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Effect of hot press forging process on different chip size, pre-compaction cycle, and holding time in direct recycling of aluminium alloy AA6061

Khamis, Siti Salwa (2015) Effect of hot press forging process on different chip size, pre-compaction cycle, and holding time in direct recycling of aluminium alloy AA6061. Masters thesis, Universiti Tun Hussein Onn Malaysia.

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Abstract

A new approach of solid-state direct recycling metal chip was examined scientifically by applying hot press forging process technique. The study is to determine the effect of different chip sizes (S), pre-compaction cycle (PCC) and holding time (t) on the mechanical and physical properties of the recycled chip of AA6061 aluminium alloy in hot press forging process. Full-factorial design coupled with response surface methodology (RSM) design was used based on the face centred, central composite design (CCD) to evaluate the effects of three main parameters as mentioned above. The mechanical properties of recycled chips were determined by measuring the ultimate tensile strength (UTS) and yield strength (YS) whereas the physical properties were studied by examining the microhardness, microstructure, and the relative density of the recycled chip. Finally, both results of mechanical and physical properties of the recycled chips were compared with the original AA6061 aluminium billet. The experimental results indicates that, hot pressed AA6061 recycled aluminium alloy using chip size (S=larger), pre-compaction cycle (PCC=4 times), and holding time (t=120 minutes) produced the higher value of UTS and YS at 122.33 MPa and 120.45 MPa respectively, which is 42% of as-received billet. It was also found that larger S used with higher number of PPC and longer the t will produce better mechanical and physical properties of the recycled AA6061 chip where t has most influential effect throughout the process followed by PCC, and S. Those results were supported by RSM optimization technique giving 98% of desirability index as both solution predicted was close to the experimental value of the reference specimen. Therefore, this study can be used as an alternative technique for recycling aluminium chips instead of conventional method which it has been carried out below the melting phase temperature.

Item Type: Thesis (Masters)
Subjects: T Technology > TA Engineering (General). Civil engineering (General) > TA401-492 Materials of engineering and construction. Mechanics of materials
Depositing User: Mr. Mohammad Shaifulrip Ithnin
Date Deposited: 05 Feb 2017 08:01
Last Modified: 05 Feb 2017 08:01
URI: http://eprints.uthm.edu.my/id/eprint/8842
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