Experimental observations on the nonproportional multiaxial ratchetting of cast AZ91 magnesium alloy at room temperature

The nonproportional multiaxial ratchetting of cast AZ91 magnesium (Mg) alloy was examined by performing a sequence of axial-torsional cyclic tests controlled by stress with various loading paths at room temperature (RT).The evolutionary characteristics and path dependence of multiaxial ratchetting were discussed.Results illustrate that the cast AZ91 Mg alloy exhibits considerable nonproportional additional softening during cyclic loading with multiple nonproportional multiaxial loading paths;multiaxial ratchetting presents strong path dependence,and axial ratchetting strains are larger under nonproportional loading paths than under uniaxial and proportional45°linear loading paths;multiaxial ratchetting becomes increasingly pronounced as the applied stress amplitude and axial mean stress increase.Moreover,stress-strain curves show a convex and symmetrical shape in axial/torsional directions.Multiaxial ratchetting exhibits quasi-shakedown after certain loading cycles.The abundant experimental data obtained in this work can be used to develop a cyclic plasticity model of cast Mg alloys.

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.

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%).

Mechanical Evaluation of AZ80 Magnesium Alloy in Cast Wrought Form

Wrought magnesium alloy AZ80 with a thick section of 20 mm was prepared by squeeze casting (SC) and permanent steel mold casting (PSMC). The porosity measurements of the SC and PSMC depicted that SC AZ80 had a pore content of 0.52%, which was 77% lower than 2.21% of PSMC AZ80 counterpart. The YS, UTS, ef, E and strengthening rate of cast AZ80 were determined by mechanical pulling. The engineering stress versus strain bended lines showed that SC AZ80 had a YS of 84.7 MPa, a UTS of 168.2 MPa, 5.1% in ef, and 25.1 GPa in modulus. But, the YS, UTS and ef of the PSMC AZ80 specimen were only 71.6 MPa, 109.0 MPa, 1.9% and 21.9 GPa. The findings of the mechanical pulling evidently depicted that the YS, UTS, ef and E of SC AZ80 were 18%, 54%, 174% and 15% higher than PSMC counterpart. The computed resilience and toughness suggested that the SC AZ80 exhibited greater resistance to tensile loads during elastic deformation and possessed higher capacity to absorb energy during plastic deformation compared to the PSMC AZ80. At the beginning of permanent change, the strengthening rate of SC AZ80 was 10,341 MPa, which was 9% greater than 9489 MPa of PSMC AZ80. The high mechanical characteristics of SC AZ80 should be primarily attributed to its low porosity level. .

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.

Experimental investigation on uniaxial cyclic plasticity of cast AZ91 magnesium alloy

The uniaxial cyclic plasticity of cast AZ91 magnesium(Mg) alloy was investigated by conducting a series of cyclic straining and stressing tests at room temperature, and a unique cyclic plasticity(especially for ratchetting) and its physical nature were revealed. The experimental results demonstrate that the cast AZ91 Mg alloy behaviors tension-compression symmetry, because the dislocation slipping and twinning occur during both the tensile and compressive deformations;although the cast AZ91 alloy presents a certain pseudo-elastic behavior during unloading due to the detwinning, there is no obvious S-shaped asymmetric hysteresis loop like that of wrought Mg alloy in the cyclic tensile-compressive tests, and an obvious cyclic hardening is observed;moreover, the ratchetting of the cast AZ91 alloy presented in the cyclic stressing tests depends remarkably on the prescribed mean stress and stress amplitude, but slightly changes with the stress rate, and the evolution of responding peak/valley strain greatly differs from that of wrought Mg alloys and stainless steels. This work provides rich experimental data for establishing the constitutive model of cast Mg alloys.

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.

Solidification microstructure of Ti-43Al alloy by twin-roll strip casting

As a near-net-shape technology,the twin-roll strip casting(TRC)process can be considered to apply to the fabrication of TiAl alloy sheets.However,the control of the grain distribution is very important in strip casting because the mechanical properties of strips are directly determined by the solidification microstructure.A three-dimensional(3D)cellular automation finite-element(CAFE)model based on ProCAST software was established to simulate the solidification microstructure of Ti-43Al alloy.Then,the influence of casting temperature and the maximum nucleation density(nmax)on the solidification microstructure was investigated in detail.The simulation results provide a good explanation and prediction for the solidification microstructure in the molten pool before leaving the kissing point.Experimental and simulated microstructure show the common texture<001>orientation in the columnar grains zone.Finally,the microstructure evolution of the Ti-43Al alloy was analyzed and the solidification phase transformation path during the TSC process was determined,i.e.,L→L+β→β→β+α→α+γ+β/B2 phase under a faster cooling rate and L→L+β→β→β+α→γ+lamellar(α_(2)+γ)+β/B2 phase under a slower cooling rate.

Effect of Ti and Ce Microalloy on Microstructure and Properties of Al-Si-Cu-Zr-Sr Cast Aluminum Alloy

The effect of Ti and Ce microalloying on the mechanical properties of Al-9Si-3.5Cu-0.2Zr-0.1Sr cast aluminum alloy was investigated,and it was hoped that the cast aluminum alloy with excellent comprehensive properties could be obtained.On the basis of Zr-Sr microalloyed cast aluminum alloy(Al-9Si-3.5Cu-0.2Zr-0.1Sr),the effects of 0.2Zr-0.1Sr-0.16Ti ternary microalloying and 0.2Zr-0.1Sr-0.16Ti-0.1Ce quaternary microalloying on the microstructure and properties of the alloy were investigated.The experimental results show that compared with Zr-Sr microalloying,Zr-Sr-Ti microalloying and Zr-Sr-Ti-Ce microalloying can effectively refine the microstructure,improve the modification effect of Si phase,and promote the improvement of Al_(2)Cu phase,thus improving the properties.The higher the degree of microalloying,the hardness is gradually increasing,but the electrical conductivity is gradually decreasing.Zr-Sr-Ti microalloying can increase the tensile strength of the alloy to 400.07 MPa and the elongation to 9.5%.Zr-Sr-Ti-Ce microalloying do not continue to improve the properties of the alloy,and the tensile strength and elongation after fracture decrease to a certain extent due to the addition of Ce.Therefore,the best comprehensive properties can be obtained by ZrSr-Ti microalloying(Al-9Si-3.5Cu-0.2Zr-0.1Sr-0.16Ti).

Effect of Ti content on microstructures and mechanical properties of cast Al-2Li-2Cu-0.5Mg alloy

Ti is regarded as one of the promising grain refiners in cast Al-Li-Cu alloys,but few research works have been done on its independent role.In this study,the effect of Ti on the microstructure evolution and mechanical properties of cast Al-2Li-2Cu-0.5Mg base alloy was investigated.The results revealed that the grains can be prominently refined with the increase of Ti addition.After adding Ti,high density TiB_(2)-Al_(3)Ti composite particles with a low lattice misfit form as heterogeneous nucleation sites for the α-Al matrix.δ’(Al3Li) and T_(1)(Al_(2)CuLi) precipitates that provide enhanced strength are dominated in the alloys after T6 aging treatment.The average size of both δ’ and half-width of δ’-precipitation free zone(PFZ) decreases gradually with the increase of Ti content.This is because the higher binding energy between Ti atoms and vacancies limits the diffusion efficiency of Li atoms,and thus results in a higher ductility.Additionally,no nano-sized Al_(3)Ti or core-shell structure of Al_(3)(Li,Ti) particles are found.The tensile property test results indicate that the Al-2Li-2Cu-0.5Mg alloy achieves optimal properties after aging at 175 °C for 32 h when 0.15wt.% Ti is added.It exhibits a yield strength of 352±5 MPa,an ultimate tensile strength of 423±6 MPa,and an elongation of(3±0.4)%.These findings are expected to offer a reliable theoretical guidance for the industrial composition design of the Al-Li-Cu series cast alloys.

Effect of secondary aging on microstructure and properties of cast Al-Cu-Mg alloy

To obtain better comprehensive properties of cast Al-Cu-Mg alloys,the secondary aging(T6I6)process(including initial aging,interrupted aging and re-aging stages)was optimized by an orthogonal method.The microstructures of the optimized Al-Cu-Mg alloy were observed by means of scanning electron microscopy and transmission electron microscopy,and the properties were investigated by hardness measurements,tensile tests,exfoliation corrosion tests,and intergranular corrosion tests.Results show that the S phase andθ’phase simultaneously exist in the T6I6 treated alloy.Appropriately increasing the temperature of the interrupted aging in the T6I6 process can improve the mechanical properties and corrosion resistance of Al-Cu-Mg alloy.The optimal comprehensive properties(tensile strength of 443.6 MPa,hardness of 161.6 HV)of the alloy are obtained by initial aging at 180℃for 2 h,interrupted aging at 90℃for 30 min,and re-aging at 170℃for 4 h.

Cu含量和热处理工艺对Al-Si-Mg-Mn-xCu铸造铝合金显微组织和力学性能的影响

采用三维X射线显微镜、光学显微镜、扫描电子显微镜、透射电子显微镜及硬度测试系统研究Cu含量及热处理工艺对真空压铸Al-Si-Mg-Mn-xCu合金显微组织和力学性能的影响。研究发现,虽然Cu含量增加会提高铸锭中气孔的密度和尺寸,但是Cu添加将促进凝固过程中含Cu初生相(Q-Al_(5)Cu_(2)Mg_(8)Si_(6)和θ-Al_(2)Cu)的形成,从而提高合金性能。合金中形成5种不同结构的初生相,包括共晶Si、α-Al(Fe,Mn)Si、β-Mg_(2)Si、Q-Al_(5)Cu_(2)Mg_(8)Si_(6)和θ-Al_(2)Cu相。随着Cu含量增加,θ相的面积分数迅速增加,α-Al(Fe,Mn)Si相面积分数首先降低,随后缓慢增加,而Q相的变化趋势与α-Al(Fe,Mn)Si相相反。这些初生相在热处理过程中会出现不同的演变规律。在随后的时效处理过程中,Q'和θ'相的协同析出能显著提高合金的时效硬化潜力。

基于ProCAST的一模多腔YL112铝合金压铸件数值模拟及工艺优化

针对YL112压铸铝合金一模多铸产品的组织性能均一性需求,采用ProCAST软件对典型一模多铸工艺进行模拟,比较了两种不同充型顺序的压铸方案。结果表明:基于顺序凝固一模多腔压铸件由于充型与凝固过程的温度场分布不均,导致近浇口端铸件出现明显缩松缩孔缺陷,造成铸件性能均一性差。后续采用等流程浇注系统,实现一模多腔铸件同时充型凝固过程,改善了铸件温度场分布,减少了工艺缺陷。经过实际生产验证,获得了组织性能均一性好的压铸件。

Crystallographic Characteristic of Intermetallic Compounds in Al-Si-Mg Casting Alloys Using Electron Backscatter Diffraction

The Al-Si-Mg alloy which can be strengthened by heat treatment is widely applied to the key components of aerospace and aeronautics. Iron-rich intermetallic compounds are well known to be strongly influential on mechanical properties in Al-Si-Mg alloys. But intermetallic compounds in cast Al-Si-Mg alloy intermetallics are often misidentified in previous metallurgical studies. It was described as many different compounds, such as AlFeSi, Al8Fe2Si, Al5（Fe, Mn）3Si2 and so on. For the purpose of solving this problem, the intermetallic compounds in cast Al-Si alloys containing 0.5% Mg were investigated in this study. The iron-rich compounds in Al-Si-Mg casting alloys were characterized by optical microscope（OM）, scanning electron microscope（SEM）, energy dispersive X-ray spectrometer（EDS）, electron backscatter diffraction（EBSD） and X-ray powder diffraction（XRD）. The electron backscatter diffraction patterns were used to assess the crystallographic characteristics of intermetallic compounds. The compound which contains Fe/Mg-rich particles with coarse morphologies was Al8FeMg3Si6 in the alloy by using EBSD. The compound belongs to hexagonal system, space group P6_2m, with the lattice parameter a=0.662 nm, c=0.792 nm. The β-phase is indexed as tetragonal Al3FeSi2, space group I4/mcm, a=0.607 nm and c=0.950 nm. The XRD data indicate that Al8FeMg3Si6 and Al3FeSi2 are present in the microstructure of Al-7Si-Mg alloy, which confirms the identification result of EBSD. The present study identified the iron-rich compound in Al-Si-Mg alloy, which provides a reliable method to identify the intermetallic compounds in short time in Al-Si-Mg alloy. Study results are helpful for identification of complex compounds in alloys.

Simulation of α-Al grain formation in high vacuum die-casting Al-Si-Mg alloys with multi-component quantitative cellular automaton method

Al-Si-Mg alloys are the most commonly used material in high vacuum die-casting(HVDC),in which the morphology and distribution ofα-Al grains have important effect on mechanical properties.A multi-component quantitative cellular automaton(CA)model was developed to simulate the microstructure and microsegregation of HVDC Al-Si-Mg alloys with different Si contents(7%and 10%)and cooling rates during solidification.The grain number and average grain size with electron backscatter diffraction(EBSD)analysis were used to verify the simulation.The relationship between grain size and nucleation order as well as nuclei density was investigated and discussed.It is found that the growth of grains will be restrained in the location with higher nuclei density.The influence of composition and cooling rate on the solute transport reveals that for AlSi7Mg0.3 alloy the concentration of solute Mg in liquid is higher at the beginning of eutectic solidification.The comparison between simulation and experiment results shows that externally solidified crystals(ESCs)have a significant effect for samples with high cooling rate and narrow solidification interval.

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.

Synergistic effects of composition and heat treatment on microstructure and properties of vacuum die cast Al-Si-Mg-Mn alloys

The purpose of this study was to prepare high-quality Al-Si-Mg-Mn alloy with a good combination of strength and ductility employing the vacuum-assisted high-pressure die cast process. An orthogonal study of heat treatments was conducted to design an optimized T6 heat treatment process for both Al-10%Si-0.3%Mg-Mn and Al-11%Si-0.6%Mg-Mn alloys. The results demonstrate that no obvious blisters and warpage were observed in these two alloys with solid solution treatment. After the optimal T6 heat treatment of 530°C×3 h + 165°C×6 h, Al-11%Si-0.6%Mg-Mn alloy has better mechanical properties, of which tensile strength, yield strength and elongation reached 377.3 MPa, 307.8 MPa and 9%, respectively. The improvement of mechanical properties can be attributed to the high density of needle-like β″(Mg_5Si_6) precipitation after aging treatment and the fine and spherical eutectic Si particles uniformly distributed in the α-Al matrix.

Strength and ductility optimization of HPDC AlSi8MgCuZn2 alloys by modifying pre-aging treatment

Considering the components produced by high pressure die casting(HPDC)process usually with ultra-large sizes and complex morphologies,high temperature solid solution treatment is not a suitable method to further improve their mechanical properties.In this study,two-stage aging treatment with different pre-aging times was designed and employed to further improve the mechanical properties of HPDC Al8SiMgCuZn alloy.The characteristics of precipitates were evaluated by a transmission electron microscope(TEM),and the precipitation strengthening mechanism was discussed.The results reveal that the strengthening is mainly contributed by the precipitation ofβ″phase after two-stage aging,and the number density and size of the precipitates are significantly depended on the pre-aging time.The number density of precipitates is increased with the pre-aging time prolonged from 0 h to 4 h,and then decreases with the further increase of pre-aging time from 4 h to 6 h.The precipitates with the highest density and smallest size are observed after pre-aging for 4 h.After pre-aged at 100℃for 4 h and then artificial aged at 200℃for 30 min,the yield strength of 207 MPa,ultimate tensile strength of 325 MPa and elongation of 7.6%are achieved.

Effect of Sn on as-cast ageing behavior of Al-Si-Mg alloy

The effect of minor additions of Sn on the as cast ageing behavior of Al 11Si 0.35Mg alloy was investigated. It is shown that precipitation has been retarded in Sn containing alloy and more time is needed to reach its peak hardness,which is bigger than that of the base alloy. Analysis of the kinetic data shows that Sn addition does not change the growth dependent parameter n , but increases the nucleation density dependent parameter k . TEM results show that there are little precipitates in Sn containing alloy at the initial stage of as cast ageing. However, the Sn addition increases the net density of precipitates during as cast ageing, because there are many dislocation loops formed as ageing progresses and Sn segregated at the edges of dislocation loops, which acts as the nuclei of precipitates.