A High-Fe Aluminum Matrix Welding Filler Metal for Hardfacing Aluminum-Silicon Alloys

A high Fe containing aluminum matrix filler metal for hardfacing aluminum silicon alloys has been developed by using iron,nickel,and silicon as the major strengthening elements,and by measuring mechanical properties,room temperature and high temperature wear tests,and microstructural analysis.The filler metal,which contains 3.0%-5.0% Fe and 11.0%-13.0% Si,exhibits an excellent weldability.The as cast and as welded microstructures for the filler metal are of uniformly distribution and its dispersed network of hard phase is enriched with Al Si Fe Ni.The filler metal shows high mechanical properties and wear resistance at both room temperature and high temperatures.The deposited metal has a better resistance to impact wear at 220℃ than that of substrate Al Si Mg Cu piston alloy;at room temperature,the deposited metal has an equivalent resistance to slide wear with lubrication as that of a hyper eutectic aluminum silicon alloy with 27% Si and 1% Ni.

Microstructure and properties of high silicon aluminum alloy with 2% Fe prepared by rheo-casting

The morphology changes of both Fe-containing intermetallic compounds and the primary Si phase of Al-20Si-2Fe- 2Cu-0.4Mg-1.0Ni-0.5Mn （mass fraction, %） alloy produced by semi-solid rheo-diecasting were studied. The semi-solid slurry of high silicon aluminum alloy was prepared by direct ultrasonic vibration （DUV） which was imposed on the alloy near the liquidus temperature for about 2 rain. Then, standard test samples of 6.4 mm in diameter were formed by semi-solid rheo-diecasting. The results show that the DUV treatment suppresses the formation of needle-like ,β-Al5（Fe,Mn）Si phase, and the Fe-containing intermetallic compounds exist in the form of fine Al4（Fe, Mn）Si2 particles. Additionally, the primary Si grows up as fine and round particles with uniform distribution in α（Al） matrix of this alloy under DUV treatment. The tensile strengths of the samples at the room temperature and 573 K are 230 MPa and 145 MPa, respectively. The coefficient of thermal expansion （CTE） between 25 ℃ and 300 ℃ is 16.052 8×10^-6 ℃^-1, and the wear rate is 1.55%. The hardness of this alloy with 2% Fe reaches HB146.3. It is discovered that modified morphology and uniform distribution of the Fe-containing intermetallic compounds and the primary Si phase are the main reasons for reducing the CTE and increasing the wear resistance of this alloy.

Modification Effect of P+Sr+Ce Compound on Microstructure and Properties of Cast High Silicon Heat-Resist Aluminum Alloy

The P ＋ Sr ＋ Ce compound modification technologies of as-cast Al-21Si-1.5Cu-1.5Ni- 2.5Fe- 0.5Mg alloy were investigated by means of orthogonal test. Orthogonal test results show that 3% （CaH2PO4 ＋ 2CASO4）＋ 0.2%Sr ＋ 0.2%Ce is the optimum additive of modification treatment which can fine eutectic and primary silicon also can change the form of rich-iron phase at same time. The needle form of rich-iron phase is Al9FeSi3, which is prored by X-ray diffraction analysis and X-ray energy spectrum analysis. After compound modification treatment, the needle form of rich-iron phase disappeared and the fish bone form of rich-iron and rich-Ce phase that is AlsCeFe emerged. Both at room temperature and at 300℃, the tensile strength of the alloy after the modification treatment with the optimum additive is 30% lager than that of the alloy unmodified. Observed by SEM, the brittle intercrystalline tensile fracture changed into a blended one in which has many dimples.

Effects of La addition on the microstructure and tensile properties of Al-Si-Cu-Mg casting alloys

The effects of La addition on the microstructure and tensile properties of B-refmed and Sr-modified A1-1 1Si-1.5Cu-0.3Mg cast- ing alloys were investigated. With a trace addition of La （0.05wt%-0. lwt%）, the mutual poisoning effect between B and Sr can be neutral- ized by the formation of LaB6 rather than SrB6. By employing a La/B weight ratio of 2：1, uniform microstructures, which are characterized by well refined ct-A1 grains and adequately modified eutectic Si particles as well as the incorporation of precipitated strengthening intermetal- lics, are obtained and lead to appreciable tensile properties with an ultimate tensile strength of 270 MPa and elongation of 5.8%.

Reduction in secondary dendrite arm spacing in cast eutectic Al–Si piston alloys by cerium addition

The effects of Ce on the secondary dendrite arm spacing（SDAS） and mechanical behavior of Al-Si-Cu-Mg alloys were investigated. The reduction of SDAS at different Ce concentrations was evaluated in a directional solidification experiment via computer-aided cooling curve thermal analysis（CA-CCTA）. The results showed that 0.1wt%-1.0wt% Ce addition resulted in a rapid solidification time, ？ts, and low solidification temperature, ？T_S, whereas 0.1wt% Ce resulted in a fast solidification time, Δ^（ta-Al）, of the α-Al phase. Furthermore, Ce addition refined the SDAS, which was reduced to approximately 36%. The mechanical properties of the alloys with and without Ce were investigated using tensile and hardness tests. The quality index（Q） and ultimate tensile strength of（UTS） Al-Si-Cu-Mg alloys significantly improved with the addition of 0.1wt% Ce. Moreover, the base alloy hardness was improved with increasing Ce concentration.

Refinement of primary Si grains in Al–20%Si alloy slurry through serpentine channel pouring process

In this study, a serpentine channel pouring process was used to prepare the semi-solid A1-20%Si alloy slurry and refine primary Si grains in the alloy. The effects of the pouring temperature, number of curves in the serpentine channel, and material of the serpentine channel on the size of primary Si grains in the semi-solid A1-20%Si alloy slurry were investigated. The results showed that the pouting temperature, number of the curves, and material of the channel strongly affected the size and distribution of the primary Si grains. The pouring tempera- ture exerted the strongest effect, followed by the number of the curves and then the material of the channel. Under experimental conditions of a four-curve copper channel and a pouring temperature of 701℃, primary Si grains in the semi-solid A1-20%Si alloy slurry were refined to the greatest extent, and the lath-like grains were changed into granular grains. Moreover, the equivalent grain diameter and the average shape coefficient of primary Si grains in the satisfactory semi-solid A1-20%Si alloy slurry were 24.4 μm and 0.89, respectively. Finally, the re- finement mechanism and distribution rule of primary Si grains in the slurry prepared through the serpentine channel pouring process were analyzed and discussed.

Strength and elongation of spray formed Al–Si–Pb alloys

The strength and elongation to fracture of spray deposited Al-Si-Pb alloys were studied as a function of lead content, silicon content, and distance from the centre to periphery of the deposit. It is found that the ultimate tensile strength, proof stress and elongation to fracture decrease, linearly and exponentially, with the increase in lead content and porosity of the deposit, respectively. Both the strengths and elongation to fracture linearly increase with increasing distance from the centre to periphery of the deposit. The ultimate tensile strength and proof stress are higher at a higher silicon content and they have a linear relationship with the hardness of the deposit.

Effect of Mg and Si on infiltration behavior of Al alloys pressureless infiltration into porous SiCp preforms

The effect of Mg and Si additon to Al matrix on infiltration kinetics and rates of Al alloys pressureless infiltration into porous SiCp preform was investigated by observing the change of infiltration distance with time as the Al alloys infiltrate into SiCp preforms at different temperatures.The results show that infiltration of SiCp preforms by Al melt is a thermal activation process and there is an incubation period before the infiltration becomes stable.With the increase of Mg content in the Al alloys from 0wt% to 8wt%,the infiltration will become much easier,the incubation period becomes shorter and the infiltration rate is faster,but these effects are not obvious when the Mg content is higher than 8wt%.As for Si addition to the Al alloys,it has no obvious effect on the incubation period,but the infiltration rate increases markedly with the increase of Si content from 0wt% to 12wt% and the rate has no obvious change when the content is bigger than 12wt%.The effect of Mg and Si on the incubation period is related to the infiltration mechanism of Al pressureless infiltration into SiCp preforms and their impact on the infiltration rate is a combined result from viscosity and surface tension of Al melt and SiC-Al wetting ability.

Improvement in mechanical properties of hypereutectic Al-Si-Cu alloys through sonosolidified slurry

For the wider applications,it is necessary to improve the ductility as well as the strength and wear-resistance of hypereutectic AlSi-Cu alloys,which are typical light-weight wear-resistant materials.An increase in the amounts of primary silicon particles causes the modified wear-resistance of hypereutectic Al-Si-Cu alloys,but leads to the poor strength and ductility.It is known that dual phase steels composed of hetero-structure have succeeded in bringing contradictory mechanical properties of high strength and ductility concurrently.In order to apply the idea of hetero-structure to hypereutectic Al-Si-Cu alloys for the achievement of high strength and ductility along with wear resistance,ultrasonic irradiation of the molten metal during the solidification,which is called sono-solidification,was carried out from its molten state to just above the eutectic temperature.The sono-solidified Al-17Si-4Cu alloy is composed of hetero-structure,which are,hard primary silicon particles,soft non-equilibrium a-Al phase and the eutectic region.Rheo-casting was performed at just above the eutectic temperature with sono-solidified slurry to shape a disk specimen.After the rheo-casting with modified sonosolidified slurry held for 45 s at 570 oC,the quantitative optical microscope observation exhibits that the microstructure is composed of 18area%of hard primary silicon particles and 57area%of soft a-Al phase.In contrast,there exist only 5 area%of primary silicon particles and no a-Al phase in rheo-cast specimen with normally solidified slurry.Hence the tensile tests of T6 treated rheo-cast specimens with modified sono-solidified slurry exhibit improved strength and 5%of elongation,regardless of having more than 3 times higher amounts of primary silicon particles compared to that of rheo-cast specimen with normally solidified slurry.

Preparation of Al-Si-Ti Master Alloys by Electrolysis of Silica and Titania in Cryolite-Alumina Melts

Aluminum silicon titanium master alloys were prepared in the laboratory by electrolysis of silica and titania dissolved in cryolite alumina melts. Alloys containing up to 12 mass% Si and 2.6 mass% Ti were formed after about 90 min of electrolysis at 950℃. The current efficiency for the preparation of the Al Si Ti alloys varied with time, temperature and cathodic current density. It is concluded that this electrolytic method may be an interesting alternative to the direct metal mixing process for formation of Al Si Ti master alloys.

Mechanical properties and friction behaviors of CNT/AlSi_(10)Mg composites produced by spark plasma sintering

The mechanical properties and friction behaviors of CNT/AlSi10Mg composites produced by spark plasma sintering (SPS) were investigated. The results showed that the densities of the sintered composites gradually increased with increasing sintering temperature and that the highest microhardness and compressive strength were achieved in the specimen sintered at 450A degrees C. CNTs dispersed uniformly in the Al-Si10Mg matrix when the addition of CNTs was less than 1.5wt%. However, when the addition of CNTs exceeded 1.5wt%, the aggregation of CNTs was clearly observed. Moreover, the mechanical properties (including the densities, compressive strength, and microhardness) of the composites changed with CNT content and reached a maximum value when the CNT content was 1.5wt%. Meanwhile, the minimum average friction coefficient and wear rate of the CNT/AlSi10Mg composites were obtained with 1.0wt% CNTs.

Microstructure and properties of a wear resistant Al-25Si-4Cu-1Mg coating prepared by supersonic plasma spraying

A high content silicon aluminum alloy(Al-25Si-4Cu-1Mg)coating was prepared on a 2A12 aluminum alloy by supersonic plasma spraying.The morphology and microstructure of the coating were observed and analyzed.The hardness,elastic modulus,and bonding strength of the coating were measured.The wear resistance of the coating and 2A12 aluminum alloy was studied by friction and wear test.The results indicated that the coating was compact and the porosity was only 1.5%.The phase of the coating was mainly composed ofα-Al andβ-Si as well as some hard particles(Al9Si,Al3.21Si0.47,and CuAl2).The average microhardness of the coating was HV 242,which was greater than that of 2A12 aluminum alloy(HV 110).The wear resistance of the coating was superior to 2A12 aluminum alloy.The wear mechanism of the 2A12 aluminum alloy was primarily adhesive wear,while that of the coating was primarily abrasive wear.Therefore,it is possible to prepare a high content silicon aluminum alloy coating with good wear resistance on an aluminum alloy by supersonic plasma spraying.