine cylinders; Engines; Hardness; Iron alloys; Magnesium; Magnesium alloys; Magnesium castings; Manufacture; Materials properties; Neutron diffraction; Neutrons; Optical microscopy; Residual stresses; Strain; User interfaces; Aluminum alloys
AbstractContinuous efforts to develop a lightweight alloy suitable for the most demanding applications in automotive industry resulted in a number of advanced aluminum (Al) and magnesium alloys and manufacturing routes. One example of this is the application of 319 Al alloy for production of 3.6L V6 gasoline engine blocks. Aluminum is sand cast around Fe-liner cylinder inserts, prior to undergoing the T7 heat treatment process. One of the critical factors determining the quality of the final product is the type, level, and profile of residual stresses along the Fe liners (or extent of liner distortion) that are always present in a cast component. In this study, neutron diffraction was used to characterize residual stresses along the Al and the Fe liners in the web region of the cast engine block. The strains were measured both in Al and Fe in hoop, radial, and axial orientations. The stresses were subsequenüy determined using generalized Hooke's law. Further, optical microscopy and hardness measurements were performed from top to bottom along the interbore region of each cylinder. The results indicate that a variation in cooling rate along the cylinder caused a refinement of dendrites at the bottom of the cylinder, resulting in increased hardness. This study gives invaluable insight on anticipated service properties of the engine block and demonstrates that neutron strain mapping is an efficient tool for optimization of manufacturing technologies.
Publication date
AffiliationNational Research Council Canada (NRC-CNRC); NRC Canadian Neutron Beam Centre (CNBC-CCFN)
Peer reviewedYes
NPARC number21271216
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Record identifierb45a3169-60eb-423e-b2b6-f110b51d1582
Record created2014-03-24
Record modified2016-05-09
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