This project proposes a combination of experimental, computational and analytical tools to address methods to minimize residual stresses and distortions in cast and heat-treated parts. Ultimately, the project will lead to develop design models that can be readily used by manufacturing engineers. Specific interest is in solid ingots made of nickel-based alloys and hollow extruded shapes made of aluminum alloys. The main objectives are to: (1) study the effects of varying heat-transfer rates (Controllable Delayed Quenching) on residual stresses, thermal distortions and material properties; (2) develop design models to predict quench-part distortion in thin-walled extruded aluminum shapes; and (3) develop integrated process models to study the optimal combinations of quench parameters to reduce residual stresses in solid ingots made of high-strength Nickel-based alloys. This project will help the materials processing industry involved in metalforming and heat-treatment to improve process design and product quality, reduce experimentation, improve the efficiency of thermal processes and hence decrease energy consumption.
