Evolution of residual stress through the processing stages in manufacturing of bore-chilled sand-cast aluminum engine blocks with pressed-in iron liners

Simple item page
dc.contributor.authorStroh, Jen_AU
dc.contributor.authorSediako, Den_AU
dc.contributor.authorLombardi, Aen_AU
dc.contributor.authorByczynski, Gen_AU
dc.contributor.authorReid, Men_AU
dc.contributor.authorParadowska, AMen_AU
dc.date.accessioned2021-12-22T20:03:46Zen_AU
dc.date.available2021-12-22T20:03:46Zen_AU
dc.date.issued2021-11-30en_AU
dc.date.statistics2021-12-15en_AU
dc.descriptionThis preprint is under consideration at The International Journal of Advanced Manufacturing Technology. A preprint is a preliminary version of a manuscript that has not completed peer review at a journal.en_AU
dc.description.abstractThe cumulative global emissions produced by the automotive industry over the last decade has put a tremendous strain on the environment. Consequently, automotive engineers and manufacturers have been forced to improve the efficiencies of their automobiles which is frequently accomplished by increasing the operating pressure, and therefore temperature, of the combustion engine. Unfortunately, in addition to the rise in operational pressures and temperatures, large tensile residual stresses often accumulate in the cylinder bridges during the casting process of aluminum engine blocks due to the use of cast-in iron cylinder liners, leading to combined stress magnitudes above the strength of the currently used aluminum alloys. Thus, the present study aims to characterize the evolution of residual stress, with application of neutron diffraction, at several critical stages of the manufacturing process of sand-cast aluminum engine blocks that have eliminated the iron cylinder liners from the casting process and replaced them with cylinder bore chills that are pressed-out after the thermal sand reclamation process. The replacement of the iron liners shifted the stress mode from purely tension to purely compression until the bore chills were removed. Following removal of the bore chills, the maximum tensile stress at the top of the cylinder bridge was ~70% lower than the engine’s predecessor which was produced with iron liners. Moreover, in the production-ready state (i.e., T7 heat treated, machined and press-fit liners inserted), the stress mode maintains the partially compressive nature with low magnitudes of tension, thereby lowering the material’s susceptibility to crack growth and propagation. This work is licensed under a Creative Commons Attribution 4.0 International License.en_AU
dc.identifier.articlenumberrs.3.rs-1083522/v1en_AU
dc.identifier.citationStroh, J., Sediako, D., Lombardi, A., Byczynski, G., Reid, M., & Paradowska, A. (2021). Evolution of residual stress through the processing stages in manufacturing of bore-chilled sand-cast aluminum engine blocks with pressed-in iron liners. Research Square. Preprint (Version 1). doi:10.21203/rs.3.rs-1083522/v1en_AU
dc.identifier.journaltitleResearch Squareen_AU
dc.identifier.urihttps://doi.org/10.21203/rs.3.rs-1083522/v1en_AU
dc.identifier.urihttps://apo.ansto.gov.au/dspace/handle/10238/12645en_AU
dc.language.isoenen_AU
dc.publisherResearch Squareen_AU
dc.subjectSanden_AU
dc.subjectAluminiumen_AU
dc.subjectMetalsen_AU
dc.subjectHeat treatmentsen_AU
dc.subjectResidual stressesen_AU
dc.subjectEnginesen_AU
dc.titleEvolution of residual stress through the processing stages in manufacturing of bore-chilled sand-cast aluminum engine blocks with pressed-in iron linersen_AU
dc.typeJournal Articleen_AU
Files
Original bundle
Now showing 1 - 2 of 2
Thumbnail Image
Name:
a8dcb9f3-2071-40c5-a2a1-077cafbc0ac3.pdf
Size:
2.8 MB
Format:
Adobe Portable Document Format
Description:
Download
Thumbnail Image
Name:
Supp material.pdf
Size:
813.22 KB
Format:
Adobe Portable Document Format
Description:
Download
License bundle
Now showing 1 - 1 of 1
Thumbnail Image
Name:
license.txt
Size:
1.63 KB
Format:
Item-specific license agreed upon to submission
Description:
Download
Collections
Journal Articles