Dual-phase steels have received extensive attention in autobody frame manufacturing due to the resulting characteristics of an interesting combination of ductile ferrite and hard martensite. Moreover, the ductile ferrite and hard martensite lead to heterogeneous deformation in the boundary between the two phases. Then, geometrically necessary dislocations (GNDs) are created to accommodate a lattice mismatch due to the deformation incompatibility of the boundary in straining. In this study, a new empirical GND model is developed, in which the GND density is a function of local plastic deformation; the GND density is distributed in the phase boundary in accordance with an “S” model of material plastic strain. The boundary conditions are applied to define the parameters. The proposed model is verified with DP600 steel. The effects of the GNDs and the width between ferrite and martensite on the strain hardening of DP600 steel are evaluated.

In order to expand the application range of casting aluminum alloy ZL105, the stirring fusion casting method was used to add carbon nanotubes (CNTs) with different content and aspect ratio into the ZL105 aluminum matrix. And then the effect of the reinforcement on the mechanical properties of the alloy was compared and analyzed. The research results show that the tensile strength and hardness of the carbon nanotube composites with different contents will be improved, but to a certain extent the elongation of the composite material will be reduced, and there is an optimal addition amount. The mechanical properties of composite materials prepared by adding CNTs with relatively small length and diameter are better. There are different forms of reinforcement mechanisms for CNTs to reinforce cast aluminum alloys, and the improvement of composite material performance is the result of the combined effect of multiple strengthening methods. The research has made a meaningful exploration for the realization of carbon nanotube reinforced aluminum matrix composites under the casting method.

Due the importance of using commercially Zamak5 in a wide range in industrial applications, however, this study was focused on the enhancing its machining issues by adding pure copper, so the effect of the addition of (1 to 3)% Cu to commercially Zamak5 on its mechanical properties, microhardness, surface texture and corrosion resistance was investigated. A CNC machining tests, microhardness tests, corrosion test, compression test, and microhardness test were performed. It was found that there is an enhancement on the flow stress at 0.2 strain of about 19% for 3% Cu addition followed by 17% and 15% in the case of 2% Cu and 1% Cu respectively. There was an enhancement in microhardness of about 11.6% in the case of 3% Cu addition. The surface finish was improved by increasing the number of copper contents (1 to 3)% to the base material Za5. Polarization measurements revealed that 3% alloy specimen inhibit the corrosion by more than 70% compared with the blank sample.

Mg-0.5Si-xSn (x=0.95, 2.9, 5.02wt.%) alloys were cast and extruded at 593K (320 o C) with an extrusion ratio of 25. The microstructure and mechanical properties of as-cast and extruded test alloys were investigated by OM, SEM, XRD and tensile tests. The experimental results indicate that the microstructure of the Mg-0.5Si-xSn alloys consists of primary α-Mg dendrites and an interdendritic eutectic containing α-Mg, Mg2Si and Mg2Sn. There is no coarse primary Mg2Si phase in the test alloys due to low Si content. With the increase in the Sn content, the Mg2Si phase was refined. The shape of Mg2Si phase was changed from branch to short bar, and the size of them were reduced. The ultimate tensile strength and yield strength of Mg-0.52Si-2.9Sn alloy at the temperature of 473K (200 o C) reach 133MPa and 112MPa respectively. Refined eutectic Mg2Si phase and dispersed Mg2Sn phase with good elevated temperature stability are beneficial to improve the elevated temperature performance of the alloys. However, with the excess addition of Sn, large block-like Mg2Sn appears around the grain boundary leading to lower mechanical properties.

This study investigates the effects of frequency, compression force and Vee angle parameters of High-Frequency Electric Resistance Welding (HF-ERW) process on mechanical properties of API X52 microalloy steel welding joint. Therefore, API X52 microalloy steel sheets having thickness of 8 mm was provided to manufacture pipes with the diameter of 16”. with direct weld seams using the HF-ERW method. During the manufacturing process, frequency values of 150, 200 and 250 kHz, compression forces of 2, 4 and 6 mark and Vee angles of 3°, 5°, and 7° were adopted. After changing the welding parameters, from the welded pipes, tensile and Charpy impact test samples prepared to macroscopically evaluate the weld metal flow and examine the effects of these parameters on mechanical properties of the welded joints. According to the results, it was concluded that frequency of 150 kHz, the compression force of 4 mark and Vee angle of 5° yields best mechanical properties in the HF-ERW joint of API X52 microalloy steel.