In-situ observation of porosity formation during directional solidification of Al-Si casting alloys

In-situ observation of porosity formation during directional solidification of two Al-Si alloys (7%Si and 13%Si) was made by using of micro-focus X-ray imaging.In both alloys,small spherical pores initially form in the melt far away from the eutectic solid-liquid (S/L) interface and then grow and coagulate during solidification.Some pores can float and escape from the solidifying melt front at a relatively high velocity.At the end of solidification,the remaining pores maintain spherical morphology in the near eutectic alloy but become irregular in the hypoeutectic alloy.This is attributed to different solidification modes and aluminum dendrite interactions between the two alloys.The mechanism of the porosity formation is briefly discussed in this paper.

Effect of slow shot speed on externally solidified crystal,porosity and tensile property in a newly developed high-pressure die-cast Al-Si alloy

The effect of slow shot speed on externally solidified crystal(ESC),porosity and tensile property in a newly developed high-pressure die-cast Al-Si alloy was investigated by optical microscopy(OM),scanning electron microscopy(SEM)and laboratory computed tomography(CT).Results showed that the newly developed AlSi9MnMoV alloy exhibited improved mechanical properties when compared to the AlSi10MnMg alloy.The AlSi9MnMoV alloy,which was designed with trace multicomponent additions,displays a notable grain refining effect in comparison to the AlSi10MnMg alloy.Refining elements Ti,Zr,V,Nb,B promote heterogeneous nucleation and reduce the grain size of primaryα-Al.At a lower slow shot speed,the large ESCs are easier to form and gather,developing into the dendrite net and net-shrinkage.With an increase in slow shot speed,the size and number of ESCs and porosities significantly reduce.In addition,the distribution of ESCs is more dispersed and the net-shrinkage disappears.The tensile property is greatly improved by adopting a higher slow shot speed.The ultimate tensile strength is enhanced from 260.31 MPa to 290.31 MPa(increased by 11.52%),and the elongation is enhanced from 3.72%to 6.34%(increased by 70.52%).

I-DCGAN and TOPSIS-IFP:A simulation generation model for radiographic flaw detection images in light alloy castings and an algorithm for quality evaluation of generated images

The intelligent detection technology driven by X-ray images and deep learning represents the forefront of advanced techniques and development trends in flaw detection and automated evaluation of light alloy castings.However,the efficacy of deep learning models hinges upon a substantial abundance of flaw samples.The existing research on X-ray image augmentation for flaw detection suffers from shortcomings such as poor diversity of flaw samples and low reliability of quality evaluation.To this end,a novel approach was put forward,which involves the creation of the Interpolation-Deep Convolutional Generative Adversarial Network(I-DCGAN)for flaw detection image generation and a comprehensive evaluation algorithm named TOPSIS-IFP.I-DCGAN enables the generation of high-resolution,diverse simulated images with multiple appearances,achieving an improvement in sample diversity and quality while maintaining a relatively lower computational complexity.TOPSIS-IFP facilitates multi-dimensional quality evaluation,including aspects such as diversity,authenticity,image distribution difference,and image distortion degree.The results indicate that the X-ray radiographic images of magnesium and aluminum alloy castings achieve optimal performance when trained up to the 800th and 600th epochs,respectively.The TOPSIS-IFP value reaches 78.7%and 73.8%similarity to the ideal solution,respectively.Compared to single index evaluation,the TOPSIS-IFP algorithm achieves higher-quality simulated images at the optimal training epoch.This approach successfully mitigates the issue of unreliable quality associated with single index evaluation.The image generation and comprehensive quality evaluation method developed in this paper provides a novel approach for image augmentation in flaw recognition,holding significant importance for enhancing the robustness of subsequent flaw recognition networks.

Microstructure and mechanical properties of Co-28Cr-6Mo-0.22C investment castings by current solution treatment

This study examined the impact of current solution treatment on the microstructure and mechanical properties of the Co-28Cr-6Mo-0.22C alloy investment castings.The findings reveal that the current solution treatment significantly promotes the dissolution of carbides at a lower temperature.The optimal conditions for solution treatment are determined as a solution temperature of 1,125°C and a holding time of 5.0 min.Under these parameters,the size and volume fraction of precipitated phases in the investment castings are measured as6.2μm and 1.1vol.%.The yield strength,ultimate tensile strength,and total elongation of the Co-28Cr-6Mo-0.22C investment castings are 535 MPa,760 MPa,and 12.6%,respectively.These values exceed those obtained with the conventional solution treatment at 1,200°C for 4.0 h.The findings suggest a phase transformation of M_(23)C_(6)→σ+C following the current solution treatment at 1,125°C for 5.0 min.In comparison,the traditional solution treatment at 1,200°C for 4.0 h leads to the formation of M_(23)C_(6)and M_(6)C carbides.It is noteworthy that the non-thermal effect of the current during the solution treatment modifies the free energy of both the matrix and precipitation phase.This modification lowers the phase transition temperature of the M_(23)C_(6)→σ+C reaction,thereby facilitating the dissolution of carbides.As a result,the current solution treatment approach achieves carbide dissolution at a lower temperature and within a significantly shorter time when compared to the traditional solution treatment methods.

A comparative study on Sn macrosegregation behavior of ternary Al-Sn-Cu alloys prepared by gravity casting and squeeze casting

A comprehensive study on Sn macrosegregation behavior in ternary Al-Sn-Cu alloys was carried out by comparative analysis between gravity casting and squeeze casting samples.The microstructure and Sn distribution of the castings were characterized by metallography,scanning electron microscopy(SEM),energy-dispersive X-ray(EDX)spectroscopy,and a direct reading spectrometer.Results show that there are obvious differences in Sn morphology between gravity casting and squeeze casting alloys.Under squeeze casting condition,the grain size of the casting is smaller and the distribution ofβ(Sn)is uniform.This effectively reduces the segregation of triangular grain boundary as well as the segregation of Sn.The segregation types of Sn in gravity casting and squeeze casting samples are obviously different.The upper surfaces of gravity casting samples show severe negative segregation,while all the lower surfaces have positive segregation.Compared with gravity casting,squeeze casting solidifies under isostatic pressure.Due to the direct contact between the upper surface of the casting and the mold,the casting solidifies faster under higher undercooling degree and pressure.Consequently,the uniform distribution of Sn reduces the segregation phenomenon on the surface of the casting.

Effects of magnesium and copper additions on tensile properties of Al-Si-Cr die casting alloy under as-cast and T5 conditions

Aluminum high pressure die casting(HPDC)technology has evolved in the past decades,enabling stronger and larger one-piece casting with significant part consolidation.It also offers a higher design freedom for more mass-efficient thin-walled body structures.For body structures that require excellent ductility and fracture toughness to be joined with steel sheet via self-piercing riveting(for instance,shock towers and hinge pillars,etc.),a costly T7 heat treatment comprising a solution heat treatment at elevated temperatures(450℃-500℃)followed by an over-ageing heat treatment is needed to optimize microstructure for meeting product requirement.To enable cost-efficient mass production of HPDC body structures,it is important to eliminate the expensive T7 heat treatment without sacrificing mechanical properties.Optimizing die cast alloy chemistry is a potential solution to improve fracture toughness and ductility of the HPDC components.The present study intends to tailor the Mg and Cu additions for a new Al-Si-Cr type die casting alloy(registered as A379 with The Aluminum Association,USA)to achieve the desired tensile properties without using T7 heat treatment.It was found that Cu addition should be avoided,as it is not effective in enhancing strength while degrades tensile ductility.Mg addition is very effective in improving strength and has minor impact on tensile ductility.The investigated Al-Si-Cr alloy with a nominal composition of Al-8.5wt.%Si-0.3wt.%Cr-0.2wt.%Fe shows comparable tensile properties with the T7 treated AlSi10MnMg alloy which is currently used for manufacturing shock towers and hinge pillars.

Recent advances on grain refinement of magnesium rare-earth alloys during the whole casting processes:A review

High-performance cast magnesium rare-earth(Mg-RE) alloys are one of the most important materials among all developed Mg alloy families, and have shown great potential in military and weapons, aerospace and aviation, orthopedic implants, etc. Controlling grain size and distribution of it is key to the promising mechanical performance of Mg-RE alloy casting components. During the casting of a real component, nearly every procedure in the fabrication process will influence the grain refinement effect. The procedure may include and may not be limited to the chemical inoculations, possibly applied physical fields, the interfere between grain refiner and purifications, and the casting techniques with different processing parameters. This paper reviews the recent advances and proposed future developments in these categories on grain refinement of cast Mg-RE alloys. The review will provide insights for the future design of grain refinement techniques,the choosing of processing parameters, and coping strategies for the failure of coarsening for cast Mg-RE components with high quality and good performance.

Eutectic Solidification in Near-eutectic Al-Si Casting Alloys

Eutectic solidification in near-eutectic Al-13 wt pct Si casting alloys and the effect of trace addition of boron or strontium on it have been investigated using thermal analysis and microstructural characterization. In unmodified alloy, dual eutectic structure has been observed. The coarse eutectic （dendrite-like Al＋ coarse Si flakes） is formed above the equilibrium temperature of eutectic （Al＋Si） reaction （577℃）. The coarse eutectic （CE） grains nucleate from the primary silicon particles formed earlier due to local enrichment of silicon solute and grow in a divorced mode between the dendritic Al phase and large silicon flakes. The fine eutectic （FE） grains nucleate later on other potential sites activated by melt undercooling and grow in coupled-growing mode with the silicon crystals as fine flakes. The formation of the FE grains is favored in the alloys containing boron because of a great number of potential nucleation sites being added from boron-containing particles. Addition of strontium to the alloys restrains completely the formation of primary silicon particles and hence limits the nucleation of the CE. This is because the eutectic point has moved far enough to make the alloy, at this composition （Al-13 wt pct Si）, hypo-eutectic. Local cooling rate during solidification has an important influence on competition formation of these two eutectics.

Effects of P+Cr complex modification and solidification conditions on microstmcture of hypereutectic Al-Si alloys by wedge-shaped copper mould casting

Large and segregated primary Si particles may drastically decrease the mechanical properties of Al-Si alloys. To solve this problem, a P-Cr complex modif ier was added into the alloy, and the effects of P-Cr complex modification and solidification conditions on the microstructure of hypereutectic Al-Si alloys casting produced in wedge-shaped copper mould were studied. The thermal analysis technique was applied to calculate the cooling rate during solidification. The microstructures were observed by means of optical and scanning electron microscopies. Results showed that the primary Si segregates in the as-cast hypereutectic Al-Si alloys. The segregation of primary Si can be inhibited by adding a P+Cr complex modif ier and increasing the cooling rate during solidif ication. The ref inement of primary Si particles by P+Cr complex modif ication is due to the formation of CrS i2 and AlP particles which act as the heterogeneous nuclei for the primary Si phase. The segregation of Si was also inhibited through the adherence of heavier CrS i2 particles to the primary Si particles.

Microstructure and Mechanical Properties of Hyper-eutectic Al-Si Alloys Fabricated by Spray Casting

微观结构和水花扔制作的高级低共熔体的 Al-Si 合金的机械性质被调查然后这些结果与那些由相比压榨演员组。水花演员组标本被发现有更好的 Si 粒子(~ 5 亩 m ) 与压榨演员组标本(10-25 亩 m ) 相比。水花演员组标本的张力的力量和延伸比那些 squeeze 扔一个也高。水花演员组标本的增加的机械性质主要由于在艾尔矩阵散布的 Si 粒子的更好的尺寸，这被考虑。

Semisolid casting with ultrasonically melt-treated billets of Al-7mass%Si alloys

The demand for high performance cast aluminum alloy components is often disturbed by increasing impurity elements,such as iron accumulated from recycled scraps.It is strongly required that coarse plate-like iron compound of β-Al5FeSi turns into harmless form without the need for applying refining additives or expensive virgin ingots.The microstructural modification of Al-7mass%Si alloy billets with different iron contents was examined by applying ultrasonic vibration during the solidification.Ultrasonically melt-treated billets were thixocast right after induction heating up to the semisolid temperature of 583 oC,the microstructure and tensile properties were evaluated in the thixocast components.Globular primary α-Al is required to fill up a thin cavity in thixocasting,so that the microstructural modification by ultrasonic melt-treatment was firstly confirmed in the billets.With ultrasonic melt-treatment in the temperature range of 630 oC to 605 oC,the primary α-Al transforms itself from dendrite into fine globular in morphology.The coarse plate-like β-Al5FeSi compound becomes markedly finer compared with those in non-treated billets.Semisolid soaking up to 583 oC,does not appreciably affect the size of β-Al5FeSi compounds;however,it affects the solid primary α-Al morphology to be more globular,which is convenient for thixocasting.After thixocasting with preheated billets,eutectic silicon plates are extremely refined due to the rapid solidification arising from low casting temperature.The tensile strength of thixocast samples with different iron contents does not change much even at 2mass% of iron,when thixocast with ultrasonically melt-treated billets.However,thixocast Al-7mass%Si-2mass%Fe alloy with non-treated billets exhibits an inferior strength of 80MPa,compared with 180MPa with ultrasonically melt-treated billets.The elongation is also improved by about a factor of two in thixocastings with ultrasonically melt-treated billets for all iron contents of Al-7mass%Si alloys,for example,the elongation of 11% in thixocast of Al-7mass%Si-0.5mass%Fe alloy with ultrasonically melt-treated billets,5% in that with non-treated billets.

Effect of Electromagnetic Frequency on Microstructures of Continuous Casting Aluminum Alloys

The relationship between electromagnetic frequency and microstructures of continuous casting aluminum alloys was studied. 7075 aluminum alloy ingot of 100 mm in diameter was produced by electromagnetic continuous casting process, the microstructures of as-cast ingot was examined by scanning electron microscopy (SEM) equipped with energy dispersive spectrometer (EDS). The results showed that electromagnetic frequency greatly influenced segregation and microstructures of as-cast ingot, and product quality can be guaranteed by the application of a proper frequency. Electromagnetic frequency plays a significant role in solute redistribution; low frequency is more efficient for promoting solution of alloying elements.

Effect of holding pressure on density and cooling rate of cast Al-Si alloy during additive pressure casting

The cast Al-Si alloy was fabricated using the Additive Pressure Casting(APC)method.The effects of holding pressure from 50 to 400 k Pa on the density,cooling rate,and mechanical properties of the alloy,and the corresponding mechanism were discussed.The results indicate that the application of high holding pressure(300 k Pa)enhances the feeding ability of the alloy,leading to an increase of the density.Meanwhile,the cooling rate of the alloy is increased by 100%.In addition,the tensile testing results show that the increase of holding pressure from 50 to 300 k Pa improves the tensile strength and elongation of the alloy by 6.2%and 81.3%,respectively.However,excessive holding pressure(400 k Pa)might lower the density and cooling rate of the alloy due to the feeding channels being blocked.

Reaction between Ti and boron nitride based investment shell molds used for casting titanium alloys

The aim of this paper was to study the reaction between a Ti-6Al-4V alloy and boron nitride based investment shell molds used for investment casting titanium. In BN based investment shell molds, the face coatings are made of pretreated hexagonal boron nitride （hBN） with a few yttria （Y2O3） and colloidal yttria as binder. The Ti-6Al-4V alloy was melted in a controlled atmosphere induction furnace with a segment water-cooled copper crucible. The cross-section of reaction interface between Ti alloys and shell mold was investigated by electron probe micro-analyzer （EPMA） and microhardness tester. The results show that the reaction is not serious, the thickness of the reacting layer is about 30-50 μm, and the thickness of α-case is about 180-200 pro. Moreover the α-case formation mechanism was also discussed.

Microstructure and storage properties of low V-containing Ti–Cr–V hydrogen storage alloys prepared by arc melting and suction casting

The microstructure and hydrogen storage properties of low V content （Ti0.46Cr0.54）100-xVx （x = 2.5-7.1, at%） and （TiyCr1-y）95V5 （y= 0.38-0.54） alloys were investigated. These alloys were prepared by arc melting and copper mould suction casting. The structures of as-cast （Ti0.46Cr0.54）100-xVx （x = 2.5, 5.0, and 7.1） alloy ingots evolve with V contents from pure Laves-（x = 2.5） to dual-phase TiCr2-BCC structures （5.0 and 7.1）, whereas the suction-cast （Ti0.46Cr0.54）100-xVx （x =2.5, 5.0, and 7.1） alloys only contain single BCC phase. The suction-cast alloy rod （Ti0.46Cr0.54）95V5, containing only 5.0 at% V is shown to possess the optimum hydrogen absorption capacity, with the maximum hydrogen content of 3.14 wt%. Furthermore, the hydrogen storage properties of the suction-cast low V alloys （TiyCr1-y）95V5 （y = 0.38-0.54） are sensitive to Ti/Cr ratios and only those alloys with Ti/Cr ratios close to the CN14 cluster [TiTCrs] have good hydrogen storage properties.

Rotary bending fatigue behavior of A356 –T6 aluminum alloys by vacuum pressurizing casting

Vacuum pressurizing casting technique, providing better mould filling and inter-dendritic feeding, can reduce the porosity greatly in cast aluminum alloys, and improve the fatigue properties. The rotary bending fatigue properties of A356-T6 alloys prepared by vacuum pressurizing casting were investigated. The S-N curve and limit strength 90 MPa under fatigue life of 107 cycles were obtained. The analyses on the fatigue fractography and microstructure of specimens showed that the fatigue fracture mainly occurs at the positions with casting defects in the subsurface, especially at porosities regions, which attributed to the crack propagation during the fatigue fracture process. Using the empirical crack propagation law of Pairs-Erdogon, the quantitative relationship among the initial crack size, fatigue life and applied stress was established. The fatigue life decreases with an increase in initial crack size. Two constants in the Pairs-Erdogon equation of aluminum alloy A356-T6 were calculated using the experimental data.

Effects of Strip Casting and Annealing on Electrochemical Properties of LPCNi_(3.55)Co_(0.75)Mn_(0.4)Al_(0.3) Hydrogen Storage Alloys

The effect of thickness (1 similar to 10 mm) of the ingots on the electrochemical properties of as-cast and annealed strip cast LPCNi3.55Co0.75Mn0.4Al0.3 hydrogen storage alloys was investigated. It is found that the 0.2 C discharge capacity of as-cast LPCNi3.55Co0.75Mn0.4Al0.3 alloy increases with the increase of the thickness of the ingots. As-east alloy with the thickness of 10 mm shows better activation property, higher 1C discharge capacity and better cyclic stability than others. It is mainly contributed to its larger unit cell volume and less internal stress. Annealed LPCNi3.55Co0.75Mn0.4Al0.3 alloy with the thickness of 3 mm shows much better comprehensive electrochemical properties than as-east one; The cyclic. stability of the alloy with the thickness of 6 mm and the activation properties of the alloys with the thickness of 3 similar to 6 mm are improved after annealing. It is mainly owing to the great release of internal stress and the decrease of the segregation of Mn in the alloys.

Solidification microstructures of Al-Zn-Mg-Cu alloys prepared by spraydeposition and conventional casting methods

High strength Al-Zn-Mg-Cu alloys were prepared by spray deposition and casting techniques. The microstructures of the Al-Zn-Mg-Cu alloys were studied using scanning electron microscopy, transmission electron microscopy, and X-ray diffraction. Secondary phases in the microstructures of the alloys prepared by spray deposition and conventional cast were examined. The results indicate that under the conventional casting condition, the microstructure of the alloy revealed the presence of coarse Al/Mg（ZnCu）2 eutectic phases, and the spray deposited process causes an obvious modification in size, morphology, and distribution of secondary phases in the microstructure as well as reduction of segregation. The superior microstructure of the spray-deposited Al-Zn-Mg-Cu alloy was attributed to the high cooling rate, and associated with the rapid solidification process.

Progress in twin roll casting of magnesium alloys: A review

Twin roll casting was commercialized for a strip production from ferrous and non-ferrous alloys in the 1950 s;however,its application to magnesium has proven difficult and still creates major challenges.This report describes global efforts in expanding manufacturing capabilities of magnesium sheet through twin roll casting path,offering many benefits,including a reduction in number of processing steps and energy savings.In addition to hardware design,alloy transformation during processing,product microstructure and properties,examples of successful solutions along with present technology and knowledge limitations are discussed.A particular attention is paid to developments at Canmet MATERIALS,having the only in North America pilot scale twin roll casting facility,devoted to magnesium.Efforts are described that aim at design of new magnesium alloys,which could take advantage of unique processing conditions during twin roll casting and contribute to the overall progress in magnesium sheet manufacturing.

Exploring the concept of castability in magnesium die-casting alloys

This paper provides a summary of the recent work completed and history of the measure of manufacturability in the magnesium diecasting industry.The most popular die-casting alloys utilized in this industry are based on the Mg-Al system,including AZ91,AM60 and AM50.These are well-established alloys,and are generally considered to be highly castable.However,the concept of castability in magnesium die-casting is not a well-defined characteristic or quantitative material property.As a result,the author investigates the subject of castability for magnesium die-cast alloys and how it relates to the development of alloys for innovative applications or improved properties.This paper provides a summary of some key findings in literature on the castability of magnesium die-cast alloys,how castability is defined and evaluated,the impact of different alloying elements on the castability of magnesium alloys,and suggestions for future work.©2020 Published by Elsevier B.V.on behalf of Chongqing University.