PNNL

Abstract

In this study, we investigate the toughness and resistance to tear of thin-wall high-pressure die-cast (HPDC) aluminum alloys in two different orientations following the implementation of friction stir processing (FSP). The FSP technique was applied to two different HPDC Al-Si alloys: the recyclable-grade, high iron, A380 alloy and the premium-quality, low iron, Aural-5 alloy. Our findings reveal significant tear resistance and strength enhancements for both alloys after FSP modification. Specifically, FSPed A380 alloy requires 126% higher energy to tear, and it has 49% higher tear strength than the HPDC counterpart. Similarly, the tear energy and tear strength of the Aural-5 alloy witness enhancements of 69% and 21%, respectively. These results highlight the potential of FSP as a viable method for augmenting the mechanical properties of HPDC aluminum alloys, thereby opening up new avenues for their utilization in diverse engineering applications for crack obstruction.