School of Engineering and Physics

MM361 PROJECT

TOPIC: MECHANICAL STRENGTHENING OF ALUMINUM

ALLOY UNDER COLD FORGING

Group 2 MEMBERS

1. William Talo (s11125333)

2. Ashneel Chand (s11121760) 
3. Isimeli Radrodro (s11089412)
4. Sharan Danish (s11097134)
Content

Introduction

Literature Review

Objectives

Experimental Work

Method

Result/Discussion

Conclusion

References
 Introduction
Applying an extensive load on a material can lead to failure even if it does not
reach the stress value required.

Therefore, to achieve a high mechanical strength of a material, strain hardening

process can be done under cold forging.
Cold forging increases the material strength under straining hardening at the
material’s room temperature.

The strain hardening process or cold working is possible through extensive

plastic deformation of a material below its recrystallization temperature [4]
 This project will do an analysis on a given data on four Aluminum copper alloys, AL-
1%wtCu, AL-2%wtCu, AL-3%wtCu and AL-4%wtCu. The given alloys were given an Aspect
Ratio of 0.3 with a mass of 10 tonnnes each and were deformed under Nil and Zinc
Lubricant conditions.
 Literature Review
Powder Metallurgy

(P/M) allows metal forming of powders such as from metallic or

ceramic materials to form a shape with dimensions, sintering under
high temperature [1].

This innovation is commonly applied to materials in powdered and

only technology used to make materials with composite materials,
refractory materials, porous materials and high duty materials [2].

Process has benefited the manufacturing industry providing a specific

density, reduction in thermal expansion, corrosion improvement and
high mechanical strength [3].
Literature Review cont.…

Strain Hardening
It is understood that after the Primary P/M process, the
porosity level of the material or preform could be high.

Preforms that contain sufficient amount of pores, creating,

more stress concentration sites which can leads to cracks
initiation under high load applications.

Strain hardening can make a metal harder through plastic

deformation.
Literature Review cont…

•Strain
  Hardening
 Plastic deformation of a material is determined by the
particle Dislocation to move.

If the there is an increased in dislocation, the metal would

not allow any further deformation due to interlocking of
particles.

The strain Hardening follows Ludwiks Power Law, such that

= K , where K is the strength coefficient and n is the strain
hardening exponent [3]
Literature Review cont.…

Strain Hardening theory

Objectives
The main objectives of the project is to determine the strain
hardening behavior of or mechanical strengthening behavior
of aluminum alloy (Al-1%wtCu, Al-2%wtCu, Al-3%wtCu
and Al-4%wtCu).

To determine the strain hardening exponent n of Aluminum

alloy

To determine the instantaneous strength coefficient k.

To determine the characteristics of strain hardening of

Aluminum Alloys
Experimental Work
•   
The first step in the experiment is to carryout Materials and
characterization
the atomized aluminum powder of about 150 to be analyzed for its
purity. The electrolyte copper powder of 37 size was also be analyzed
for it purity.

The second step is to carryout Blending, compaction and Sintering

The amount of powder needed were measured and has to be blended in
pot mill for a sufficient amount of time (about 18 hours) to produce a
uniform mix. The powder will be compacted to produce a preform
diameters of 28.2967mm Heights of 9.733mm using hydraulic press of
148. The compacted preforms will be under ceramic coating, to protect
it from rusting or oxidation. The preforms will be recoated and dried
for some time (about 10 hours).
 
• The final step would involve cold formation.
The preforms has to be clean to get rid of the ceramic
residues. Then it would be machined to give the initial height
to diameter ratio of 0.3. With the preforms compressed under
a 148 hydraulic press, Measurements were taken at increment
of 2 Tonnes. At each increment, the measured height to
diameter ratio were obtained, using a digital Vernier Caliper.
Characteristics of the Aluminum Alloy
Preforms

Preform Condition AR in g/cc Ho/Do Mass in Ton

s

Al- Nil 0.3 2.762 0.34 10

1%wtCu
Al-
Al- Nil
Nil 0.3
0.3 2.825
2.825 0.34
0.34 10
10
2%wtCu
2%wtCu
Al- Zinc 0.3 2.887 0.34 10
Al- Zinc 0.3 2.887 0.34 10
3%wtCu
3%wtCu
Al- Zinc 0.3 2.95 0.34 10
Al-
4%wtCu Zinc 0.3 2.95 0.34 10
4%wtCu
Method
Selection
of
Project
Topic

Literature
Review

Identify Main
Parameters

Sufficient
Source No

Yes
 Carryout
Experiment

Data and Graphical

analysis using Excel

Results, Discussion and

Conclusion
Results and Discussion
• Figure 1 below shows the stress and density plot
• density and stress are directly proportional
• It is evident, that there is steep rise in the first stage, then a retardation in the second stage, then finally an even more
steeper rise.
• the third stage begins to resist deformation, which constitutes an even steeper rise in stress

160

140

120

100
AL-1%wtCu
σ(MPa)

AL-2%wtCu
80
AL-3%wtCu
60 AL-4%wtCu

40

20

0
2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75
Density
• from figure 2 (Axial vs Stress), It can be observed that stress is
proportional to Strain
• There is a sudden steep rise and then a gradual rise in stress

160

140

120
σ(MPa)

100
AL-
1%wtCu
80 AL-
2%wtCu
AL-
60 3%wtCu

40

20

0
0 0.1 0.2 0.3 0.4 0.5 0.6

Axial Strain
•  figure 3 shows the stress-strain log-log scale.
• determine the Power Law relationship, obeys Ludwik’s law, given as
=K.
1000
σ(MPa)

100

AL-1%wtCu
AL-2%wtCu
AL-3%wtCu
AL-4%wtCu

10
0.01 0.1 1

Axial Strain
• The table below shows the calculated values for Strain Coefficient, K and Hardening Exponent obtained from the Stress
Strain Graph
• It can be observed that for higher Strain Coefficient values resulting in low hardening exponent values.
• This concludes that for a higher value of K, would have a higher rate of strain hardening.

•Conversely, the preforms exhibit less stress at the start and further deformation resulting in the strengthening of the material.

Preform ‘K’ Values ‘n’ Values

AL-1%wtCu 26 0.44

AL-2%wtCu 25 0.52

AL-3%wtCu 23 0.46

AL-4%wtCu 20 0.5
Conclusion

• Upon completion of the project, it was concluded that work

hardening comprises of geometric and matrix work
hardening.
• Initial stage of preform compression is high work hardening
rate but also the work hardening rate falls quite quickly to at
this stage as porosities begin to close which is attributed to
geometric work hardening.
• The second stage is attributed to matrix work hardening as
there is gradual strain inducement and pores move at equal
pace in direction of deformation
Reference
[1] Torralba, J. (2014). .11 - Improvement of Mechanical and Physical Properties
in Powder Metallurgy. [online] Sciencedirect.com. Available at:
https://www.sciencedirect.com/science/article/pii/B9780080965321003162
[Accessed 5 Mar. 2020].
 
[2] Narayan, S. and Rajeshkannan, A. (2020). Strain hardening behavior in
forming of sintered iron-0.35% carbon powder metallurgy preform during cold
upsetting. [online] Available at: http://www.scielo.br/scielo.php?
script=sci_arttext&pid=S1516-14392011000400004&lng=en&tlng=en [Accessed
7 Mar. 2020].
 
[3] Rajeshkannan, A., Rengamani, D. and Sharma, A. (2013). Some aspects on
geometric and matrix work-hardening characteristics of sintered cold forged
copper alloy preforms. Materials Research, [online] 17(1), pp.196-202. Available
at:
https://www.researchgate.net/publication/262617397_Some_Aspects_on_Geomet
ric_and_Matrix