Microstructure and properties of 35 kg large aluminum alloy flywheel housing components formed by squeeze casting with local pressure compensation

The squeeze casting method with local pressure compensation was proposed to form a flywheel housing component with a weight of 35 kg.The numerical simulation,microstructure observation and phase characterization were performed,and the influence of local pressure compensation on feeding of thick-wall position,microstructure and mechanical properties of the formed components were discussed.Results show that the molten metal keeps a good fluidity and the filling is complete during the filling process.Although the solidification at thick-wall positions of the mounting ports is slow,the local pressure compensation effectively realizes the local forced feeding,significantly eliminating the shrinkage cavity defects.In the microstructure of AlSi9Mg alloy,α-Al primarily consists of fragmented dendrites and rosette grains,while eutectic Si predominantly comprises needles and short rods.The impact of local pressure compensation on strength is relatively minimal,yet its influence on elongation is considerable.Following local pressure compensation,the average elongation at the compensated areas is 9.18%,which represents a 44.90%higher than that before compensation.The average tensile strength is 209.1 MPa,and the average yield strength is 100.6 MPa.The local pressure compensation can significantly reduce or even eliminate the internal defects in the 35 kg large-weight components formed by squeeze casting.

Investigation of rheo-diecasting mold filling of semi-solid A380 aluminum alloy slurry

The rheo-diecasting mold filling capacity and the microstructure of the semi-solid A380 aluminum alloy slurry were investigated. The results show that the mold filling capacity was strengthened with increasing pouring temperature or increasing injection pressure. Under certain process parameters, the mold cavity was fully filled. However, the mold filling capacity decreased with increasing holding time. The mold filling capacity was improved with increasing shape factor of primary α(Al) grains; however, the solid fraction and the grain size significantly increased at the same time. In addition, the microstructures along the route of the spiral samples obviously differed. The grain size decreased gradually from the near-end to the far-end, whereas the shape factor increased gradually.

Squeeze casting of aluminum alloy A380: Microstructure and tensile behavior

A380 alloy with a relatively thick cross-section of 25 mm was squeeze cast using a hydraulic press with an applied pressure of 90 MPa. Microstructure and tensile properties of the squeeze cast A380 were characterized and evaluated in comparison with the die cast counterpart. Results show that the squeeze cast A380 possesses a porosity level much lower than the die cast alloy, which is disclosed by both optical microscopy and the density measurement technique. The results of tensile testing indicate the improved tensile properties, specifically ultimate tensile strength(UTS: 215.9 MPa) and elongation(Ef: 5.4%), for the squeeze cast samples over those of the conventional high-pressure die cast part(UTS: 173.7 MPa, Ef: 1.0%). The analysis of tensile behavior shows that the squeeze cast A380 exhibits a high tensile toughness(8.5 MJ·m-3) and resilience(179.3 k J·m-3) compared with the die cast alloy(toughness: 1.4 MJ·m-3, resilience: 140.6 k J·m-3), despite that, during the onset of plastic deformation, the strain-hardening rate of the die cast specimen is higher than that of the squeeze cast specimens. The microstructure analyzed by the scanning electron microscopy(SEM) shows that both the squeeze and die cast specimens contain the primary α-Al, Al2 Cu, Al5 Fe Si phase and the eutectic Si phase. But, the Al2 Cu phase present in the squeeze cast alloy is relatively large in size and quantity. The SEM fractography evidently reveals the ductile fracture features of the squeeze cast A380 alloy.

Effects of process parameters on semi-solid squeeze casting performance of aluminum alloy scrolls for scroll compressors

The aluminum alloy scroll is one of the key parts of the scroll compressors widely used in the air-conditioning,refrigeration,and heat pump systems.In this work,the semi-solid squeeze casting(SSSC)process was used to fabricate the aluminum alloy scroll.The effects of process parameters including the pouring temperature,mold temperature,and squeezing velocity on the filling and solidification behaviors of the alloys were investigated through simulations based on the power law cut-off(PLCO)material model.Results show that there is a significant increase in the flow velocity of the slurry,and the area of the high-speed region enlarges with the increase of the pouring temperature.The homogeneity of the temperature and velocity fields in the slurry is improved with an increase in mold temperature.Both the filling time and its variation rate decrease with an increase in squeezing velocity.The maximum solidification time exhibits a linear variation with the increase in pouring temperature.The shrinkage area is decreased by increasing the mold temperature.The optimal process parameters of the SSSC process were obtained from simulation analysis,which are the pouring temperature of 595°C,mold temperature of 350°C,and squeezing velocity of 0.3 m·s-1.Moreover,the qualified scroll casting was fabricated using the SSSC process under the optimal process parameters.

Evaluation of the mold-filling ability of alloy melt in squeeze casting

The mold-filling ability of alloy mclt in squceze casting process was evaluated by means of the maximum length of Archimedes spiral line. A theoretical evaluating model to predict the maximum filling length was built based on the flowing theory of the incompressible viscous fluid. It was proved by experiments and calculations that the mold-tilling pressure and velocity are prominent influencing factors on the mold-filling ability of alloy melt. The mold-filling ability increases with the increase of the mold-filling pressure and the decrease of the proper mold-filling velocity. Moreover, the pouring temperature relatively has less effect on the mold-filling ability under the experimental conditions. The maximum deviation of theoretical calculating values with experimental results is less than 15%. The model can quantitatively estimate the effect of every factor on the mold-filling ability.

Numerical simulation for mold-filling of thin-walled aluminum alloy castings in traveling magnetic field

The numerical simulation for mold-filling of thin-walled aluminum alloy castings in horizontal traveling magnetic field is performed. A force model of Al alloy melt in the traveling magnetic field is founded by analyzing traveling magnetic field carefully. Numerical model of Al alloy mold-filling is founded based on N-S equation, which was suitable for traveling magnetic field. By using acryl glass mold with indium as alloy melt, the experiment testified the filling state of alloy in traveling magnetic field. The results of numerical simulation indicate that the mold-filling ability of gallium melt increases continually with the increase of the input ampere turns.

Mould filling ability and microstructure of aluminum alloy under electromagnetic die casting

In order to solve the mould filling problem of large thin walled aluminum alloy castings effectively, a new casting technology called electromagnetic die casting has been developed. Emphasis has laid on studying the mould filling ability and microstructure under the mentioned method. The results show that the mould filling ability of A357 is increasing continually with the increasing of the input voltage, that is, the magnetic induction intensity. The pressure head of the molten metal increases from the lowest one at the input of the mould to the highest one at the end of the mould while in a conventional mould the pressure head depends invariably on the sprue height. Under electromagnetic die casting, the grains of A357 alloy are refined, and the pattern of eutectic silicon of alloy changes from rough plate to smooth strip.

Processing map and hot deformation behavior of squeeze cast 6082 aluminum alloy

The hot deformation behavior and microstructure evolution of 6082 aluminum alloy fabricated through squeeze casting(SC)under different pressures were studied.The alloy was subjected to hot compression tests and 3D hot processing maps were established.The microstructure evolution was studied by optical microscope(OM),scanning electron microscope(SEM),and electron backscattered diffraction(EBSD).It is found that more dynamic recrystallization(DRX)grains are generated during the deformation of the specimen fabricated under higher SC pressure.At high temperature the effect of SC pressure on microstructure evolution weakens due to the dissolution of second phase particles.In addition,uneven second phase particles in specimens fabricated under higher SC pressure compressed with low temperature and middle strain rate would result in flow localization instability.Finally,the optimum deformation conditions for the 6082 aluminum alloy fabricated by SC were obtained at the temperatures of 430−500℃ and the strain rates of 0.01−1 s^(−1).

Enhanced mechanical properties of 6082 aluminum alloy via SiC addition combined with squeeze casting

In order to improve mechanical properties of 6082 aluminum alloy,the SiC_(p)/Al 6082 composites were prepared by the addition of the micron-sized SiC_(p)articles combined with the squeeze casting.The effects of the SiC_(p)content and squeeze casting on the microstructure and mechanical properties of the 6082 aluminum alloy were investigated by SEM,EDS,TEM,tensile testing and hardness testing analysis methods.Research results exhibited that the SiC_(p)content and squeeze casting had a significant impact on the microstructure and mechanical properties of the 6082 aluminum alloy.The addition of the SiC_(p)refined the grain size of the 6082 aluminum alloy while caused the increase of the porosity with increasing the SiC_(p)content,especially in the permanent mold casting condition.Compared to the permanent mold casting,the squeeze casting obviously reduced pore defects,refined grain size and made the SiC_(p)distribute evenly as well as bond tightly with the Al matrix.The tensile strength,yield strength,elongation,elastic modulus and hardness of the 6082 aluminum alloy obtained with the SiC_(p)and squeeze casting were remarkably improved,and the optimal mechanical properties were obtained with a 2 wt.%SiC_(p),and they increased 10.73%,72.7%,193.9%,23.5%and 25.2%,respectively,compared to those of the6082 aluminum alloy obtained without SiC_(p)and squeeze casting.The fracture surface of the SiC_(p)/Al 6082 composites obtained with the squeeze casting was dense and exhibited a ductile fracture mode.

Effect of yttrium on microstructure and mold filling capacity of a near-α high temperature titanium alloy

The addition of rare earth yttrium(Y) can improve the performances of high temperature titanium alloys,such as the tensile ductility,thermal stability and creep property,etc.However,few studies on the effect of Y on the castability of titanium alloys have been carried out,which is significant to fabrication of thin-walled complex titanium castings by investment casting.In this study,the microstructure and mold filling capacity of a Ti-1100 alloy with different Y additions(0,0.1wt.%,0.3wt.%,0.5wt.% and 1.0wt.%) were investigated systematically through investment casting experiments,and the casting experiments were carried out in a centrifugal titanium casting machine.The microstructures of the alloy were observed via the optical microscopy,scanning electron microscopy and transmission electron microscopy.The mold filling capacity was tested by using of a grid pattern and was evaluated by the number of segments completely filled by the cast alloy.The results indicate that the grain size is decreased and the mold filling capacity is improved significantly with increasing the addition of Y from 0 to 1.0wt.%.The average primary grain size of Ti-1100 alloy is reduced from 250 μm to 50 μm and the mold filling capacity is increased from 61.5% to 100%.Considering the potential harmful effect on tensile properties of titanium alloys due to high concentrations of Y,it is suggested that Y addition should be about 0.3wt.%.

Microstructures and mechanical properties of semi-solid squeeze casting ZL104 connecting rod

Semi-solid squeeze casting（SSSC） and liquid squeeze casting（LSC） processes were used to fabricate a ZL104 connecting rod, and the influences of the process parameters on the microstructures and mechanical properties were investigated. Results showed that the tensile strength and elongation of the SSSC-fabricated rod were improved by 22% and 17%, respectively, compared with those of the LSC-fabricated rod. For SSSC, the average particle size（APS） and the shape factor（SF） increased with the increase of re-melting temperature（Tr）, whereas the tensile strength and elongation increased first and then decreased. The APS increased with increasing the mold temperature（Tm）, whereas the SF increased initially and then decreased, which caused the tensile strength and elongation to increase initially and then decrease. The APS decreased and the SF increased as squeezing pressure（ps） increased, and the mechanical properties were enhanced. Moreover, the optimal Tr, ps and Tm are 848 K, 100 MPa and 523 K, respectively.

Computer simulation for centrifugal mold filling of precision titanium castings

Computer simulation codes were developed based on a proposed mathematical model for centrifugal mold filling processes and previous computer software for 3D mold filling and solidification of castings (CASM-3D for Windows). Sample simulations were implemented for mold filling processes of precision titanium castings under gravity and different centrifugal casting techniques. The computation results show that the alloy melt has a much stronger mold filling ability for thin section castings under a centrifugal force field than that only under the gravity. A 'return back' mold filling manner is showed to be a reasonable technique for centrifugal casting processes, especially for thin section precision castings.

Theoretical Analysis of the Solidification of Aluminum Alloy Billetin Air-Slip DC Mold

Based on the heat transfer analysis of Air-Slip DC mold, a numerical model was presented to study the quantitative relationships between critical solidification layer and casting rate, pouring temperature and mold cooling ability etc. The analytical results show that the Air-Slip mold heat transfer condition plays important roles on choices of a casting rate and the pouring temperature, and that the product of billet diameter and casting rate is a certain constant under a certain condition of the mold.

A Qualitative Study of the Influence of Grooved Mold Surface Topography on the Formation of Surface Marks on As-Cast Ingots of Aluminum Alloy 3003

The effects of the wavelength and orientation of machined grooves on a mold surface, casting speed, and melt superheat on the formation of surface marks on as-cast ingots were studied with an immersion casting tester and copper mold chill blocks. The mold surface topographies included a polished smooth surface, and those with machined unidirectional parallel contoured grooves oriented either parallel (vertical) or perpendicular (horizontal) to the casting direction. The unidirectional grooves were 0.232 mm deep with wavelength or spacing between 1 and 15 mm. The casting speed and melt superheat were between 1 and 200 mm/s, and 10 and 50 K, respectively. Two primary types of surface marks were observed on ingots cast with the copper mold with smooth surface topography, namely the finer and closely spaced ripples (Type I), and the widely spaced but coarser laps (Type II). The latter were more prevalent at the higher casting speeds and melt superheats. Qualitatively, formation of both types of surface marks on the as-cast ingots of the aluminum alloy 3003 appeared to be alleviated by increase in casting speed and melt superheat, and by the use of molds with grooved surface topography. In fact, casting with a mold surface with 1 mm spaced grooves that are perpendicular to the casting direction eliminated the formation of surface marks at casting speeds greater than 1 mm/s. It also improved the uniformity of the ingot subsurface microstructure and eliminated the associated subsurface segregation.

Pressure-driven mold filling model of aluminum alloy melt/semi-solid slurry based on rheological behavior

The pressure-driven mold filling ability of aluminum alloy melt/semi-solid slurry is of great significance in pressure casting processes,and the rheological behavior of the alloy has a crucial effect on the mold filling ability according to fluid dynamics.In this work,a pressure-driven mold filling model is first proposed based on the rheological behavior of the alloys.A356 alloy is employed as an example to clarify the rheological behavior of aluminum alloys,which obeys the power law model and is affected by temperature.The rheological behavior of the alloy in semi-solid state is modelled with the coupling of shear rate and temperature.The stop of mold filling attributes to the pressure loss which is caused by the viscosity during the flow of the melt/semi-solid slurry.Pressure loss caused by viscous flow and heat transfer between the alloy and the mold are calculated and coupled during the mold filling of the melt/semi-solid slurry.A pressure-driven mold filling model of aluminum alloy melt/semi-solid slurry is established based on steady-state rheological behavior.The model successfully predicts the filling length of melt/semi-solid slurry in pressure casting processes.Compared with the experimental results,the model can provide a quantitative approach to characterize the pressure-driven mold filling ability of aluminum alloy melt.The model is capable of describing the stop filling behavior of other aluminum alloys in pressure casting processes with corresponding rheological parameters and heat transfer coefficient.

Elevated Temperatures Tensile Characteristics of Cast A356/Al₂O₃Nanocomposites Fabricated Using a Combination of Rheocasting and Squeeze Casting Techniques

In the present investigation, the tensile properties of A356/Al2O3 nanocomposites at both ambient and elevated temperatures were studied. The A356/Al2O3 nanocomposites were fabricated using a combination between the rheocasting and squeeze casting techniques. The A356 matrix alloy was reinforced with Al2O3 nanoparticulates having average sizes of 60 nm and 200 nm with different volume fractions up to 5 vol%. The results revealed that the A356/Al2O3 nanocomposites exhibited better mechanical properties than the A356 monolithic alloy. Such improvement in the mechanical properties was observed at both room and elevated temperatures up to 300°C. Increasing the volume fraction and/or reducing the size of Al2O3 nanoparticulates increase both the tensile and yield strengths of the nanocomposites.

Aging behavior of AlNp/2024Al composites fabricated by squeeze casting

2024 aluminum matrix composites reinforced with different size AlN particles (0.5, 4 and 10μm) were fabricated by the squeeze-casting technology. The aging behavior and microstructure of AlNp/2024Al composites were investigated by Brinell hardness measurement and transmission electron microscopy (TEM). The results show that the precipitation sequence of AlNp/2024Al composites is similar to that of the matrix alloy aged at 160 and 190℃, but the age hardening rate of composites is improved, and the AlN particles with large size promote the precipitation process more obviously, in comparison with smaller AlN particles. With increasing temperature, the precipitation processes are accelerated, and the time to reach the peak hardness is shortened. The acceleration of the formation of GP region and phase S' in the composites is attributed to the interfaces (between particles and the matrix) and the high density of dislocations introduced by addition of AlN particles.

Filling mode and regularity of vertical centrifugal casting process of titanium alloy in thin-walled cylinder cavity

The mold filling process of titanium alloy in a thin-walled cylinder cavity under vertical centrifugal casting process was studied by means of the hydraulic simulation experiments. Results show that the filling mode of the melt in the cylinder cavity varies with casting wall-thickness. When the casting wall-thickness is less than or equal to the thickness of the first layer during the filling process, the melts fill the cavity from the bottom to the top.When the casting wall-thickness is greater than the thickness of the first layer during the filling process, the melts first fill the largest radius parts of the cavity with a certain thickness of the first layer from the bottom to the top of the cavity, and then they fill the cavity from the larger radius part to the smaller radius part. The melt filling ability increases with the increment of the mold rotational speed and the pouring temperature. In another aspect, the melt filling ability rises with the decrement of the melt viscosity, and the melt with the better filling ability is prone to fill the cylinder cavity layer by layer.

A MOLD MATERIAL USED FOR TITANIUM-ALUMINUM ALLOY-CALCIA

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MICROSTRUCTURE ANALYSIS AND MECHANICAL PROPERTIES OF Zn-Al ALLOY ROD PRODUCED BY HEATED MOLD CONTINUOUS CASTING

The new technology of continuous casting by heated mold was used to produce directional solidification ZA alloy lines to eliminate the inter defects of these lines and increase their mechanical properties. The results are as follows: (1) The microstruc-ture of the ZA alloy lines is the parallel directional dendritic columnar crystal. Every dendritic crystal of eutectic alloy ZA5 was composed of many layer eutectic β and η phases. The micro structure of hypereutectic ZA alloys is primary dendritic crystal and interdendritic eutectic structure. The primary phase of ZA8 and ZA12 is β, among them, but the primary phase of ZA22 and ZA27 is a. (2) Through the test to the as-cast ZA alloy lines made in continuous casting by heated mold, it is found that the tensile strength and hardness increase greatly, but the elongation decreases. With the increase of aluminum amount from ZA 5 to ZA 12, ZA22 and ZA27, the tensile strength increases gradually. ZA27 has the best comprehensive mechanical properties in these four kinds of ZA alloys. (3) Heat treatment can decrease the dendritic segregation and improve the elongation of ZA alloy, but make their strength decrease slightly.