Technical Capabilities The Technical Capabilities of the IRC

Technical Capabilities The Technical Capabilities of the IRC have been continuously developing since the inception of the Chair in 1993. The IRC secured major equipment grants from NSERC and from the University of Windsor for laboratory/office renovations and equipment installation. The IRC currently operates four labs totaling 400 square metres. The IRC also has access to various analytical and testing laboratories operated by the Department of Mechanical, Automotive and Materials Engineering and various other Departments and Faculties at the University of Windsor, the CANMET National Laboratory as well as many other domestic and international universities.

Metal Casting Facility For Melting and Casting of Aluminum Alloys © All rights reserved

Metal Casting Facility For Melting and Casting of Aluminum Alloys Equipment Applications l 50 k. W Ajax Induction Furnace (25 kg aluminum l Engineering of cast alloys and technological processes. l Effects of alloying and minor elements on casting l l l l l capacity), water cooled power leads, hydraulic tilt operation. 12 k. W PSH Electric Resistance Programmable Holding Furnace (12 kg capacity). Foseco Rotary Degassing Unit for both the Ajax and PSH Furnaces. Electromagnetic Stirring and Vibration Equipment for liquid metal treatment. 15 k. W Ajax Induction Vacuum Melter (0. 5 kg aluminum capacity). Carbolite MTF 12/38/250 1 k. W Programmable Tube Furnace (1200°C) for thermocouple calibration. Alscan-F Hydrogen Analyzers (2). Stahl Reduced Pressure Hydrogen Analyzer. Universal Metallurgical Simulator and Analyzer. Aluminum Thermal Analysis System (Al. TAS). Environmental Aluminum Thermal Analysis System (Enviro-Al. TAS). structure and resulting mechanical characteristics. l Design performance and evaluation of laboratory and industrial experiments. l Certification of ingot quality by assessment of metal cleanliness, fluidity, feedability, structural analysis and comprehensive thermal analysis. l Liquid metal processing (furnace & in mould).

Environmental Aluminum Thermal Analysis System (ENVIRO-Al. TAS) © All rights reserved

Metal Casting Facility For Melting and Casting of Aluminum Alloys Equipment l 1 and/or 2 K-Type Thermocouple Technique using a ENVIRONMENTAL ALUMINUM THERMAL ANALYSIS SYSTEM (ENVIRO-Al. TAS) l The IRC has developed a new Environmental Aluminum Thermal Analysis System (Enviro-Al. TAS), which is a second generation version of the Al. TAS. The Enviro-Al. TAS produces cooling curves and calculated fraction solid of thermal analysis test samples that experience elevated riser pressures of 0 -15 psi (to simulate metallostatic head pressure), different cooling rates ranging from 0. 1 to 1°C/sec and thermal gradient. The Enviro-Al. TAS system yields a substantial body of new information on the role of fluid flow within interdendritic regions as solidification progresses from liquidus to solidus. This information is necessary for the development of advanced alloys having a higher fatigue life. l l graphite, ceramic or stainless steel test cup; up to 32 thermocouples for analysis of actual castings. OMEGA Digital RTD Calibration System HI-RES Thermometer and Calibration Furnace. National Instruments and/or Fluke Data Loggers (Hardware) and Lab. View 5. 1 Software. Automatic control of riser pressure and cooling rate. Metallurgical analysis of solidifying test samples. System analysis of solidifying sample environment. Uses l Thermal data acquisition and automated analysis of the solidification process. Applications l Solidification study of aluminum alloy castings. l Determination of solid fraction, volume fraction and l l temperature formation of various phases. Dendrite Coherency Point Characteristics (DCP). Secondary Dendrite Arm Spacing (DAS). Segregation and porosity level analysis. Grain refining and Si modification analysis of aluminum

Heat Treatment Facility For Studies of New Heat Treatment Processes Equipment Applications l 2 Lindberg Series 2000 Temperite Programmable Heat l Improvement of microstructure, properties and l l Treatment Furnaces. l Honeywell Digital Controllers with RS-422/485 communication ports. l Auto tune, set point and programming. l Temperature goes up to 760°C. Electrically Heated Convection Box Type Furnace. High Frequency System for heat treatment of various test samples. Quenching and cooling equipment using low melting temperature alloys, oil, atomized water and compressed air. Thermoelectric Power (TEP) System. dimensional stability of actual casting sections and laboratory test samples. Form of Data Output l Interfacable to a PC and provides drivers to work with Lab. View 5. 01. THERMOELECTRIC POWER (TEP) SYSTEM Uses l Quantification of casting structural transformations. Applications l Solubility of alloying elements. l Age hardening studies.

Heat Treatment Facility For Studies of New Heat Treatment Processes

Metallographic Sample Preparation Laboratory For Preparation of Analytical Planes Equipment l Buehler Ecomet 4/Automet 2 Semi-Automatic Grinder l l l l l Polisher. Buehler Handimet II Roll Grinder. Buehler Surfmet I Belt Surfacer. Buehler Metlap Dispensing System. Buehler Simplimet 3 Mounting Press Unit. Buehler Electroetching/Polishing Cell. Weighing Balances. Vacuum Sputtering Apparatus. Ultrasonic Cleaners. Saw and other tools. Hot Mounting Press and Cold Mounting Kits (various resins). Uses and Applications l Sectioning and mounting of the metallographic samples. l Grinding and polishing to achieve representative analytical surfaces. l Cost effective operation.

Metallographic Sample Preparation Laboratory For Preparation of Analytical Planes

Micro Thermal Analysis Laboratory For Calorimetry and Dilatometry Analyses DILATOMETER DIFFERENTIAL SCANNING CALORIMETER Equipment l DIL 402 EP NETZSCH. Equipment Features l Temperature Range: up to 1650°C. l Special sample holders for molten metals, powders, single fibers, etc. l Automatic pushrod adjustment. l Vacuum tight. Equipment l DSC 404 C Pegasus NETZSCH. Equipment Features l Temperature Range: up to 1650°C. l Exchangeable measuring heads for optimization of the sensitivity and time constant. l Evacuation and operation with purge gas possible. Uses l Measures the expansion and contraction of solids with l Determination of thermodynamic properties of high the temperature change. performance materials. Applications l The effect of the heat treatment and solidification l Specific heat, melting temperatures, transition process on residual stress formation, optimization of heat treatment process, TSR, alloy chemical composition, linear thermal expansion coefficients, sintering temperatures, phase transformations, decomposition temperatures, glass transition temperatures and softening points. enthalpies, phase transformations, phase diagrams, crystallization temperatures, degree of crystallinity, glass transition temperatures, decomposition effects, reaction kinetics, purity, latent heat of fusion.

Micro Thermal Analysis Laboratory For Calorimetry and Dilatometry Analyses

Image Analysis Laboratory For Quantitative Analysis of As Cast and Heat Treated Structures Equipment l l l Image Analysis System. Black/White and Colour Cameras with Microscope. Stereo Viewer. Light Optical Stereo Microscope. Light Optical Microscope.

Image Analysis Laboratory For Quantitative Analysis of As Cast and Heat Treated Structures QUANTITATIVE IMAGE ANALYSIS (IA) Equipment Applications l Leica DM R Automated Microscope for Image Analysis with l Size, shape and distribution of microstructural features l l l macroviewer, zoom lenses and joystick. Ademic MX 12 High Resolution Camera with 102 x 102 mm motorized stage. Leica Stereomicroscope with 3 x viewing optics. Kaiser RT 1 Light System. Leica Q 5501 W Computer System with Materials and Metallurgical Software. Laser Jet HP 3 (black and white). Lexmark Optra 1275 Colour Printer. in the metal and alloys. l Porosity (gas and shrinkage) and segregation. l Spatial distribution of fibre materials, particles in composites, and crystalline phases. l Statistically valid interpretations of the stereological l l Uses l Fully automated, interactive image processing and analysis system provides quantitative stereological information. l l Image sources for digitized image information are: SEM, EDS, TEM and Macrostand. l l l parameters of micro and macro structural features; microchemistry aspects. Statistical planning of quantitative metallographic (stereological) analysis. Automatic and semi-automatic measurement of feature spacing (e. g. near neighbour spacing for all selected features of interest, mean free path, fatigue striation spacing, dendrite arm spacing). Single and multiphase (interconnected, locked) nonmetallic inclusion, phase or particle size distribution. Quantitative stereoscopy for fractography, failure analysis, porosity analysis, machined surface characterization and others. Automatic analysis of particle and pore size. Possibilities of three dimensional structure reconstruction based on sectional contours.

Image Analysis Laboratory For Quantitative Analysis of As Cast and Heat Treated Structures

Image Analysis Laboratory For Quantitative Analysis of As Cast and Heat Treated Structures LIGHT OPTICAL MICROSCOPE Equipment l Leica DM R Automated Microscope. Form of Data Output l Display of images on a computer monitor screen, printer and scanner. l Photomicrographs and pictures. Uses l Phase identification. l Microstructure and macrostructure interpretation; effect of heat treatment, solidification process and other factors on microstructural parameters. Applications Alloying and impurity elements; liquid metal treatment. Failure analysis. Corrosion study. Solidification microstructure (matrix, phase and inclusion) analysis. l Wear study. l Coating and substrate analysis. l Structure study of metal matrix composites. l l Form of Data Output l Comprehensive and fully documented reports which support the findings, interpretation, conclusions and recommendations. l Calibrated black and white micrographs and macrographs (up to 1000 x magnification).

Electron Microscopy Laboratories * For Metallographic Characterization of Materials & Components SCANNING ELECTRON MICROSCOPE (SEM) Equipment Applications l JEOL JSM 5800 LV Scanning Electron Microscope l l l equipped with: l KEVEX Sigma Microanalyzer Level LPX 3 LEDS. l Image Processing and Analysis System. Uses l Imaging of topographical and/or microstructural and macrostructural features of polished and rough specimen surfaces. l Quantitative or semi-quantitative element and image analyses. Fracture surface analysis. Metallographic cross-sectional structure studies. Micron and sub-micron particle study. Material and component defects. Wear surface studies. Others (see EDS and IA).

Electron Microscopy Laboratories* For Metallographic Characterization of Materials & Components ENERGY DISPERSIVE X-RAY SPECTROSCOPY (EDS) Equipment Features l l l 90 MHz Pentium Processor with 256 KB Cache. Intelligent peak identification and labeling. Quantitative matching of spectra. Spectrum processing. Analysis program with and without standards. Conductive coating and contamination. Uses l Elemental identification of major, minor or trace elements (Boron and higher atomic number elements). l Quantitative and semi-quantitative analysis. l Automated SEM Image Analysis. Applications l Phase (single and multi-components) matrix identification, chemical composition analysis. l Contaminant species identification. l Segregation analysis. l Particle and rough surface analysis (software to compensate for topographical effects on X-ray signal). l Diffusion, corrosion, wear, machinability, segregation, precipitation studies. l Quality control analysis. l Effect of process parameters on product internal structure and surface characteristics. l Metallurgical defects in failure analysis. Forms of Data Output l X-ray spectrum showing peaks of all elements present for Z. l Calculated weight % and atomic % of elements detected (full standards, without standards, ZAF matrix correction procedure).

Electron Microscopy Laboratories* For Metallographic Characterization of Materials & Components

Electron Microscopy Laboratories* For Metallographic Characterization of Materials & Components TRANSMISSION ELECTRON MICROSCOPE (TEM) Equipment l JEOL JSM-100 CX Transmission Electron Microscope. Uses l Microstructural features on twin jetted bulk samples. l Imaging of microstructural features. l Qualitative and quantitative elemental analysis of microstructural features. l Crystal structure and orientation for determination of microstructural features. l Lattice imaging of crystals with interplanar spacing. Applications l Examination of microstructural features. l Very high magnification characterization of the microstructure of metals and alloys. l Identification of precipitates. l Crystallographic study of precipitates.

X-Ray Diffraction Laboratory* For Qualitative Compound Identification (Stoichiometry) of Crystalline Solids & Powdered Mixtures Equipment l Rigaku X-ray Diffraction System. Applications l Phase identification. l Determination of residual stress on casting surface. l Identification of metal casting and processing agents (e. g. slugs, refractories). l Surface condition determination (e. g. alloy layers). Form of Data Output l List of identified species.

Mechanical Testing Facility* For Characterization of Mechanical Properties of Materials & Components Equipment l l Nanohardness System. Microhardness Testing. Universal Mechanical Testing Workstation (UMTS). Instron Creep Machine. MICROHARDNESS TESTING Uses l Vickers hardness. l Knoop hardness. Applications l Anisotropy of crystalline surfaces. l Quality control. l Hardness of phases, inclusions, decarburization zone, welds. l Deformation and fracture. l Grain boundary solute migration. l Wear correlation. NANOHARDNESS SYSTEM Uses l Nanohardness analysis of various materials and metallurgical features (thin film, constituents and phases). Applications l Creep analysis of aluminum alloys. l Elastic modules determination of various phases and metal matrix.

Mechanical Testing Facility* For Characterization of Mechanical Properties of Materials & Components WORKSTATION (UMTS) Some Features Equipment l Axial Servohydraulic Dynamic Two Column Load l Instron Fast Track 8800 Series 8802 Model. Uses l l l l High Cycle Fatigue. Precision Tensile and Compressive Testing. Fracture Mechanics. Low Cycle Fatigue. Flexure. Components. Environmental Testing. l l l l Frame. Enables applications from thermomechanical fatigue. Also has the requirements to test for crack propagation and stress corrosion. Materials and component testing temperature chambers. Dynacell, the world's first truly dynamic load cell. Reduces dynamic load errors and increases productivity by allowing higher frequency operation while maintaining test validity. Fatigue and tension/compression testing. Precise and versatile servohydraulic testing system. Low Cycle Fatigue Testing. Its modular approach allows test set-up and analysis from the machine computer or from a remote network computer. Maximum Fatigue Rated Capacity: +/- 250 k. N (56 Kip). High stiffness, precision aligned loading frame with fixed lower plates and adjustable upper crosshead. Complies with SAE and ASTM standards. Zero slippage hydraulic grips.

Mechanical Testing Facility* For Characterization of Mechanical Properties of Materials & Components INSTRON CREEP MACHINE Capabilities l Monotonic to 1300 k. N. l Determination of Dendrite Coherency Point Characteristics. l Creep and fatigue to 250 k. N at 8 Hz. l Room and elevated temperature reproduction. l Correlation between finite element analysis and actual performance. Features l Complies with SAE and ASTM standards. l Infinite speed increments from creep to high rate testing. l Position, load and strain control and monitoring in a manual or automatic fashion. l Real time capability. l Computer assisted data acquisition, manipulation and report generation. l Zero slippage hydraulic grips. l Simulation of service conditions on a variety of components (products). Typical Tests l l l l Tensile (room and elevated temperatures). Creep. Low Cycle Fatigue. Compression. 3 and 4 point bending. Crack propagation. Service life simulation. Impact. Typical Test Applications l l l Machined specimens. Round and flat stock. Fasteners. Welds. Cast and formed components. Forms of Data Output Automated material characteristic determination. Tabular data spreadsheet. Statistical data evaluation. Computer generated XY plots e. g. stress/strain, S/N curves. l Fatigue life determination. l l

Mechanical Testing Facility* For Characterization of Mechanical Properties of Materials & Components

Other Equipment* ELECTRONIC TESTING EQUIPMENT PHYSICAL TESTING EQUIPMENT l Charpy Impact Tester (2). l Hardness Tester (30). SURFACE ROUGHNESS MEASUREMENTS l l L and N Potentiometer Facility. 1 MHz Oscilloscope. Various analogue meters. Power supplies. Equipment TRIBOLOGICAL TESTING l Taylor-Hobson Talysurf. Uses l Utilized for machined surfaces, capable of all roughness measurements, Ra, Rn, Rz, etc. in both English and ISO definitions. SPECTROMETER Equipment l l l High temperature sliding wear test equipment. Block on ring wear testers (3). High temperature solid particle erosion rig. Abrasion tester. High speed reciprocating wear rig. Uses Equipment l Wear testing. l Analyte 16 Spectrometer for Chemical Applications Composition Testing. Uses l Evaluation of wear mechanism. l Determination of friction and wear behaviours of a variety of materials. l Complete analysis of elements in aluminum alloys. l Evaluation of sliding wear performance at elevated temperatures (up to 1000°C).

* Equipment operated by the University of Windsor Faculty of Engineering. For more information about the IRC visit our web site @ http: //cronus. uwindsor. ca/fordirc.