Combining Sr and Na additions in hypoeutectic Al-Si foundry alloys

From recent published data, it is still unclear whether combining additions of Na and Sr have synergistic effects or deleterious interactions, This paper clarifies the interactions between these two modifiers and investigates the effects of such interactions on alloy solidification and castability. It was found that combined additions of Sr and Na do not appear to cause improvement of the modification of the eutectic microstructure even after only a short period after addition. Na addition may promote Sr vaporization and/or oxidation kinetically. leading to a quicker loss of both modifiers, which is blamed for the rapid loss of the modification effect during melt holding. Quenching trials during the eutectic arrest indicate that addition of Sr into Na-modified melts does not alter the eutectic solidification behaviour The effect of Na on eutectic solidification dominates, and the eutectic is observed to evolve with a significant dependency on the thermal gradient, Combining Sr and Na additions produced no beneficial effects on porosity and casting defects. (c) 2005 Elsevier B.V. All rights reserved.

Dissolution, recovery and fade of Sr master alloys in Al-7Si-0.5Mg casting alloys

A number of commercial Al-Sr master alloys of differing Sr content and product form have been added to Al-7Si-0.5Mg casting alloy melts and held at constant temperature for periods up to 7 hours following the addition. The master alloys were added to achieve a specific Sr target level of 200 ppm, and the melts were held at various temperatures (most at 710ºC, but also 670, 690, 740 and 770ºC). A total of thirty six melt trials were conducted and during each trial chill-cast disc samples were taken throughout for subsequent chemical analysis. The Sr concentration versus time data of each trial has been considered in terms of Sr dissolution/recovery behaviour, as well as Sr loss/fade. Trends in the data are identified and discussed, and implications for industrial practices are suggested.

Recent advances in understanding the eutectic solidification in Al-Si foundry alloys

The formation of the Al-Si eutectic is generally the final stage of the solidification process of Al-Si foundry alloys. This means that it can be expected to have a significant impact on the feeding of a casting, and consequently the formation of casting defects, in particular porosity. Understanding and controlling the eutectic solidification process are therefore very important. This paper reviews the recent advances and unique techniques used in improving our understanding of both eutectic nucleation and growth. The role of different modifiers in controlling the eutectic solidification mechanisms is presented and the relationship between eutectic solidification mechanisms and porosity formation is outlined. This new approach to aluminium foundry alloy metallurgy is likely to form the basis for further optimisation of alloy performance and master alloys for the future.

Microstructure and mechanical properties of spray-formed Al-Si-Pb alloys

Liquid phase co-spray forming (LPCSF) was employed to produce two Al-Si-Pb alloys. The preforms thus obtained were then subjected to hot extrusion at different extrusion ratios. Following extrusion, the materials were tensile tested at room temperature. The distribution of Pb particles and the microstructural characterization in as-formed preforms and in the extruded rods were studied on the basis of SEM observation. The influence of the Pb content on the mechanical properties was investigated. (C) 2002 Published by Elsevier Science B.V.

As-cast morphology of iron-intermetallics in Al-Si foundry alloys

The as-cast three-dimensional morphologies of alpha-Al-15(Fe,Mn)(3)Si-2 and beta-Al5FeSi intermetallics were investigated by serial sectioning. Large beta-Al5FeSi intermetallics were observed to grow around pre-existing dendrite arms. The alpha-Al-15(Fe,Mn)(3)Si-2 intermetallic particle was observed to have a central polyhedral particle and an external highly convoluted three-dimensional structure. (c) 2005 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Effects of combined additions of Sr and AlTiB grain refiners in hypoeutectic Al-Si foundry alloys

Strontium is the most widely used and a very effective element for modifying the morphology of eutectic silicon, while Ti and B are commonly present in the commercial grain refiners used for Al-Si alloys. Systematic studies on the effects of combined additions of Sr and different AlTiB grain refiners on the Al + Si eutectic and primary aluminium solidification have been performed. While slight coarsening of both eutectic Si and primary aluminium grains occurs during holding, no obvious interactions are observed between Sr and AlTiB grain refiners when the addition level of grain refiners is low. As a result, a well-modified and grain refined structure was obtained. However, strong negative interactions between Sr and Al1.5Ti1.5B3 were observed as the addition level of the grain refiner increases. It was found that these interactions have a much more profound impact on the eutectic solidification than the primary Al solidification. The melt treated with combined additions of Sr and Al1.5Ti1.5B still shows good grain refinement efficiency even after losing its modification completely. The mechanism responsible for such negative interactions is further discussed. (c) 2006 Elsevier B.V. All rights reserved.

Effect of Si additions and heat treatment on the mechanical behaviour of an Al-5Mg casting alloy

Adding 1%Si to binary Al-5Mg alloy slightly increases the yield stress in comparison with the Si free alloy but dramatically reduces the ductility and tensile strength due to the formation of brittle eutectic Mg2Si and pi-Al8FeMg3Si6 particles. Adding 3%Si slightly reduces the yield stress, presumably due to some of the Mg being tied up in the Mg2Si, and further reduces the ductility due to the increased volume fraction of intermetallics. Solution heat treatment at 436degreesC decreases the yield stress of both Si containing alloys, and slightly increases the ductility in the alloy with 3%Si. Subsequent ageing at 180degreesC has no further effects on the strength or ductility. The loss in strength of the heat treated alloys seems to be due to overageing Of Mg2Si precipitates dispersed in the bulk of the alloy. (C) 2004 W. S. Maney Son Ltd.

Influência da convecção termossolutal na transição colunar/equiaxial em ligas Al-Si sob condições unidirecionais e transitórias de extração de calor

A relação entre macroestrutura e propriedades mecânicas de um material tem sido objeto de intensa investigação pois o tamanho dos grãos, a orientação cristalina e a distribuição dos mesmos exercem influência direta no comportamento mecânico dos produtos acabados. Assim, o entendimento dos fatores que influenciam a formação das zonas estruturais coquilhada, colunar e equiaxial nos materiais fundidos como, por exemplo, o sistema de liga, composição da liga, temperatura de vazamento, temperatura do molde, material do molde, coeficientes de transferência de calor na interface metal/molde, taxa de resfriamento, gradientes térmicos, dimensão da peça, presença de convecção no líquido, transporte de soluto, etc é de fundamental importância para a melhoria da eficiência do processo de fundição envolvido. Com base no conhecimento dos princípios termofísicos em que essas zonas são formadas, é possível manipular de forma bastante razoável a estrutura dos produtos fundidos e, conseqüentemente, as propriedades mecânicas dos mesmos. Tendo como principal foco a análise da mudança da zona colunar para a equiaxial, este trabalho apresenta um estudo teórico-experimental sobre a transição colunar/equiaxial (TCE) das ligas hipoeutéticas Al- 3%Si, Al-7%Si Al-9%Si solidificadas unidirecionalmente em um dispositivo horizontal refrigerado a água sob condições transientes de fluxo de calor. A condição de contato térmico na superfície de extração de calor foi padronizada como sendo polida. Os perfis térmicos foram medidos em diferentes posições do lingote e os dados foram armazenados automaticamente. Um método numérico é utilizado na determinação de variáveis térmicas de solidificação como coeficientes de transferência de calor na interface metal/molde (h_i), velocidades das isotermas liquidus (V_L), gradientes térmicos (G_L) e taxas de resfriamento (T_R) que influenciam diretamente a referida transição estrutural. Os resultados teóricos e experimentais apresentaram boa concordância. Um estudo comparativo entre os resultados obtidos neste trabalho e valores propostos na literatura para analisar a TCE durante a solidificação unidirecional vertical ascendente sob condições transientes de extração de calor das ligas investigadas, também é apresentado.

Stress states in individual Si particles of a cast Al-Si alloy: Micro-Raman analysis and microstructure based modeling

The stress states in Si particles of cast Al-Si based alloys depend on its morphology and the heat treatment given to the alloy. The Si particles fracture less on modification and fracture more in the heat treated condition. An attempt has been made in this work to study the effect of heat treatment and Si modification on the stress states of the particles. Such understanding will be valuable for predicting the ductility of the alloy. The stress states of Si particles are estimated by Raman technique and compared with the microstructure-based FEM simulations. Combination of Electron Back-Scattered Diffraction (EBSD) and frequency shift, polarized micro-Raman technique is applied to determine the stress states in Si particles with (111) orientations. Stress states are measured in the as-received state and under uniaxial compression. The residual stress, the stress in the elastic-plastic regime and the stress which causes fracture of the particles is estimated by Raman technique. FEM study demonstrates that the stress distribution is uniform in modified Si, whereas the unmodified Si shows higher and more complex stress states. The onset of plastic flow is observed at sharp corners of the particles and is followed by localization of strain between particles. Clustering of particles generates more inhomogeneous plastic strain in the matrix. Particle stress estimated by Raman technique is in agreement with FEM calculations. (C) 2014 Elsevier B.V. All rights reserved.

Semisolid structure formation and semisolid casting

Semisolid metal forming has now been accepted as a viable technology for production of components with complex shape and high integrity. The advantages of semisolid metal forming can only be achieved when the feedstock material has a non-dendritic semisolid structure. A controlled nucleation method has been developed to produce such structures for semisolid forming. By controlling grain nucleation and growth, fine-grained and non-dendritic microstructures that are suitable for semisolid casting can be generated. The method was applied to hypoeutectic and hypereutectic Al-Si casting alloys, Al wrought alloys and a Mg alloy. Parameters such as pouring temperature, cooling rate and grain refiner addition were controlled to achieve copious nucleation, nuclei survival and dendritic growth suppression during solidification. The influences of the controlling parameters on the formation of semisolid structure were different for each of these alloy groups. The as-cast structures were then partially remelted and isothermally held. Semisolid structures were developed and followed by semisolid casting into a stepped die.

Strength-ductility behaviour of Al-Si-Cu-Mg casting alloys in T6 temper

A comparative study of the mechanical properties of 20 experimental alloys has been carried out. The effect of different contents of Si, Cu, Mg, Fe and Mn, as well as solidification rate, has been assessed using a strength-ductility chart and a quality index-strength chart developed for the alloys. The charts show that the strength generally increases and the ductility decreases with an increasing content of Cu and Mg. Increased Fe (at Fe/Mn ratio 0.5) dramatically lowers the ductility and strength of low Si alloys. Increased Si content generally increases the strength and the ductility. The increase in ductility with increased Si is particularly significant when the Fe content is high. The charts are used to show that the cracking of second phase particles imposes a limit to the maximum achievable strength by limiting the ductility of strong alloys. The (Cu + Mg) content (at.%), which determines the precipitation strengthening and the volume fraction of Cu-rich and Mg-rich intermetallics, can be used to select the alloys for given strength and ductility, provided the Fe content stays below the Si-dependent critical level for the formation of pre-eutectic alpha-phase particles or beta-phase plates.