Al-Cu铸造铝合金热处理工艺现状问题及解决措施分析

本文通过对铸造铝合金处理工艺的方式进行了适当阐述,并分析了当前铸造Al-Cu的热处理工艺试验及仿真现状,发现了关于热处理工艺、力学性能、微观组织的相关机制仍不明确,三者之间的关系较为模糊,难以为铝合金工艺的调控提供参考价值。基于此,本文对Al-Cu铸造铝合金的热处理工艺现状问题进行剖析,并提出了解决措施,从而解决铝合金热处理工艺存在的问题。

Al-Cu铸造铝合金热处理工艺研究现状及应对策略

以ZL205A为代表的Al-Cu系铸造铝合金具有高强度、高塑性和高抗蚀性等诸多优异特性,为使其进一步具备满足汽车车身、飞机舱体、柴油机缸体等工业铸件所需要的力学性能,通常需要采用热处理工艺来强化提高ZL205A铸件的力学性能。因此,简要介绍了高强度铸造铝合金材料热处理工艺优化方式,并着重分析了近年来Al-Cu系铸造铝合金热处理工艺试验和仿真模拟等研究的应用现状,发现目前研究过程中铝合金铸件的热处理工艺、微观组织以及力学性能之间的内在关联不够清晰,实验结果通常无法作为调控铝合金铸件综合性能的热处理工艺参考。最后提出了Al-Cu铸造铝合金热处理工艺应对策略,以启示挖掘出适用高强度铸造铝合金的热处理工艺方法。

Al-Cu-Mn-Fe-Ag-Zr合金的微观组织与室温和高温性能研究

Al-Cu合金具有低密度、耐热性好和潜在的高温稳定性等优点,广泛应用于汽车和航空航天等领域。为提高Al-Cu基铸造合金的耐热性能,本文制备了质量分数为Al-4%Cu-0.5%Mn-0.1%Fe-0.4%Ag-0.3%Zr(简称AC)的合金。采用OM和SEM分析了合金的微观形貌及化学成分,采用XRD分析了合金的物相结构,采用EBSD研究了晶粒形态与尺寸分布,采用TEM分析了合金在时效处理后的微观组织和析出相形态,采用高低温拉伸试验机进行了室温和高温力学性能测试。结果表明,AC合金在铸造过程中形成的金属间化合物主要包括Al_2Cu和Al_7Cu_2Fe,其中,Al_2Cu相在固溶处理后溶入基体中,并在时效处理后重新沉淀为θ′相,成为主要的强化相。此外,经T6热处理后,合金中还包含着T_(Mn)(Al_(20)Cu_2Mn_3)相,Ag元素固溶于铝基体中,而Zr元素则使得合金析出L1_2-Al_3Zr纳米相,其与θ′相存在位向关系。测试了合金在室温和高温(200、300和400℃)下的拉伸性能,对应屈服强度可分别达236、155、129和61 MPa。

再生铸造Al-Cu合金中富Fe相形态及控制研究现状

Fe是铝合金中的有害杂质元素,废铝再生时Fe将不断累积,控制富Fe相的危害是促进废铝回收和高效利用的关键环节。综述了铸造Al-Cu合金中富Fe相的研究现状,包括富Fe相的类型以及富Fe相的控制方法。结果表明,在AlCu合金中富Fe相的形貌与种类取决于不同的合金成分以及铸造工艺条件,其存在形式主要是针状β-Fe,Al3(FeMn)以及汉字状的α-Fe、AlmFe、Al6(FeMn)相。针状β-Fe被认为是热处理过程中最稳定的富Fe相,其他富Fe相将在热处理过程中发生固态相变,最终转变成β-Fe。改变富Fe相形态是控制富Fe相的有效方式,主要方法包括中和变质、改变熔铸工艺和施加外场作用,但是无法从根本上解决富Fe相增多对铝合金的危害。开发更加有效的中和变质剂或者高效、经济的除Fe技术是未来的发展方向。铸造Al-Cu合金中富Fe相的研究主要集中于重力铸造条件下的,而对于超声波、压力等特种条件下富Fe相的研究将受到重视。

Al-Cu系铸造铝合金中Cr元素在模拟酸雨溶液中腐蚀行为的研究

本文研究了在Al-Cu系铸造高强度铝合金中添加不同含量的铬Cr元素对铝合金腐蚀性能的影响。试验中采用5%NaCl＋0.8%Na2S2O4＋0.05%NaNO3配成模拟酸雨溶液,PH为4,在60℃温度下浸泡480 h,用失重法分析单位面积上损失的重量随Cr含量的变化情况,以考察Al-Cu系铸造铝合金的抗酸雨腐蚀能力。结果表明：H＋、Cl-和SO42-共同作用在铝合金表面产生较多的蚀坑,破坏其氧化膜,使腐蚀加剧,腐蚀产物形貌以团状和块状为主。铸造铝合金中所添加的Cr元素含量在0.05%~0.15%时,随其含量的增加对腐蚀的抑制作用逐渐增强;当Cr含量达到0.15%~0.2%时,对腐蚀的抑制作用最强,此时铝合金抗酸雨腐蚀性能最佳。

铸造Al-5Cu合金准固态断裂行为的研究

采用SEM观察手段并结合EDX分析 ,在合金的准固态区 ,通过观察Al 5Cu Mn合金准固态拉伸和热裂应力测试试样的断口形貌 ,研究了Ti、Ce等合金元素及其交互作用对Al 5Cu Mn合金准固态断裂行为的影响及其影响机理。通过对试验合金准固态力学性能的测试和大量SEM断口的观察分析研究 ,结果表明 ,Al 5Cu Mn中添加Ti元素可明显提高合金抗热裂能力 ,主要是由于其良好的细化晶粒效果 ;适量Ce元素的加入 ,不仅可细化晶粒 ,而且其在晶间富集形成的化合物还可有效改善低熔点共晶反应在准固态区的力学行为 ,对减小热裂倾向非常有利 ;Ti和Ce的综合作用对合金抗热裂水平的提高比单一元素更有效 ;热裂的产生首先表现为枝晶枝臂的屈服 ,其后的扩展则表现为脆性断裂占优的穿晶。

高强度铸造铝铜合金微观组织对性能的影响

研究了微观组织对ZL205A系铸造铝铜合金热处理后强度和塑性的影响。结果表明:影响该合金强度和塑性性能的微观组织主要是晶粒尺寸、晶内、晶界沉淀相,弥散析出相和未固溶相。晶界处主要是θ相、N相、初生T相的混合组织,当呈针状或条状时恶化合金性能,当呈半连续的骨骼对合金性能影响较小。晶内细小弥散的二次T相是主要强化相,当T相聚集长大会降低强度。过剩相θ相,当呈大块分布时降低合金塑性,当呈细小均匀分布时对合金性能影响较小。

电压和时间对铝铜铸造合金微弧氧化膜层的影响

在硅酸盐体系中,分别在不同的电压(450、500和550 V)下对4组试样进行不同时间(20、40、60和80 min)的微弧氧化实验,并结合试样生成膜层的厚度、硬度、耐蚀性能及SEM分析,探索不同电压和时间对Al-Cu系铸造合金表面微弧氧化陶瓷膜层的影响。结果表明,在550 V电压下,微弧氧化60 min时,材料表面获得最佳的微弧氧化膜层。

(Si+Mn)/Fe对Al-5Cu合金铸态组织及力学性能的影响

在Al-5Cu-0.3Fe高强铸造合金中添加Mn和Si,采用OM、SEM、EDS及DSC等分析方法研究(Si+Mn)/Fe质量比(K=3、4、5和6)对其铸态组织及力学性能的影响。结果表明:随着K值的增大,富Fe相形貌的变化趋势为针状→汉字状→粗大汉字状富Fe相聚集,富Fe相由针状Al 3FeMn向汉字状Al 6FeMn转变。Al-5.0Cu-0.3Fe-1Si-x Mn合金,K=4时,拉伸断口展现良好的塑性特征,合金的综合力学性能最佳,比K=3时抗拉强度和延伸率分别提高了22%和65%。Si和Mn元素对Al-5.0Cu-0.3Fe合金的富Fe相有良好的变质作用。适当减少Mn的添加量,而增加Si的含量,保持(Si+Mn)/Fe=4,有助于减少合金的孔洞缺陷,降低热裂敏感性,较好地调控富Fe相形貌和尺寸。

Al-4.5Cu合金热裂倾向的研究

为解决高强度铝铜合金的热裂倾向 ,通过合金化手段 ,采用正交设计 ,研究了Ti、Ce、La、Bi等合金元素及其交互作用对Al- 4 .5Cu合金热裂倾向的影响。结果表明 :在铝铜合金中加入微量的Ti、Ce、La、Bi能不同程度地提高合金热裂抗力。其中Ti是作为变质元素起作用的 ,通过细化晶粒增大晶粒接触面积 ,提高液膜结合强度 ,从而提高热裂抗力 ;Ce、La、Bi是表面活性元素 ,通过改变晶粒生长过程以及枝晶形貌和晶粒间结合形式来提高抗力。Ce、La、Bi的交互作用对铝铜合金的热裂抗力也有显著影响 ,其最佳配比为 :Ce :La :Bi=0 .2 % :0 .15 % :0 .10 %。

Low cycle fatigue behavior of T4-treated Al-Zn-Mg-Cu alloys prepared by squeeze casting and gravity die casting

Gravity die casting(GC) and squeeze casting(SC) T4-treated Al-7.0Zn-2.5Mg-2.1Cu alloys were employed to investigate the microstructures,mechanical properties and low cycle fatigue(LCF) behavior.The results show that mechanical properties of SC specimens are significantly better than those of GC specimens due to less cast defects and smaller secondary dendrite arm spacing(SDAS).Excellent fatigue properties are obtained for the SC alloy compared with the GC alloy.GC and SC alloys both exhibit cyclic stabilization at low total strain amplitudes(less than 0.4%) and cyclic hardening at higher total strain amplitudes.The degree of cyclic hardening of SC samples is greater than that of GC samples.Fatigue cracks of GC samples dominantly initiate from shrinkage porosities and are easy to propagate along them,while the crack initiation sites for SC samples are slip bands,eutectic phases and inclusions at or near the free surface.

Microstructure and mechanical properties of squeeze-cast Al−5.0Mg−3.0Zn−1.0Cu alloys in solution-treated and aged conditions

The microstructure and mechanical properties at different depths of squeeze-cast,solution-treated and aged Al−5.0Mg−3.0Zn−1.0Cu alloy were investigated.For squeeze-cast alloy,from casting surface to interior,the grain size ofα(Al)matrix and width of T-Mg32(AlZnCu)49 phase increase significantly,while the volume fraction of T phase decreases.The related mechanical properties including ultimate tensile strength(UTS)and elongation decrease from 243.7 MPa and 2.3%to 217.9 MPa and 1.4%,respectively.After solution treatment at 470℃ for 36 h,T phase is dissolved into matrix,and the grain size increases so that the UTS and elongation from surface to interior are respectively reduced from 387.8 MPa and 18.6%to 348.9 MPa and 13.9%.After further peak-aging at 120℃ for 24 h,numerous G.P.II zone andη′phase precipitate in matrix.Consequently,UTS values of the surface and interior increase to 449.5 and 421.4 MPa,while elongation values decrease to 12.5%and 8.1%,respectively.

Recrystallization behavior of cold rolled Al-Zn-Mg-Cu fabricated by twin roll casting

The Al-Zn-Mg-Cu alloy strip can be successfully fabricated by twin roll casting. In order to determine the effect of thickness reduction and heat treatment temperature on the recrystallization behavior, the strips were rolled and subsequently heat treated under various conditions. As a result, a fine grained microstructure （average grain size -13 μm, average grain aspect ratio -1.7） and high mechanical properties （UTS ≥360 MPa, δ ≥20%） were obtained by cold rolling with thickness reduction of 60% and heat treatment at 500 ℃ for 1 h. Also, the effect of the microstructure on mechanical properties of the Al-Zn-Mg-Cu alloy strip was discussed. Consequently, the low cost and high strength Al-Zn-Mg-Cu alloy sheet can be fabricated by twin roll casting by proper thermo-mechanical processes.

Effect of Cu addition on overaging behaviour,room and high temperature tensile and fatigue properties of A357 alloy

The aims of the present work are to evaluate the overaging behaviour of the investigated Cu-enriched alloy and to assess its mechanical behaviour,in terms of the tensile and fatigue strength,at room temperature and at 200℃,and to correlate the mechanical performance with its microstructure,in particular with the secondary dendrite arm spacing(SDAS).The mechanical tests carried out on the overaged alloy at 200℃ indicate that the addition of about 1.3 wt.%Cu to the A357 alloy enables to maintain ultimate tensile strength and yield strength values close to 210 and 200 MPa,respectively,and fatigue strength at about 100 MPa.Compared to the quaternary(Al−Si−Cu−Mg)alloy C355,the A357−Cu alloy has greater mechanical properties at room temperature and comparable mechanical behaviour in the overaged condition at 200℃.The microstructural analyses highlight that SDAS affects the mechanical behaviour of the peak-aged A357−Cu alloy at room temperature,while its influence is negligible on the tensile and fatigue properties of the overaged alloy at 200℃.

Effects of under-aging treatment on microstructure and mechanical properties of squeeze-cast Al-Zn-Mg-Cu alloy

The effects of under-aging treatment on the microstructure and mechanical properties of Al-Zn-Mg-Cu alloy produced by squeeze casting were investigated using optical microscopy(OM),X-ray diffractometry(XRD),scanning electron microscopy(SEM),transmission electron microscopy(TEM)and hardness and tensile testing.The results showed that most of secondary phases were dissolved intoα(Al)matrix while no significant grain growth happened under the condition of solution treatment at 470°C for 4 h.Due to the strengthening effect of GP zones,for alloys treated by under-aging process,the increase of aging time and aging temperature improved the ultimate tensile strength(UTS)and yield strength(YS),but decreased the elongation(δ)to some extent.By utilizing appropriate aging time and temperature,the best combination of strength and ductility could be obtained to fulfill the design requirements of automobile components.

Effect of T6I6 treatment on dynamic mechanical behaviour of Al-Si-Mg-Cu cast alloy and impact resistance of its cast motor shell

The effect of T6I6 treatment on the dynamic mechanical and microstructure behaviour of Al-Si-Mg-Cu cast alloy was investigated using split Hopkinson pressure bar(SHPB), transmission electron microscopy(TEM), and highresolution transmission electron microscopy(HRTEM). Besides, the impact resistances of T6I6 and T6 motor shells of new energy vehicles made of Al-Si-Mg-Cu cast alloy were compared using a trolley crash test. The results indicated that the main strengthening-phases of the T6 peak-aged and T6I6 peak-aged alloy were GP zone and β″ precipitates. T6I6treatment can increase the density and size of β″ precipitates in peak-aged alloy and enhance both its tensile strength(σb)and elongation(δ). The dynamic toughness values of T6I6 samples are 50.34 MJ/m^(3) at 2000 s^(-1) and 177.34 MJ/m^(3) at 5000 s^(-1) which are 20% and 12% higher than those of T6 samples, respectively. Compared with a T6 shell, the overall deformation of T6I6 shell is more uniform during the crash test. At an impact momentum of 3.5×10;kg·m/s, the T6I6shell breaks down at 0.38 s which is 0.10 s later than the T6 shell.

Effect of heat treatments on microstructure and mechanical properties of sand cast Al−2Li−2Cu−0.5Mg−0.2Sc−0.2Zr alloy

This study focused on modifying heat treatment schemes to enhance the mechanical properties of sand cast Al−2Li−2Cu−0.5Mg−0.2Sc−0.2Zr alloy.Different three-stage solution treatment schemes((460℃,32 h)+(520℃,24 h)+(530/540/550℃,4/12/24/32 h))and aging temperatures(125,175,225℃)were designed for comparison.The microstructure evolutions were analyzed by optical microscopy(OM),scanning electron microscopy(SEM)and transmission electron microscopy(TEM).The results showed that the three-stage solution treatment of(460℃,32 h)+(520℃,24 h)+(530℃,12 h)could dissolve most of the secondary phases.The TEM results illustrated that fineδ'(Al_(3)Li)particles were homogeneously distributed in the matrix after aging at 175℃for 8 h,accompanied by a small amount of lath-shaped S′(Al_(2)CuMg)and plate-like T_(1)(Al_(2)CuLi)phases.The best comprehensive properties of yield strength of 376 MPa,ultimate tensile strength of 458 MPa and elongation of 4.1%were obtained by the optimal heat treatment scheme((460℃,32 h)+(520℃,24 h)+(530℃,12 h)+(175℃,8 h)).

Evaluation of significant manufacturing parameters in lost foam casting of thin-wall Al-Si-Cu alloy using full factorial design of experiment

Controlling process parameters of lost foam casting （LFC） enables this process to produce defect-free complex shape castings. An experimental investigation on lost foam casting of an A1-Si-Cu cast alloy was carried out. The effects of pouting temperature, slurry viscosity, vibration time and sand size on surface finish, shrinkage porosity and eutectic silicon spacing of thin-wall casting were investigated. A full two-level factorial design of experimental technique was used to identify the significant manufacturing factors affecting the properties of casting. Pouring temperature was found as the most significant factor affecting A1-Si-Cu lost foam casting quality. It was shown that flask vibration time interacted with pouring temperature influenced euteetic silicon spacing and porosity percentage significantly. The results also revealed that the surface quality of the samples cast in fine sand moulds at higher pouring temperatures was almost unchanged, while those cast in coarse sand moulds possessed lower surface qualities. Furthermore, variation in slurry viscosity showed no significant effect on the evaluated properties compared to other parameters.