Assessing efficacy of standard impregnation techniques on die-cast aluminum alloys using X-ray micro-CT

Utilizing lightweight Al alloys in various industrial applications requires achieving precise pressure tightness and leak requirements.Vacuum pressure impregnation(VPI)with thermosetting polymers is commonly used to address leakage defects in die-cast Al alloys.In this study,the efficacy of the VPI technique in sealing alloy parts was investigated using a combination of nondestructive micro X-ray computed tomography(micro XCT)and a standard leak test.The results demonstrate that the commonly used water leak test is insufficient for determining the sealing performance.Instead,micro XCT shows distinct advantages by enabling more comprehensive analysis.It reveals the presence of a low atomic number impregnates sealant within casting defects,which has low grey contrast and allows for visualizing primary leakage paths in 3D.The effective atomic number of impregnated resin is 6.75 and that of Al alloy is 13.69 by dual-energy X-ray CT.This research findings will contribute to enhancing the standard VPI process parameters and the properties of impregnating sealants to improve quality assurance for impregnation in industrial metals.

Effects of on-line solution and off-line heat treatment on microstructure and hardness of die-cast AZ91D alloy

The effects of on-line solution, off-line solution and aging heat treatment on the microstructure and hardness of the die-cast AZ91D alloys were investigated. Brinell hardness of die-cast AZ91D alloy increases through on-line solution and off-line aging treatment but decreases after off-line solution treatment. By X-ray diffractometry, optical microscopy, differential thermal analysis, scanning electron microscopy and X-ray energy dispersive spectroscopy, it is found that the microstructures of the die-cast AZ91D magnesium alloy before and after on-line solution and off-line aging are similar, consisting of α-Mg and β-Al12Mg17. The precipitation of Al element is prevented by on-line solution so that the effect of solid solution strengthening is enhanced. The β-Al12Mg17 phases precipitate from supersaturated Mg solid solution after off-line aging treatment, and lead to microstructure refinement of AZ91D alloy, so the effect of precipitation hardening is enhanced. The β-Al12Mg17 phases dissolve in the substructure after off-line solution treatment, which leads to that the grain boundary strengthening phase is reduced significantly and the hardness of die cast AZ91D is reduced.

Microstructure and mechanical properties of Mg-6Gd-3Y-0.5Zr alloy processed by high-vacuum die-casting

GW63K （Mg-6Gd-3Y-0.5Zr） magnesium alloys were prepared successfully by high-vacuum die-casting. Effects of fast shot speed and vacuum level on the grain size and mechanical properties of this alloy were studied. Microstructure of the alloys was analyzed by SEM, EDX and optical microscope （OM）. The effect of heat treatment on high vacuum die-casting （HVDC） GW63K alloy was also studied. The results indicate that with the increase of fast velocity, the tensile yield strength hardly changes, but the elongation first increases, then decreases. The optimum heat treatment process is solution treatment at 748 K for 2 h and aging at 473 K for 80 h. Under this condition, GW63K magnesium alloy exhibits a maximum tensile strength and elongation of 308 MPa and 9.45%. There is significant correlation between ductility and the presence of external solidified cells （ESCs）. The as-cast GW63K alloy consists ofα-Mg and Mg24（Gd,Y）5 particles. After heat treatment, Gd and Y atoms dissolve intoα-Mg matrix.

Corrosion behavior of Mg-Gd-Zn based alloys in aqueous NaCl solution

The corrosion behavior of Mg-10Gd-xZn(x=2,6 wt.%)alloys in 0.5 wt.%NaCl solution was investigated.Microstructures of both the alloys consisted of(Mg,Zn)_(3) Gd phase and lamellar long period stacking ordered(LPSO)phase.The morphology of the second phase at the grain boundary differed in both alloys:it was a continuous network structure in Mg-10Gd-6Zn,whereas it was relatively discrete in Mg-10Gd-2Zn.The dendrites were finer in size and highly branched in Mg-10Gd-6Zn.The corrosion results indicated that the increase in Zn content increased the corrosion rate in Mg-10Gd-xZn alloys.Micro-galvanic corrosion occurred near the grain boundary in both alloys initially as the grain boundary phase was stable and acted as a cathode,however,filiform corrosion dominated in the later stage,which was facilitated by the LPSO phase in the matrix.Severe micro-galvanic corrosion occurred in Mg-10Gd-6Zn due to the higher volume of second phase.The stability of the second phase at the grain boundary was altered and dissolved after the long immersion times.Probably the NaCl solution chemically reacted with the grain boundary phase and de-stabilized it during the long immersion times,and was removed by the chromic acid used for the corrosion product removal.

High Cycle Fatigue Properties of Die-Cast Magnesium Alloy AZ91D with Addition of Different Concentrations of Cerium

The effect of addition of different concentrations of Ce on high-cycle fatigue behavior of die-cast magnesium alloy AZ91D was investigated. Mechanical fatigue tests were conducted at the stress ratio of R = 0.1, and fatigue strength was evaluated using up-and-down loading method. The results show that the grain size of AZ91D alloy is remarkably refined, and the amount of porosity decreases and evenly distributes with the addition of Ce. The fatigue strength of AZ91D alloy at room temperature increases from 96.7 up to 116.3 MPa （ 1% Ce） and 105.5 MPa （2 % Ce）, respectively, at the number of cycles to failure, Nf = 1 × 10^7. The fatigue crack of AZ91D alloy initiates at porosities and inclusions, and propagates along grain boundaries. The fatigue striations on fractured surface appear with Ce addition. The fatigue fracture surface of test specimens shows mixed-fracture characteristics of quasi-cleavage and dimple.

Corrosion performance of high pressure die-cast Al-6Si-3Ni and Al-6Si-3Ni-2Cu alloys in aqueous NaCl solution

The corrosion performance of high pressure die-cast Al？6Si？3Ni （SN63） and Al-6Si-3Ni-2Cu （SNC632） alloys in 3.5%（mass fraction） NaCl solution was investigated. X-ray diffraction （XRD） and microstructural studies revealed the presence of singlephase Si and binary Al3Ni/Al3Ni2 phases along the grain boundary. Besides, the single Cu phase was also identified at the grainboundaries of the SNC632 alloy. Electrochemical corrosion results revealed that, the SNC632 alloy exhibited nobler shift incorrosion potential （φcorr）, lower corrosion current density （Jcorr） and higher corrosion resistance compared to the SN63 alloy.Equivalent circuit curve fitting analysis of electrochemical impedance spectroscopy （EIS） results revealed the existence of twointerfaces between the electrolyte and substrate. The surface layer and charge transfer resistance （Rct） of the SNC632 alloy was higherthan that of the SN63 alloy. Immersion corrosion test results also confirmed the lower corrosion rate of the SNC632 alloy andsubstantiated the electrochemical corrosion results. Cu addition improved the corrosion resistance, which was mainly attributed to theabsence of secondary Cu containing intermetallic phases in the SNC632 alloy and Cu presented as single phase.

Grain size dependence of annealing strengthening of an extruded Mg-Gd-Zn alloy subjected to pre-compression deformation

In this work, pre-strain annealing strengthening(PSAS) effect was investigated in an extruded Mg-1.0Gd-1.5 Zn(wt.%) alloy with respect to different grain sizes. The evolution of microstructures was provided by scanning electron microscopy(SEM), electron backscattered diffraction(EBSD), transmission electron microscopy(TEM) and high-angle annular dark-field scanning transmission electron microscopy(HAADF-STEM) under the initial state, pre-compression, intermediate annealing and re-compression conditions. The obtained results showed a grain size-dependent PSAS effect in the alloy. The sample with larger grain sizes corresponded to a higher strengthening effect, which mainly resulted from a more remarkable hindrance for the growth of existing twins and a larger proportion of activation for the nucleation of new twins. This was closely associated with the increase of back stress and friction stress for twin boundary motion impeded by the larger restraint of dislocations, the higher stress field surrounding solutes and the more Zn segregation. In addition to twinning behavior, Guinier Preston(G.P.) zones on basaldislocations were found after intermediate annealing and provided an extra strengthening by inhibiting the motions of gilding pre-existing dislocations and newly formed ones, but it was independent on the grain size.

Effect of Li on formation of long period stacking ordered phases and mechanical properties of Mg-Gd-Zn alloy

Alloys with composition of Mg_(96-x)Gd_3Zn_1Li_x(at.%)(x=0, 2, 4, and 6) were prepared by conventional casting. The microstructures of these alloys under as-cast and solid-solution conditions have been observed, and the mechanical properties were investigated. The results showed that Li is an effective element to refine the grains and break the eutectic networks in as-cast MgGd_3Zn_1 alloy. During solid solution treatment, these broken eutectic networks are spheroidized and highly dispersed. In addition, plentiful lamellar long period stacking ordered(LPSO) phases are precipitated in an α-Mg matrix when the Li addition is not more than 4%. Solid-solution treated Mg_(92)Gd_3Zn_1Li_4 alloy exhibits an optimal ultimate tensile strength(UTS) of 226 MPa and elongation of 5.8%. The strength of MgGd_3Zn_1 alloy is improved significantly, meanwhile, the toughness is apparently increased.

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.

Low-cycle fatigue behavior of permanent mold cast and die-cast Al-Si-Cu-Mg alloys

Fatigue failure is one of the main failure forms of Al-Si-Cu-Mg aluminum alloys. To feature their mechanical aspect of fatigue behavior, the low-cycle fatigue behavior of permanent mold cast and die-cast AI-Si- Cu-Mg alloys at room temperature was investigated. The experimental results show that both permanent mold cast and die-cast AI-Si-Cu-Mg alloys mainly exhibit cyclic strain hardening. At the same total strain amplitude, the diecast AI-Si-Cu-Mg alloy shows higher cyclic deformation resistance and longer fatigue life than does the permanent mold cast AI-Si-Cu-Mg alloy. The relationship between both elastic and plastic strain amplitudes with reversals to failure shows a monotonic linear behavior, and can be described by the Basquin and Coffin-Manson equations, respectively.

Study on Key Joining Technology and Test Method of Steel/Al Hybrid Structure Body-in-White

Green and low carbon promote the application and development of light-weight materials in body-in-white. Large-scale die-casting Al alloy (DCAA) and high-strength thermo-formed steel sheet (TFSS) have put forward higher requirements for the application of joining technology of high-strength steel/Al dissimilar materials. Taking the new die-casting Al alloy body as an example, this paper systematically studies the progress of the latest joining methods of steel/Al dissimilar material with combination of two-layer plate and three-layer plate. By analyzing the joining technologies such as FSPR, RES, FDS and SPR, the technology and process characteristics of steel/Al dissimilar material joining are studied, and the joining technical feasibility and realization means of different material combination of the body are analyzed. The conditions of material combination, material thickness, material strength, flange height, preformed holes and joint spacing for achieving high-quality joining are given. The FSPR joining technology is developed and tested in order to meet with the joining of parts with DCAA and TFSS, especially for the joining of three-layer plates with them. It finds the method and technical basis for the realization of high quality joining of dissimilar materials, provides the early conditions for the application of large DCAA and TFSS parts in body-in-white, and meets the design requirements of new energy body. .

Effect of rare earth additions on microstructure and mechanical properties of AZ91 magnesium alloys

In order to meet the demands of high temperature components in automobile, the microstructure and mechanical properties of several new die-casting AZ91-rare earth (RE) magnesium alloys were studied. The alloys were characterized by optical microscopy (OM), scan electron microscopy (SEM), energy dispersive X-ray spectrometry (EDX), tensile and creep tests. The results show that Ce addition has little effect on the mechanical properties of AZ91 alloy at high temperature, while Y and Nd addition play important role in the improvement of creep resistance. New alloys containing Y or Nd with excellent high temperature performance are selected to produce cylinder head cover of high power diesel engine of Red Flag car and oil pan of Besturn car. The new magnesium alloys with RE addition for die-casting have potential to produce power-train parts, and can greatly decrease weight.

New technique for preparing A356 alloy semisolid slurry and its rheo-diecast microstructure and properties

A new technique for preparing semisolid slurry,namely,distributary-confluence runner(DCR),was combined with die-casting(DC)to conduct rheological die-casting(R-DC)of A356 alloy.The mechanism of DCR for semisolid slurry preparation was determined via numerical simulations and experiments.The microstructure and mechanical properties of A356 alloys prepared via DC and R-DC were studied.High-quality slurry containing numerous primary α-Al(α1-Al)with an average size of 49μm and a shape factor of 0.81 could be prepared via DCR.Simulation results indicated that the unique flow state and physical field changes during slurry preparation were conducive to accelerating the uniformity of melt temperature and composition fields,nucleation exfoliation,and spherical growth.Compared with the alloy prepared via DC,the tensile strength,yield strength,and elongation of A356 alloy prepared via R-DC increased by 19%,15%,and 107%,respectively.

Weibull analysis of effect of T6 heat treatment on fracture strength of AM60B magnesium alloy

The effect of T6heat treatment on the fracture strength and reliability of AM60B alloy was studied.The tensile specimens were poured at three different temperatures of670,685and700?C for different holding times of5,10and15min.The fluidity test was also conducted to determine the fluidity length under different pouring temperatures and holding times.According to the results,the optimum pouring temperature and holding time were determined as685?C and10min,respectively.SEM fractography of the tensile specimens reveals that the entrained oxides and oxide-related porosities are the main factors responsible for the reduction of fracture strength under the non-optimal casting conditions.The Weibull statistical approach was used to quantify the scatter of fracture strength in as-cast and heat-treated conditions.For this purpose,T6schedule was applied to the specimens prepared under the optimal casting condition.It is found that,despite minor effect on the average fracture strength,T6heat treatment improves the reliability of castings,where the Weibull modulus is increased by75%.According to the microstructural and fractography observations,this improvement is related to the evolution of more uniform microstructure and the elimination of coarse brittleβ-particles in heat-treated samples.

Opportunities and challenges of Chinese die-casting market

The present status and perspectives of Chinese die-casting market were commented. In 2003, the total output of die castings in the whole country was 708000 tons, in which the outputs of Al-alloy, Zn-alloy, Mg-alloy, Cu-alloy die castings were 474600 tons, 222000 tons, 5800 tons, 5600 tons, respectively, each accounted for 67%, 31.35%, 0.85%, 0.8% of the total. The annual sale volume of die-casting machines was approximately 1800. And the gross output value of dies approached RMB 38 billion, in which die-casting dies accounted for about 10%. In the die-casting industry of the entire country, the foreign capital enterprises, public-run enterprises, township and village enterprises, private enterprises accounted for over 80% of the total die-casting enterprises. Super huge die-casting groups are forming.

Mechanism of cryogenic,solid solution and aging compound heat treatment of die-cast Al alloys considering microstructure variation

To develop a new compound heat treatment process for improving the mechanical properties of die-cast Al alloys,this study investigated the effects of cryogenic,solution and aging compound treatment on the microstructure and mechanical properties of die-cast Al alloys.The characterization methods used were optical microscopy(OM),scanning electron microscopy(SEM),transmission electron microscopy(TEM),electron backscatter diffraction(EBSD),and tensile tests;and the Image Pro Plus software was used for statistical analysis.The results indicated that compared with T6 heat treatment,the compound heat treatment process consisting of cryogenic treatment(-196.C for 12 h),solid solution treatment(476.C for 22 min),and aging(159.C for 403 min)significantly enhanced the mechanical properties of the diecast Al alloys.For instance,the tensile strength increased from 224.3 to 249.5 MPa;the hardness increased from HV110.5 to HV 124.6,and the elongation increased from6.28%to 7.72%,which in relative terms corresponds to11.2%,12.8%and 22.9%,respectively.The compound heat treatment process of the alloy led to significant refinement of its a-Al phases.In addition,Si phases tended to be more ellipsoidal or granular,while the tips of Fecontaining phases became rounded,which played a key role in enhancing the mechanical properties and microstructure stability of the alloys.

Microstructure and mechanical properties of high-strength high-pressure die-cast Mg–4Al–3La–1Ca–0.3Mn alloy

A new high-pressure die-cast(HPDC) Mg–4 Al–3 La–1 Ca–0.3 Mn(ALaX431) alloy with high strength has successfully been fabricated. This HPDC alloy in peakaged state exhibits tensile yield strength(TYS) of 220 MPa at room temperature and TYS of 145 MPa at 250 ℃,higher than the corresponding strength of HPDC Mg alloys reported so far. These high strengths are mainly due to the formation of fine grained structure, semi-continuous reticular structure consisting of stable Al_(3)La and(Mg,Al)2 Ca particles along grain boundaries and numerous nanoscale Al_(2)Ca precipitates within grains. Due to its higher strength than existing HPDC Mg alloys, the new developed alloy has great application potential.

Effect of mischmetal on mechanical properties and microstructure of die-cast magnesium alloy AZ91D

Effects of the mischmetal addition in range of 0.4 wt.% to 1.7 wt.% on the microstructure and mechanical properties of die-cast magnesium AZ91D were investigated to improve the elevated temperature mechanical properties of the alloy by scanning electron microscopy, transmission electron microscopy, X-ray diffraction and tensile tests. The results revealed that mechanical prop- erties of die-cast magnesium alloy AZ91D-0.4%MM at 100 ℃ were near to those of die-cast magnesium alloy AZ9 ID. The ultimate tensile strength, 0.2% proof yield strength and elongation to failure of die-cast magnesium alloy AZ91D at 170 ℃ were 178, 129 MPa and 20%, respectively. In comparison, the ultimate tensile strength, 0.2% proof yield strength and elongation to faihtre of die-cast magnesium alloy AZ91D-0.4%MM at 170℃reached to 206, 142 MPa and 26%, respectively increased by 15.7%, 10% and 30%. Proper addition of mischmetal could enhance the mechanical properties at an elevated temperature, which was attributed to the formation of A1-RE phases with high thermal stability. Hence sliding of grain boundaries and cracks could be effectively hindered by A1-RE phases.

Synchronously Improving the Thermal Conductivity and Mechanical Properties of Al–Si–Fe–Mg–Cu–Zn Alloy Die Castings Through Ultrasonic-Assisted Rheoforming

An ultrasonic vibration-assisted air-cooled stirring rod process(ACSR+UV)was used to efficiently prepare a large-volume semisolid slurry with a mass of more than 40 kg.A low-cost Al–Si–Fe–Mg–Cu–Zn die-casted alloy with high thermal conductivity,high plasticity and medium strength was developed.The alloy was used to manufacture large,thin-walled parts for 5 G base stations by using the ACSR+UV rheological die-casting(ACSR+UV R-DC)process.Investigations were performed on the microstructure,porosity,mechanical properties,fracture behaviour and thermal conductivity of the ACSR+UV R-DC alloy,which was then compared to traditionally die-casted(T-DC)and ACSR R-DC alloys.The mechanisms for the microstructural refinement and enhancement of the mechanical and thermal conductivity performances of the ACSR+UV R-DC alloy were also analysed.The results showed that the ACSR+UV process increased the nucleation rate of the melt due to the increase in the nucleation area and the generation of cavitation bubbles.A radial-and an axial-forced convection was also generated inside the melt under the combined effects of acoustic flow and mechanical stirring,thereby homogenising the melt composition field and the temperature field.Therefore,the ACSR+UV R-DC process not only refined the primaryα-Al(α_(1)-Al),the eutectic silicon and the secondaryα-Al(α_(2)-Al),but also greatly improved the morphology and the distribution of the β-Al5FeSi phase.The mechanical properties of the ACSR+UV R-DC alloy were higher than those of the T-DC and the ACSR R-DC alloys.Compared to the T-DC alloy,the ultimate tensile strength,elongation and yield strength of the ACSR+UV R-DC alloy were increased by 34%,122%and 19%,respectively.This was because the ACSR+UV R-DC technique gave the alloy the characteristics of high density,fine sphericalα1-Al grain and a fine and uniform β-phase,which improved the fracture behaviour of the alloy.The thermal conductivity of the ACSR+UV R-DC alloy was 184 W/(m K),which was 10.2%and 3.4%higher than that of T-DC and ACSR R-DC alloys,respectively.This was because the refined eutectic silicon and β phases in the ACSR+UV R-DC alloy facilitated an easier electron flow through the eutectic region,and the decrease in porosity increased the effective area of heat conduction.