Hostname: page-component-586b7cd67f-t8hqh Total loading time: 0 Render date: 2024-11-24T02:41:32.908Z Has data issue: false hasContentIssue false
  • English
  • Français

Alloy development and reheating process exploration of Al–Si casting alloys with globular grains for thixoforming

Published online by Cambridge University Press:  02 May 2016

Jiao Jiao Wang ,
Zhong Min Zhang ,
A.B. Phillion ,
Shu Zhen Shang  and
Gui Min Lu
Jiao Jiao Wang*
Affiliation:
The Key Laboratory of Pressure Systems and Safety, Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
Zhong Min Zhang
Affiliation:
Research and Development Department, Shanghai Junsoft Digital Science & Technology Co., Ltd, Shanghai 200051, China
A.B. Phillion
Affiliation:
Materials Science and Engineering, McMaster University, Hamilton L8S 4L7, Ontario, Canada
Shu Zhen Shang
Affiliation:
The Key Laboratory of Pressure Systems and Safety, Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
Gui Min Lu*
Affiliation:
The Key Laboratory of Pressure Systems and Safety, Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
*
a) Address all correspondence to these authors. e-mail: [email protected]
b) e-mail: [email protected]
Get access

Abstract

A novel two-stage reheating process with new alloy design has been developed to improve the microstructure morphology of semisolid Al–Si casting aluminum alloy for thixoforming. The process consists of first reheating the material to the liquidus temperature, holding for 5 min, and then lowering to the predetermined two-stage reheating temperature between 843–863 K and holding for 10 min. The experimentally-obtained grain diameter, roundness, and the amount of liquid trapped within the solid phase were characterized, along with the microstructure obtained using the traditional feedstock reheating process. The Wilcox test (with α = 0.05) was then applied to statistically analyze the measured differences in the microstructures obtained using the two different processing routes. It was found that a refined near-spherical structure with uniform globule size, higher sphericity, lower coarsening rate constant, and less entrapped liquid was obtained via the new two-stage reheating process in comparison with the microstructure obtained using the traditional feedstock reheating process.

Keywords

castingmorphologymicrostructure
Type
Articles
Information
Journal of Materials Research , Volume 31 , Issue 16 , 29 August 2016 , pp. 2482 - 2492
Check for updates
Copyright
Copyright © Materials Research Society 2016 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

Campo, K.N., Proni, C.T.W., and Zoqui, E.J.: Influence of the processing route on the microstructure of aluminum alloy A356 for thixoforming. Mater. Charact. 85, 26 (2013).Google Scholar
Chen, Q., Zhao, Z., Chen, G., and Wang, B.: Effect of accumulative plastic deformation on generation of spheroidal structure, thixoformability and mechanical properties of large-size AM60 magnesium alloy. J. Alloys Compd. 632, 190 (2015).Google Scholar
Chen, G., Chen, Q., Wang, B., and Du, Z-m.: Microstructure evolution and tensile mechanical properties of thixoformed high performance Al–Zn–Mg–Cu alloy. Met. Mater. Int. 21(5), 897 (2015).Google Scholar
Chen, Z., Wang, T., Gao, L., Fu, H., and Li, T.: Grain refinement and tensile properties improvement of aluminum foundry alloys by inoculation with Al–B master alloy. Mater. Sci. Eng., A 553, 32 (2012).Google Scholar
Ai, C., Zhao, X., Liu, L., Zhang, H., Ru, Y., Pei, Y., Zhou, J., Li, S., and Gong, S.: Influence of withdrawal rate on last stage solidification path of a Mo-rich Ni3Al based single crystal superalloy. J. Alloys Compd. 623, 362 (2015).Google Scholar
Huang, K., Wang, N., Li, Y., and Marthinsen, K.: The influence of microchemistry on the softening behaviour of two cold-rolled Al–Mn–Fe–Si alloys. Mater. Sci. Eng., A 601, 86 (2014).Google Scholar
Jia, S., Zhang, D., and Nastac, L.: Experimental and numerical analysis of the 6061-based nanocomposites fabricated via ultrasonic processing. J. Mater. Eng. Perform. 24(6), 2225 (2015).Google Scholar
Ai, C., Li, S., Zhang, H., Liu, L., Ma, Y., Pei, Y., and Gong, S.: Effect of withdrawal rate on microstructure and lattice misfit of a Ni3Al based single crystal superalloy. J. Alloys Compd. 592, 164 (2014).Google Scholar
Du, K., Zhu, Q., Li, D., and Zhang, F.: Study of formation mechanism of incipient melting in thixo-cast Al–Si–Cu–Mg alloys. Mater. Charact. 106, 134 (2015).Google Scholar
Shang, S.Z., Wang, J.J., Lu, G.M., and Tang, X.L.: Study on the semi-solid thixo-diecasting process of aluminum alloys and die design. In Solid State Phenomena, Vol. 192 (Trans Tech Publications, Zurich, 2013); p. 460.Google Scholar
Chen, Q., Chen, G., Han, L., Hu, N., Han, F., Zhao, Z., Xia, X., and Wan, Y.: Microstructure evolution of SiC p/ZM6 (Mg–Nd–Zn) magnesium matrix composite in the semi-solid state. J. Alloys Compd. 656, 67 (2016).Google Scholar
Wang, J.J., Lu, G.M., and Yu, J.G.: Numerical analysis of semi-solid die-casting automobile part based on the thermo-visco-plastic constitutive relation. In Advanced Materials Research, Vol. 1096 (Trans Tech Publications, Zurich, 2015); p. 268.Google Scholar
Zhu, X., Jiang, W., Li, M., Qiao, H., Wu, Y., Qin, J., and Liu, X.: The effect of Mg adding order on the liquid structure and solidified microstructure of the Al–Si–Mg–P alloy: An experiment and ab initio study. Metal 5(1), 40 (2014).Google Scholar
Huang, K., Engler, O., Li, Y., and Marthinsen, K.: Evolution in microstructure and properties during non-isothermal annealing of a cold-rolled Al–Mn–Fe–Si alloy with different microchemistry states. Mater. Sci. Eng., A 628, 216 (2015).Google Scholar
Wang, J., Shang, S., Lu, G., and Yu, J.: Viscosity estimation of semi-solid alloys based on thermal simulation compression tests. Int. J. Mater. Res. 104(3), 255 (2013).Google Scholar
Zabler, S., Ershov, A., Rack, A., Garcia-Moreno, F., Baumbach, T., and Banhart, J.: Particle and liquid motion in semi-solid aluminium alloys: A quantitative in situ microradioscopy study. Acta Mater. 61(4), 1244 (2013).Google Scholar
Brabazon, D., Browne, D., and Carr, A.: Mechanical stir casting of aluminium alloys from the mushy state: Process, microstructure and mechanical properties. Mater. Sci. Eng., A 326(2), 370 (2002).Google Scholar
Tzimas, E. and Zavaliangos, A.: Mechanical behavior of alloys with equiaxed microstructure in the semisolid state at high solid content. Acta Mater. 47(2), 517 (1999).Google Scholar
Meng, Y., Sugiyama, S., and Yanagimoto, J.: Microstructural evolution during partial melting and semisolid forming behaviors of two hot-rolled Cr–V–Mo tool steels. J. Mater. Process. Technol. 225, 203 (2015).Google Scholar
Jia, S. and Nastac, L.: The influence of ultrasonic stirring on the solidification microstructure and mechanical properties of A356 alloy. Chem. Mater. Eng. 1(3), 69 (2013).Google Scholar
Zhu, L. and Sohn, H.Y.: Growth of 2M-wollastonite polycrystals by a partial melting and recrystallization process for the preparation of high-aspect-ratio particles. J. Ceram. Sci. Technol. 3(4), 169 (2012).Google Scholar
Moradi, M., Nili-Ahmadabadi, M., Poorganji, B., Heidarian, B., and Furuhara, T.: EBSD and DTA characterization of A356 alloy deformed by ECAP during reheating and partial re-melting. Metall. Mater. Trans. A 45(3), 1540 (2014).Google Scholar
Wang, J., Phillion, A., and Lu, G.: Development of a visco-plastic constitutive modeling for thixoforming of AA6061 in semi-solid state. J. Alloys Compd. 609, 290 (2014).Google Scholar
Padhy, G., Wu, C., Gao, S., and Shi, L.: Local microstructure evolution in Al 6061-T6 friction stir weld nugget enhanced by ultrasonic vibration. Mater. Des. 92, 710 (2016).Google Scholar
Chen, G., Chen, Q., Qin, J., and Du, Z-m.: Effect of compound loading on microstructures and mechanical properties of 7075 aluminum alloy after severe thixoformation. J. Mater. Process. Technol. 229, 467 (2016).Google Scholar
Birol, Y.: Comparison of thixoformability of AA6082 reheated from the as-cast and extruded states. J. Alloys Compd. 461(1), 132 (2008).Google Scholar
Wang, J., Brabazon, D., Phillion, A., and Lu, G.: An innovative two-stage reheating process for wrought aluminum alloy during thixoforming. Metall. Mater. Trans. A 46(9), 4191 (2015).Google Scholar
Kearney, A.: Properties of cast aluminum alloys. In Metals Handbook, 10th ed., Vol. 2 (ASM International, Materials Park, 1990); p. 152.Google Scholar
Liu, D., Atkinson, H.V., and Jones, H.: Thermodynamic prediction of thixoformability in alloys based on the Al–Si–Cu and Al–Si–Cu–Mg systems. Acta Mater. 53(14), 3807 (2005).Google Scholar
Abedi, A., Shahmiri, M., Esgandari, B.A., and Nami, B.: Microstructural evolution during partial remelting of Al–Si alloys containing different amounts of magnesium. J. Mater. Sci. Tech. 29(10), 971 (2013).Google Scholar
Salleh, M.S., Omar, M.Z., and Syarif, J.: The effects of Mg addition on the microstructure and mechanical properties of thixoformed Al–5%Si–Cu alloys. J. Alloys Compd. 621, 121 (2015).Google Scholar
Shankar, S., Riddle, Y.W., and Makhlouf, M.M.: Eutectic solidification of aluminum–silicon alloys. Metall. Mater. Trans. A 35(9), 3038 (2004).Google Scholar
Bolouri, A., Shahmiri, M., and Kang, C.G.: Coarsening of equiaxed microstructure in the semisolid state of aluminum 7075 alloy through SIMA processing. J. Mater. Sci. 47(8), 3544 (2012).Google Scholar
Dalgaard, P.: Introductory statistics with R (Springer Science & Business Media, Berlin, 2008); pp. 95 and 107.Google Scholar
Wang, Z., Ji, Z., Hu, M., and Xu, H.: Evolution of the semi-solid microstructure of ADC12 alloy in a modified SIMA process. Mater. Charact. 62(2011) 925–930.Google Scholar
Babaghorbani, P., Salarfar, S., and Nili-Ahmadabadi, M.: Kinetics of coarsening and solid sphericity during reheating of ductile iron and Al alloys. In Solid State Phenomena, Vol. 116–117, Kang, C.G., Kim, S.K., and Lee, S.Y., eds. (Trans Tech Publications, Zurich, 2006); pp. 205–208.Google Scholar