Jaime Lazaro-Nebreda

Jaime Lazaro-Nebreda
Brunel University London · Brunel Centre for Advanced Solidification Technology (BCAST)

Doctor in Physics

About

36
Publications
6,950
Reads
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274
Citations
Citations since 2017
20 Research Items
226 Citations
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2017201820192020202120222023020406080
Introduction
(1) Technology development for Al and Mg alloys for: (a) recycling and recovery. (b) melt cleanliness and purification (c) melt conditioning for grain refinement (d) in-line systems for industrial continuous casting processes such as ingot casting, sand casting, low&high pressure die casting and twin-roll casting. (2) Experience in 3D characterization by NDT such as X-ray radioscopy and tomography. (3) Experience in manufacturing and characterization of metal composites and metallic foams.
Additional affiliations
October 2014 - present
Brunel University London
Position
  • Research Associate
Description
  • http://www.brunel.ac.uk/bcast
July 2011 - August 2011
Technische Universität Berlin
Position
  • PhD Student
Description
  • http://www.tu-berlin.de/
July 2010 - October 2010
University of Nottingham
Position
  • PhD Student
Education
October 2008 - April 2014
Universidad de Valladolid
Field of study
  • Ph.D. in Physics
October 2007 - September 2008
Universidad de Valladolid
Field of study
  • Master Degree in Physics Instrumentation
October 2002 - September 2007
Universidad de Valladolid
Field of study
  • Degree in Physics

Publications

Publications (36)
Article
Full-text available
The search for more efficient methods for degassing aluminum alloy melts has always been of great interest for the metal industry because the presence of hydrogen and oxides in the melts' prior casting was detrimental to the integrity and properties of the final products. In this work, we present an overview of the progress and key findings from th...
Article
Full-text available
This article provides an overview of high-pressure die casting (HPDC)-related research undertaken at the EPSRC Future LiME Hub between 2015–2022. The project aimed to identify the cause of variability in the tensile ductility of die-cast structures, and to develop novel processing techniques to address this issue. Variability in tensile ductility w...
Article
Full-text available
The main problem of recycling aluminium scrap is the gradual accumulation of impurities, especially iron, which tend to form undesired intermetallic compounds that affect the integrity and the mechanical performance of the castings. In this paper, we aim to provide an overview on the topic of iron removal from aluminium melts through primary interm...
Research
Among the available molten aluminum degassing methods, the industry uses rotary degassing due to its simplicity and improved performance compared to other available methods. For this method, the degassing efficiency is dependent on the effective size reduction and distribution of the gas bubbles inside the molten metal. However, strategies for impr...
Article
The automotive industry is speeding towards an electric future, with car companies like BMW and Volvo Cars initiating plans to shift their vehicle line-up to low-to-zero emission models. The UK government believes that the manufacture and sale of electric vehicles (EVs) will achieve an ambitious 60% share of the market by 2030. However, the sector...
Article
Full-text available
High-shear melt conditioning (HSMC) technology was used for degassing and de-ironing of an aluminum alloy recovered from the Zorba cast fraction of the non-ferrous scrap from shredded end-of-life vehicles. The results showed that the recovery of aluminum alloys from the Zorba cast fraction was more than 80%. High-shear melt conditioning improved th...
Article
Controlling the formation of noncompact second phase particles during direct chill (DC) casting of aluminium alloys with grain refiner addition remains challenging, as it results in energy intensive homogenisation and deformation problems. In this work, we employed a novel strategy in the DC casting of A6082 alloy to produce billets with a fine-sca...
Article
Full-text available
The degassing of aluminium alloy melts is a crucial step in the production of high-quality casting products, as the presence of dissolved hydrogen and oxide bi-films is detrimental to the mechanical properties. Current rotary degassing techniques are effective, but they lack efficiency because of the high gas flow and long processing times required...
Article
Full-text available
High shear melt conditioning technology refines the as-cast structure of light alloy melts, thereby improving the mechanical properties of the casting and reducing the occurrence of defects, without requiring chemical grain refiners. To upscale the technology and apply it to processes involving larger melt volumes, a computational fluid dynamics st...
Article
This paper describes the application of X-ray tomography to predict the tensile fracture properties of aluminium alloy die-castings containing natural casting defects. A new estimator (Z-project) is presented that can predict the areal fraction of porosity involved during tensile failure to a higher degree of accuracy than conventional methods, whi...
Article
Full-text available
The melt conditioned direct chill (MC-DC) casting process has been used for the production of billets of AA-6111 alloy formulated from recycled aluminium derived from incinerator bottom ash (IBA). The billets were homogenised and then extruded into planks. Optical metallography of the MC-DC billets showed equiaxed refined grains in comparison to DC...
Article
Full-text available
The accumulation of iron in molten aluminium is one of the main concerns for the recycling and casting industries because it leads to the formation of undesirable Fe-rich intermetallic compounds which are detrimental to mechanical properties. Many methods have been developed in the past to reduce the iron accumulated in molten aluminium scrap, but...
Article
Full-text available
The reduced solubility of hydrogen in molten aluminium is believed to be a key factor influencing the formation of gas porosity, which adversely affects the mechanical properties. In this study, two crucibles of AlSi10MnMg alloy were degassed using conventional rotary degassing and high shear melt conditioning (HSMC) respectively and then cast into...
Article
Full-text available
To promote mechanical properties and reduce the performance instability of A380 alloy produced by high-pressure die casting, a high shear melt conditioning (HSMC) technology was developed and applied to the melt prior to pouring into the shot sleeve. The experimental results show that, with the application of HSMC, the variation of elongation and y...
Conference Paper
A380 (Al9Si3Cu) alloy has been widely employed to produce thin-wall components via high pressure die casting (HPDC). During HPDC processing, there is a significant problem of property variation even with the very stable and precision automated casting procedure. The enlarged variation lowers the component performance and affects the steady and unif...
Conference Paper
Melt quality is crucial for both continuous and shape casting of light alloys and in order to improve it, removal of excessive inclusions, accumulated impurities and unwanted gases becomes necessary. To address this problem, a new multi-purpose high shear liquid metal treatment technology, based on intensive melt shearing by a rotor/stator unit, ha...
Conference Paper
Melt quality is crucial for both continuous and shape casting of light alloys. The recently developed melt conditioning technology where intensive shearing is applied to the melt by a rotor/stator type mechanism, in order to achieve uniform temperature and chemical composition, together with dispersion and distribution of the harmful inclusions suc...
Conference Paper
Full-text available
Dissolved hydrogen in aluminium alloys is detrimental to the mechanical properties of castings due to the resulting porosity. Rotor/stator based high shear melt conditioning (HSMC) technology disperses each argon bubble into many small bubbles, which increases the overall surface area of bubbles in the melt with minimal disturbance of the melt surf...
Conference Paper
Full-text available
Aluminium scrap, with accumulated impurities such as Fe, is typically either downgraded to low quality cast products or diluted with expensive primary aluminium in order to reduce Fe concentration to under the allowed specification limits. However, the increasing demand of high quality components at affordable cost makes iron removal a major concer...
Article
This work studies the different stages of the fabrication of aluminum foams from PM precursors and aims on finding the parameters affecting the generation of defects in the cellular structure. Results show that foam's cellular anisotropy is directly related to the structural anisotropy of the initial precursor and the way it starts expanding. Homog...
Article
This study evaluates the influence of solidification rate on the generation and control of pore connectivity of closed-cell aluminium foams. Additionally, it gives the experimental support to evaluate and model the effect of this pore connectivity on the mechanical properties. A collection of AlSi10 foams produced via powder metallurgy route, with...
Article
This work studies the effect of some production parameters on the pore connectivity grade (i.e., the open-cell content associated cracks and missing cell walls) of aluminium foams produced via powder metallurgy route. Two types of precursors, extruded and hot uniaxially compressed, were used to create a varied group of Al–Si and Al–Si-Mg alloy-base...
Patent
The invention relates to a novel method of producing aluminum foams by incorporating silicon oxide (SiO2) nanoparticles, said nanoparticles causing a sufficient increase in viscosity to stabilise the bubbles in the metal while said metal remains in a molten state. The method according to the invention is suitable for use in the production of panels...
Article
Full-text available
Aluminium foaming via melt route by using calcium carbonate is far known since a few years ago. However, some other carbonates have not been explored, or results on them have not been reported in sufficient detail. This work presents the results of a systematic study foamability evaluation by using an alternative mixture of carbonates with molten a...
Article
Full-text available
Aluminium foams produced by the powder metallurgical route are known to present an initial –anisotropic– semisolid expansion that has a detrimental effect on the foamability and on the subsequent quality of the final cellular structure. The present work proposes a method oriented to modify the precursors’ microstructure and overcome this problem. I...
Article
Full-text available
This work investigates the causes of the anisotropic early expansion (below the melting point) of powder metallurgical (PM) aluminum foam precursors by evaluating the crystallographic anisotropy induced during the production of the precursor materials. A varied group of precursors prepared using different parameters and techniques (direct powder ex...
Article
Full-text available
This work reports a detailed study on the early expansion (before the melting point) of powder metallurgical (PM) aluminium foam precursors and its influence on the intrinsic anisotropy existing in the final cellular structure of PM foams. Hot uniaxial compressed tablets, rectangular and cylindrical extruded profiles and thixocast PM precursors hav...
Article
Full-text available
Present research work evaluates the influence of both density and size on the treatability of Aluminum-based (6000 series) foam-parts subjected to a typical solid solution heat treatment (water quenching). The results are compared with those obtained for the bulk alloy, evaluating the fulfilment of cooling requirements. Density of the foams was mod...
Article
An analysis on the influence of solid phase thermal conductivity and cellular structure on the heat transfer mechanisms (HTMs) by means of studding diverse case studies combining theoretical and experimental data. The radiation and conduction mechanisms have been analyzed for cellular materials based on insulating and conductive matrixes using simi...
Article
Heat transport equations have been used to solve, by implementing the Finite Element Method (FEM), three different cases representative of the aluminium foams life: the production process (solidification in the molten state), post-production (water quenching heat treatments) and applications (fire barriers).
Conference Paper
The influence of different fabrication parameters on the pore interconnection grade of aluminium foams produced by the powder metallurgical route has been analyzed for porosities between 0.70 and 0.85 and, within this range, the curve presented a parabolic profile with a minimum. The compaction method –direct extrusion or hot uniaxial compaction– o...
Conference Paper
The anisotropic expansion in the semisolid state causes part of the defects present in the final cellular structure in foams produced using powder metallurgy (PM). In this work, PM aluminium precursors, compacted by direct powder extrusion and hot uni-axial compression, has been analysed in terms of their micro-structural anisotropy to further und...
Article
In this work, the effective diffusion coefficient of the gas contained in closed cell polyethylene foams under static loading is measured. To do this, compressive creep experiments were performed on low density polyethylene foams produced under a gas diffusion process. Density dependence of this coefficient has been analysed as well as the variatio...
Conference Paper
The cooling velocity of AA6061 aluminium foams has been simulated by Finite Elements Analysis (FEA) to reproduce the experimentally measured temperature drop in during a water quenching. Samples were characterized in a helical medical scanner and the density was determined by a novel image analysis procedure named Symmetrical to Skin Density Distri...

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Projects

Projects (2)
Archived project
1) Determination of the key parameters of the manufacturing process 2) Development and evaluation of improvement strategies 3) Characterization of the fabrication-structure-properties relationship and development of predictive models
Project
In order to get a good quality product, removing inclusions and impurities becomes necessary. The project aims to develop innovative methods and technologies for cleaning and conditioning the aluminium melt before casting.