Effects of a novel refiner Al-3Ti-4.35La combined with Sr on microstructure and mechanical properties of as-cast A356 alloy

It is a practically significant issue to refine and modify industrial Al-Si casting alloy to improve its properties.In the present study,a novel refiner Al-3Ti-4.35La alloy,prepared by a melt-reaction method,was used,combined with Sr to refine the as-cast A356 alloy.Their effects on the as-cast microstructures and mechanical properties of A356 alloy were investigated.The results indicate that the combined addition of Al-3Ti-4.35La intermediate alloy and Sr can improve the microstructure and enhance the mechanical properties of A356 alloy.After adding 0.3wt.%Al-3Ti-4.35La and 0.03wt.%Sr to the as-cast A356 alloy,the average grain size ofα-Al decreases from 693.47μm to 264.13μm(a decrease of 61.91%),the secondary dendrite arm spacing(SDAS)is decreased by 47.8%from 32.09μm to 16.75μm,and the eutectic Si is transformed from an acicular structure to short rods and a granular structure.The ultimate tensile strength(UTS)and elongation(EL)of the as-cast A356 alloy modified by Al-3Ti-4.35La and Sr reach 216.3 MPa and 10.6%,which are enhanced by 29.54%and 134.66%compared with the unmodified alloy,respectively.The fracture mode is transformed from transgranular fracture to intergranular fracture,and the ductile toughness of the alloy is improved.After adding the Al-3Ti-4.35La and Sr,the undercooling for the nucleation ofα-Al and eutectic Si increases,leading to an accelerated nucleation rate and an increased number of nuclei,which shortens the duration of the eutectic reaction and consequently inhibits grain growth.

Effects of cooling rate on solution heat treatment of as-cast A356 alloy

The effect of cooling rate of the solidification process on the following solution heat treatment of A356 alloy was investigated,where the cooling rates of 96 K/s and 3 K/s were obtained by the step-like metal mold.Then the eutectic silicon morphology evolution and tensile properties of the alloy samples were observed and analyzed after solution heat treatment at 540 °C for different time.The results show that the high cooling rate of the solidification process can not only reduce the solid solution heat treatment time to rapidly modify the eutectic silicon morphology,but also improve the alloy tensile properties.Specially,it is found that the disintegration,the spheroidization and coarsening of eutectic silicon of A356 alloy are completed during solution heat treatment through two stages,i.e.,at first,the disintegration and spheroidization of the eutectic silicon mainly takes place,then the eutectic silicon will coarsen.

Effect of individual and combined additions of Al-5Ti-B,Mn and Sn on sliding wear behavior of A356 alloy

The effect of grain refiner, Mn and Sn additions on the sliding wear behavior of A356 aluminum alloys was investigated. The microstructure and worn surfaces of the studied alloys were characterized by optical microscopy（OM）, scanning electron microscopy（SEM）, and transmission electron microscopy（TEM）. The experimental results indicate that the alloy refined by Al-5Ti-B alloy exhibits equiaxed α（Al） dendrites and performs better wear resistance compared with the alloy without the grain refiner. Moreover, the addition of Mn can change the β-Al5 Fe Si phase to α-Al（Mn,Fe）Si phase and reduce the possibility of crack formation, thus improving the wear resistance. Sn added to A356 aluminum alloy forms Mg2 Sn precipitates after heat treatment. Therefore, the unrealizable precipitation hardening Mg2 Si phase and the softening β-Sn phase can reduce the hardness of the alloy, and finally reduce the wear resistance.

Effect of as-solidified microstructure on subsequent solution-treatment process for A356 Al alloy

For the compromise of mechanical properties and product cost, the end-chilled sand casting technique was applied to studying the microstructure evolution of A356 Al alloy with cooling rate and the effect of different as-cast microstructures on the subsequent solution-treatment process. The experimental results show that the secondary dendrite arm spacing (SDAS) of primaryα(Al), the size of eutectic Si and the volume fraction of Al?Si eutectic are reduced with increasing the cooling rate. Eutectic Si, subjected to solution treatment at 540 °C for 1 h followed by water quenching to room temperature, is completely spheroidized at cooling rate of 2.6 K/s; is partially spheroidized atcooling rate of 0.6 K/s; and is only edge-rounded at cooling rates of 0.22 and 0.12 K /s. Whilst the microhardness is also the maximum at cooling rate of 2.6 K/s. It consequently suggests that subjected to modification by high cooling rate, the eutectic Si is more readily modified, thus shortening the necessary solution time at given solution temperature, i.e., reducing the product cost.

Effects of moulding sands and wall thickness on microstructure and mechanical properties of Sr-modified A356 aluminum casting alloy

The effects of different cooling conditions on the mechanical properties and microstructures of a Sr-modified A356 （Al-7Si-0.3Mg） aluminum casting alloy were comparatively investigated using three moulding sands including quartz, alumina and chromite into multi-step blocks. The results show that the mechanical properties and microstructures using chromite sand are the best. As the cooling speed increases, the dendrite arm spacing （DAS） decreases significantly and the mechanical properties are improved, and the elongation is more sensitive to the cooling speed as compared with the tensile strength. The increase of the properties is primarily attributed to the decrease of the DAS and the increase of the free strontium atoms in the matrix. In particular, the regression models for predicting both the tensile strength and the elongation for Sr-modified A356 aluminum casting alloy were established based on the experimental data.

Preparation of semisolid A356 alloy slurry with larger capacity cast by serpentine channel

The integral microstructure of semisolid A356 alloy slurry with larger capacity cast by serpentine channel was studied and the influence of cooling ability of serpentine channel on the microstructure was investigated. The results indicate that ideal slurry with larger capacity can be prepared through serpentine channel with good cooling ability. When the serpentine channel was continuously cooled, both the longitudinal and the radial microstructure of the slurry was composed of granular primary phase and the integral microstructure uniformity of the slurry was good. However, uncooled serpentine channel can only produce larger slurry with fine grains in positions adjacent to its centre and with a large number of dendrites in positions close to its edge, thus, the radial microstructure of larger slurry is nonuniform. The pouring temperature is set up to 680 °C and the solid shell inside the channel can be avoided at this pouring temperature.

Influence of serpentine channel pouring process parameters on semi-solid A356 aluminum alloy slurry

Semi-solid A356 aluminum alloy slurry was prepared by using serpentine channel pouring process, and the influences of the channel diameters and pouring temperatures on the semi-solid A356 aluminum alloy slurry were investigated. The experimental results show that when the channel diameter is 20 and 25 mm, respectively, and the pouring temperature is 640-680 ℃, the average diameter of primary α（Al） grains in the prepared A356 aluminum alloy slurry is 50-75 and 55-78 μm, respectively, and the average shape factor of primary α（Al） grains is 0.89-0.76 and 0.86-0.72, respectively. With the decline in the pouring temperature, the microstructure of semi-solid A356 aluminum alloy slurry is more desirable and a serpentine channel with smaller diameter is also advantageous to the microstructure imProvement. During the preparation of semi-solid A356 aluminum alloy slurry, a large number of nuclei can be produced by the chilling effect of the serpentine channel, and owing to the combined effect of the chilled nuclei separation and melt self-stirring, primary α（Al） nuclei can be multiplied and spheroidized finally.

Wear and corrosion resistant coatings on surface of cast A356 aluminum alloy by plasma electrolytic oxidation in moderately concentrated aluminate electrolytes

Plasma electrolytic oxidation of a cast A356 aluminum alloy was carried out in aluminate electrolytes to develop wear and corrosion resistant coatings. Different concentrations of 2, 16 and 24 g/L NaAlO2 solutions and a silicate electrolyte （for comparison） were employed for the investigation. Wear performance and corrosion resistance of the coatings were evaluated by WC （tungsten carbide） ball-on-flat dry sliding tests and electrochemical methods, respectively. The results show that the coating formed for a short duration of 480 s in 24 g/L NaAlO2 solution generated the best protection. The coating sustained 30 N load for sliding time of 1800 s, showing very low wear rate of -4.5×10^-7 mm3/（N· m）. A low corrosion current density of -8.81×10^-9 A/cm2 was also recorded. Despite low α-Al2O3 content of the coating, the compact and nearly single layer nature of the coating guaranteed the excellent performances.

Porosity sensitivity of A356 Al alloy during fiber laser welding

In order to decrease the metallurgical porosity and keyhole-induced porosity during deep penetration laser welding of Al and its alloys, and increase the mechanical properties of work-piece, the effects of welding parameters such as laser power, welding speed and defocusing value on both kinds of porosities were systemically analyzed respectively, and the shape and fluctuation of plume of the keyhole were observed to reflect the stability of the keyhole. The results show that increasing laser power or decreasing laser spot size can lead to the rising of both number and occupied area of pores in the weld; meanwhile, the plume fluctuates violently over the keyhole, which is always companied with the intense metallic vapor, liquid metal spatter and collapsing in the keyhole, thus more pores are generated in the weld. The porosity in the weld reaches the minimum at welding velocity of 2.0 m/min when laser power is 5 kW and defocusing value is 0.

Effect of yttrium on the microstructure of a semi-solid A356 Al alloy

The semi-solid slurry of an A356 Al alloy, which was grain-fined by yttrium, was manufactured by low temperature pouring, The effects of grain-refining on the morphology and the grain size of the primary α phase in the semi-solid A356 Al alloy were researched. The results indicate that the semi-solid A356 AI alloy with particle-like and rosette-like primary α-Al can be prepared by low temperature pouring from a liquid grain-refined A356 alloy. The grain size and particle morphology of primary α-Al in the A356 Al alloy are markedly improved by the addition of 0.5 wt,% Y. The fining mechanism of Y on the morphology and grain size of the primary α-Al in the semi-solid A356 Al alloy was delved.

EFFECT OF GRAIN REFINING ON PRIMARYαPHASE IN SEMI-SOLID A356 ALLOY PREPARED BY LOW SUPERHEAT POURING AND SLIGHT ELECTROMAGNETIC STIRRING

The semi-solid slurry of A356 alloy, which is grain-refined by Al-Ti-B master alloy, is prepared by low superheat pouring and slight electromagnetic stirring. The effects of grain refining on the morphology and the grain size of the primary α phase in the slurry manufactured are researched. The results indicate that the slurry with particle-like and rosette-like primary α phases can be prepared by low superheat pouring and slight electromagnetic stirring from liquid A356 alloy grain-refined, in which the pouring temperature can be suitably raised. Compared with the A356 samples without grain refining, the grain size and particle morphology of primary α phase as well as the distribution of the grain with particle-like or rosette-like along radial in the ingot in A356 are markedly improved by grain refining.

New technique for preparing A356 alloy semisolid slurry and its rheo-diecast microstructure and properties

A new technique for preparing semisolid slurry,namely,distributary-confluence runner(DCR),was combined with die-casting(DC)to conduct rheological die-casting(R-DC)of A356 alloy.The mechanism of DCR for semisolid slurry preparation was determined via numerical simulations and experiments.The microstructure and mechanical properties of A356 alloys prepared via DC and R-DC were studied.High-quality slurry containing numerous primary α-Al(α1-Al)with an average size of 49μm and a shape factor of 0.81 could be prepared via DCR.Simulation results indicated that the unique flow state and physical field changes during slurry preparation were conducive to accelerating the uniformity of melt temperature and composition fields,nucleation exfoliation,and spherical growth.Compared with the alloy prepared via DC,the tensile strength,yield strength,and elongation of A356 alloy prepared via R-DC increased by 19%,15%,and 107%,respectively.

Gating system optimization of low pressure casting A356 aluminum alloy intake manifold based on numerical simulation

To eliminate the shrinkage porosity in low pressure casting of an A356 aluminum alloy intake manifold casting, numerical simulation on fi lling and solidifi cation processes of the casting was carried out using the ProCAST software. The gating system of the casting is optimized according to the simulation results. Results show that when the gating system consists of only one sprue, the fi lling of the molten metal is not stable; and the casting does not follow the sequence solidifi cation, and many shrinkage porosities are observed through the casting. After the gating system is improved by adding one runner and two in-gates, the fi lling time is prolonged from 4.0 s to 4.5 s, the fi lling of molten metal becomes stable, but this casting does not follow the sequence solidifi cation either. Some shrinkage porosity is also observed in the hot spots of the casting. When the gating system was further improved by adding risers and chill to the hot spots of the casting, the shrinkage porosity defects were eliminated completely. Finally, by using the optimized gating system the A356 aluminum alloy intake manifold casting with integrated shape and smooth surface as well as dense microstructure was successfully produced.

Effect of Mg and semi solid processing on microstructure and impression creep properties of A356 alloy

The effects of Mg and semi solid processing on the creep properties ofA356 A1 alloy were investigated. The results show that the dislocation climb controlled creep is the dominant creep mechanism and it is not affected by the semi solid processing and further addition of Mg. Mg improves the alloy creep properties probably by forming large Chinese script Mg2Si compounds at the interdendritic regions. The semi solid processed specimens exhibit better creep properties in comparison with the as cast ones. It is attributed to the reduction in the stacking fault energy resulting from the significant dissolution of Mg in the a（A1） phase.

Effect of various melt and heat treatment conditions on impact toughness of A356 aluminum alloy

The microstructure and impact behavior of A356 aluminum alloy were studied after melt treatment processes of grain refinement and modification under both non-heat treated and T6 heat treated conditions. The modification and grain refinement were done with the addition of Al-10%Sr and Al-5Ti-1B master alloys, respectively. All casting parameters were kept constant in order to focus on the influence of mentioned treatments. The results indicate that the eutectic silicon morphology is the main parameter to control the impact behavior of alloy. Consequently, the individual grain refinement of as-cast alloy does not improve the impact toughness as the modification does. While, simultaneous grain refinement and modification provide higher impact toughness in comparison with individual treatments. T6 heat treatment of the alloy improves the impact toughness under all melt-treated conditions. This is related to the further modification of eutectic silicon particles. To verify the results and clarify the mechanisms, three-point bending test and fractography were used to interpret the improvement of impact toughness of the alloy.

Microstructure characteristics and tensile property of ultrasonic treated-thixocast A356 alloy

Billets of A356 aluminum alloy were treated using ultrasonic vibrations during solidification.The billets were reheated to the semisolid state at different routes to optimize the procedure.Billets were,then,thixocast using a die casting machine.The results showed that the ultrasonic-treated billets exhibited finely distributed α（Al） globules after reheating and thixocasting.The thixocast ultrasonic-treated billets showed higher ultimate tensile strength and elongation compared with the untreated billets.Moreover,the thixocast parts showed a tendency to ductile fracture under tension when made from ultrasonic-treated billets,while those made of untreated billets showed brittle fracture with obvious straight facets.These results revealed the feasibility and competence of ultrasonic melt treatment as a potential route for preparing billets for thixocasting.

Effect of NaOH on plasma electrolytic oxidation of A356 aluminium alloy in moderately concentrated aluminate electrolyte

Plasma electrolytic oxidation(PEO)of cast A356 aluminum alloy was carried out in 32 g/L NaAlO_(2) with the addition of different concentrations of NaOH.The stability of the aluminate solution is greatly enhanced by increasing the concentration of NaOH.However,corresponding changes in the PEO behaviour occur due to the increment of NaOH concentration.Thicker precursor coatings are required for the PEO treatment in a more concentrated NaOH electrolyte.The results show that the optimal NaOH concentration is 5 g/L,which improves the stability of storage electrolyte to about 35 days,and leads to dense coatings with high wear performance(wear rate:4.1×10^(−7) mm^(3)·N^(−1)·m^(−1)).

Filling ability of semi-solid A356 aluminum alloy slurry in rheo-diecasting

The effects of slurry temperature, injection pressure, and piston velocity on the rheo-filling ability of semisolid A356 alloys were studied by the reho-diecasting methods. The results show that the slurry temperature of the semi-solid A356 aluminum alloy has an important effect on the filling ability; the higher the slurry temperature, the better is the filling ability, and the appropriate slurry temperature for rheo-filling is in the range of 585-595℃. The injection pressure also has a great effect on the filling ability, and it is appropriate to the rheo-filling when the injection pressure is in the range of 15-25 MPa. The piston velocity also has a great effect on the filling ability, and it is appropriate to the rheo-filling when the piston velocity is in the range of 0.072-0.12 m/s. The filling ability of the slurry prepared by low superheat pouring with weak electromagnetic stirring is very good and the microstructural distribution in the rheo-formed die castings is homogeneous, which is advantageous to the high quality die casting. 2008 University of Science and Technology Beijing. All rights reserved.

Research on fractal characteristics of primary phase morphology in semi-solid A356 alloy

Semi-solid slurry of A356 alloy was prepared by low superheat pouring and slightly electromagnetic stirring, and the fractal characteristics of morphology in semi-solid primary phase was researched. The fractal dimensions of primary phase morphology in the semi-solid A356 alloy were calculated by the program written to calculate the fractal dimensions of box-counting in the image of solid phase morphology in semi-solid metal slurry. The results indicated that the morphology of primary phase in semi-solid A356 prepared by low superheat pouring and slightly electromagnetic stirring is characterized by fractal dimension, and the primary phase morphology obtained by the different processing parameters has different fractal dimensions. The morphology of primary phase at the different position of ingot has different fractal dimensions, which reflected the effect of solidified conditions at different positions in the same ingot on the morphology of semi-solid primary phase. Solidification of semi-solid alloy is a course of change in fractal dimension.

Semi-solid A356 alloy slurry for rheocasting prepared by a new process

To obtain the semi-solid slurry with uniform and fine structure morphology that satisfies the requirement of rheocasting process, a new process for preparing semi-solid AI alloy slurry was developed, in which local chilling was combined with low superheat pouring and slight electromagnetic stirring （LSPSEMS）. The morphology and the size of primary a-AI in the A356 alloy slurry prepared with the new process, i.e., LSPSEMS with local chilling, were investigated using MIAPS image analyzing software, and the grain refinement mechanism was discussed. The results indicate that the semi-solid primary phase consists of particle-like or globular-like a-AI, and the morphology and grain size of primary a-AI in the slurry can be markedly improved by the new process. The fine primary a-AI distributes uniformly in the slurry, which satisfies the requirement of rheocasting. Compared with the alloy prepared by LSPSEMS, the average equal-area-circle grain diameter of primary a-AI in semi-solid A356 alloy ingot prepared by the new process is decreased from 85.6μm to 68.8 μm at the central area, 112.6 μm to 77.6 μm at the transition area and is 84.7 μm in the edge area, respectively. The corresponding shape factor of primary a-AI is increased from 0.78 to 0.83, 0.54 to 0.77 and 0.28 to 0.59, respectively. In addition, the pouring temperature could be suitably raised from 620-630℃ of the traditional process to 650℃ using this technique, which is convenient for practical operation. The mechanism of grain refinement, in the new process, is that the local chilling quickens up the temperature decrease in the center of the melt. The nuclei could not grow up in a short time so the finer grains are formed in the melt.