Microstructure and mechanical properties of hypereutectic Al-Si alloy modified with Cu-P

The microstructure and mechanical properties of Al-14.6Si castings modified by Cu-P master alloy under different conditions were studied with optical microscope（OM） and mechanical testing and simulation（MTS）.The results indicate that the Cu-P master alloy possesses not only obvious modification effect,but also longevity effect with more than 8 h on the hypereutectic Al-Si alloy.It is shown from thermal calculation,scanning electron microscope（SEM）,and energy dispersive analysis of X-rays（EDAX） that the modification mechanism of Cu-P on primary silicon in the castings is heterogeneous nucleation around AlP particles.The Cu-P master alloy has no or little modifying effect on eutectic silicon,even though it has obvious modification on primary silicon in the castings.This may be because of the fast transformation of eutectic silicon at a very narrow temperature,which will notably weaken the role of AlP particles as heterogeneous nuclei for eutectic silicon.

Microstructure evolution and phase transformation of traditional cast and spray-formed hypereutectic aluminium-silicon alloys induced by heat treatment

Microstructural evolution and phase transformation induced by different heat treatments of the hypereutectic aluminium-silicon alloy, Al-25Si-5Fe-3Cu （wt%, signed as 3C）, fabricated by traditional cast （TC） and spray forming （SF） processes, were investigated by differential scanning calorimetry （DSC） and scanning electron microscopy （SEM） combined with energy dispersive X-ray spectroscopy and X-ray diffraction techniques. The results show that A17Cu2Fe phase can be formed and transformed in TC- and SF-3C alloys between 802-813 K and 800-815 K, respectively. The transformation from β-Al5FeSi to δ-Al4FeSi2 phase via peritectic reaction can occur at around 858-870 K and 876-890 K in TC- and SF-3C alloys, respectively. The starting precipitation temperature of δ-Al4FeSi2 phase as the dominant Fe-bearing phase in the TC-3C alloy is 997 K and the exothermic peak about the peritectic transformation of δ-Al4FeSi2→β-Al5FeSi is not detected in the present DSC experiments. Also, the mechanisms of the microstructural evolution and phase transformation are discussed.

Modification ofβ-Al_5FeSi Compound in Recycled Al-Si-Fe Cast Alloy by Using Sr,Mg and Cr Additions

The effects of Sr,Mg,Cr,Sr/Mg and Sr/Cr combined additions on the Fe-containing intermetallic phase in a recycled Al-Si-Fe cast alloy are investigated.The experimental results show that the additions of Cr and Sr/Cr successfully modified the platelet and flake-likeβ-Al-5FeSi phases （β-compound） into the fibrousα-Al-8Fe-2Si （α-compound）.The additions of Sr and Sr/Mg were less effective to modify theβ-compound into theα-compound,while the eutectic Si was fully modified into the fibrous morphology.A small secondary dendrite arm spacing （DAS） was found in the Sr-added,Cr-added and Sr/Cr-added alloys,especially in a steel mold.The Sr,Sr/Cr and Sr/Mg combined additions modify the eutectic Si simultaneously.A sludge phase was found in the addition of Cr-added,Sr/Cr-added and Mg-added alloys,especially in the graphite mold casting.The volume fraction ofβ-compounds was decreased by the addition of various modifying elements. The Cr and Sr/Cr combined additions are very effective to modify theβ-compound for the recycled Al-Si-Fe based alloys.

Effect of mixing rate and temperature on primary Si phase of hypereutectic Al-20Si alloy during control ed diffusion solidification(CDS) process

Controlled Diffusion Solidification(CDS) is a promising process relied on mixing two liquid alloys of precisely controlled chemistry and temperature in order to produce a predetermined alloy composition. In this study, the CDS was employed to prepare hypereutectic Al-20%Si(mass fraction) alloy using Al-30%Si and pure Al of different temperatures. The mixing rate was controlled using three small crucibles with a hole of different diameters in their bottom. The effect of mixing rate and temperature on the microstructure of the primary Si-phase during the mixing of molten Al and Al-30%Si was studied. The results showed that when the diameter of the small crucible bottom hole is 16 mm, a higher mass mixing rate 0.217 kg·s-1 would results in a lower stream velocity 0.414 m·s-1. Conversely a lower mass mixing rate 0.114 kg·s-1(the diameter of the small crucible bottom hole is 8 mm) would result in a higher fluid stream velocity 0.879 m·s-1. A lower mass mixing rate would be better to refine the primary Si than a higher mass mixing rate. Meanwhile, the morphology and distribution of primary Si could also be improved. Especially, when Al-30%Si alloy at 820 °C was mixed with pure Al at 670 °C in the case of a mass mixing rate of 0.114 kg·s-1 and a pouring temperature of 680 °C, the average size of the primary Si phase would be only 18.2 μm. Its morphology would mostly be octahedral and the primary Si would distribute uniformly in the matrix microstructure. The lower mass mixing rate(0.114 kg·s-1) will enhance the broken tendency of Al-30%Si steam and the mixing agitation of resultant melt, so the primary Si phase can be better refined.

Mechanical properties of hypereutectic Al-Si alloy by semisolid processing

Semisolid hypereutectic Al Si alloy billets were obtained by electromagnetic stirring, in which microstructure of primary silicon gets rounder and there are a large number of rosette α phases appearing. Compared with conventional gravity die casting alloys, the tensile strength and elongation of semisolid forming hypereutectic Al Si get obviously improved. Change of primary silicon morphology of semisolid hypereutectic Al Si alloy made by electromagnetic stirring is the main reason of better tensile strength, and a large number of rosette α phases precipitation is the main reason of better elongation.

Semi-solid characteristics and thixoforming of hypereutectic Al-Si alloy

Effects of processing parameters on microstructure evolutions by mechanical stirring, procedures for obtaining thixotropy in semi solid slurries, and procedure for thixoforging component, were investigated in hypereutectic Al Si alloy. It is shown that 605 ℃ was the proper temperature for stirring treatment of this alloy, at which the coarse and plate primary Si crystals were effectively changed to globular crystals with a mean diameter of 200 μm after 50 min stirring, that billets with excellent thixotropy were obtained after 50 min remelting at 575 ℃, in which solid fraction of matrix and primary Si crystals was about 60%, and that a perfect near net shape component of disc casting was obtained by thixoforging.

Microstructure Characteristics and Apparent Viscosity of Hypereutectic Al-24%Si Alloy Melt During Semi-solid State Stirring

The microstructural evolution and apparent viscosity of hypereutectic Al-24%Si alloy during semi-solid state shearing were studied with a Searte type viscometer. When the alloy melt was continuously stirred from 720 degreesC to eutectic temperature, the primary Si crystals were gradually changed from elongated platelets to near-spherical shapes. It was found that some nondendritic a-phase formed when the melt was stirred below 585 degreesC. The experiment showed that the semi-solid stirring had strong effect on inhibiting the anisotropic growth of Si crystals during solidification. The apparent viscosity of the alloy melt increased slowly with the decreasing of temperature before the formation of nondendritic alpha -phase, which caused the dramatic increase of apparent viscosity.

Influences of complex modification of P and RE on microstructure and mechanical properties of hypereutectic Al-20Si alloy

P and RE complex modification of hypereutectic Al-Si alloys was conducted. The influences of P, RE content on the microstructure and mechanical properties of alloys were investigated. The complex modifications of P and RE make the coarse block primary silicon obviously refined and the large needle eutectic silicon modified to the fine fibrous or lamella ones. P mainly refines the primary silicon, but excess P is unfavorable to the refinement of primary silicon. RE can well refine the primary and eutectic silicon, but its modification effect on the eutectic silicon is more obvious. P can repress the modification of RE on the eutectic silicon. The alloys with the additions of 0.08% P and 0.60% RE have the optimal microstructure and the highest mechanical properties. Compared with the unmodified alloy, the primary silicon of alloys can be refined from 66.4 μm to 23.3 μm and the eutectic silicon can be refined from 8.3 μm to 5.2 μm. The tensile strength is improved from 256 MPa to 306 MPa and the elongation is improved from 0.35% to 0.48%.

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.

Modification and aging precipitation behavior of hypereutectic AI-21wt.%Si alloy treated by P+Ce combination

In the present study, the tested hypereutectic Al-21 wt.%Si alloys were prepared by modifying the melt using different proportions of P and Ce, and then applying T6 heat treatment. The modif ication effects and mechanism of P+Ce complex modif ier on the Si phase of hypereutectic Al-21 wt.%Si alloy were studied, and the aging precipitation behavior after modif ication was characterized by means of tensile strength measurement, OM, SEM and TEM analysis. The results show that the massive primary silicon phase particles are signif icantly ref ined after modif ication, while the needle-like eutectic silicon crystals become f ibrous and short. It was found that the mechanism of phosphorus modifi cation on the primary silicon can be attributed to heterogeneous nucleation of Al P, while the modification mechanism of Ce can be explained by adsorbing-twinning theory. In the aged microstructure of the modif ied hypereutectic Al-21 wt.%Si alloy, there existed some strengthening phases such as Al4Cu9, Al2 Cu, AlC u3, and Al57Mn12. The P+Ce complex modif ier not only affected the size of primary silicon and eutectic silicon, but also the aging behavior of alloys under the heat treatment process. When Al-21 wt.%Si alloy was modif ied using 0.08%wt.P + 0.6wt.% Ce, the aging precipitates were dispersed uniformly in the alloy, and its mechanical properties at room and elevated temperatures are optimized(Rm = 287.6 MPa at RT, Rm = 210 MPa at 300 ℃).

Refinement and thermal analysis of hypereutectic Al-25%Si alloy

Refinement and thermal analysis of hypereutectic Al 25%Si alloy were investigated with scanning electron microscope (SEM) and differential scanning calorimeter (DSC). The results show that the average size of primary silicon in Al 25%Si alloy without and with phosphorus addition are 250 μm and 30 μm, respectively. But the primary and eutectic growth temperature is raised by about 17.3 ℃ and 4?℃ respectively due to phosphorus addition. The primary nucleation temperatures are 745.0 ℃ and 762.0 ℃ for untreated and treated samples and in addition, the enthalpy changes of primary and eutectic transformation are -261.0 J/g and -397.3 J/g without phosphorus addition, -294.2 J/g and -386.1 J/g with phosphorus addition, respectively. Otherwise the mechanisms of refinement and thermal transformation of Al 25%Si alloy in solidifying process are also discussed. [

Influence of hydrogen content on the behavior of grain reflnement in hypereutectic aluminum-silicon alloy

Dissolved hydrogen is harmful to mechanical properties of refinedhypereutectic aluminum-silicon alloys. In the present work, by using a stepped-form mold and thehydrogen-detecting instrument HYSCAN II, the relationship between the initial hydrogen content inthe melt and the refinement effect on the casting of hypereutectic aluminum-silicon alloy wasinvestigated. The experimental results show that the cooling rate, the hydrogen content and thegrain refinement effect are three interactive factors. When the hydrogen content is above 0.20mL/100 g and the cooling rate is lower than that in 50 mm-thick step, hydrogen dissolved in thealloy melt influences the grain refinement effect. With increasing the cooling rate, the criticalhydrogen content increases too. It is expected that much hydrogen in the melt make the netinterfacial energy larger than or equal to zero, resulting in the shielding of the particles AlPduring solidification and that the critical gas content is closely related to the critical radius ofembryo bubbles.

Semi-solid processing of hypereutectic A390 alloys using novel rheoforming process

The feasibility of semi solid processing of hypereutectic A390 alloys using a novel rheoforming process was investigated.A combination of the swirl enthalpy equilibration device (SEED) process, isothermal holding using insulation and addition of solid alloy during swirling was introduced as a novel method to improve the processability of semi solid slurry.The effects of isothermal holding and the addition of solid alloy on the temperature gradient between the centre and the wall and on the formation of α(Al) particles were examined.In additional tests, phosphorus and strontium were added to the molten metal to refine the primary and eutectic silicon structure to facilitate semi solid processing.The results show that the combination of the SEED process with two additional processing steps can produce semi-solid A390 alloys that can be rheoprocessed.The microstructure reveals an adequate amount of non-dendritic α(Al) globules surrounded by liquid, which greatly improves the processability of semi-solid slurry.

Hydrogen Content and Porosity Behavior of Hypereutectic Aluminum-silicon Alloy with Phosphorus

By making castings that pick up gas from moisture in red sand molds,the porosity generated at different cooling rates was discussed during solidification of hypereutectic Al-25%Si alloy without and with phosphorus additions. The effect of phosphorus addition on hydrogen content in the melt was also studied. It was observed that the phosphorus addition made hydrogen content in alloy melts present a “see-saw' tendency.In addition to primary silicon refinement,the phosphorus promoted gas porosity formed not only in slowly cooled sections, but also in rapidly cooled sections. There was a small difference in density of full dense sample between P-refined and unrefined castings, with a larger density associated with phosphorous addition. The change of the surface tension seemed more reasonable to explain the mechanism of porosity behavior.

Effect of Nd on Microstructure and Mechanical Properties of Hypereutectic Al-25Si Alloy

The modification mechanism of Nd on Al-25Si alloy was studied. The result showed that pure Nd (0.3%) could significantly refine primary silicon in hypereutectic Al-25Si alloy. And the morphology of primary silicon was transformed from star-shaped to block and the size of primary silicon changed from 150～200 μm to 40～80 μm after modification. The morphology of silicon and elements presence was detected by means of SEM-EDS, XRD was carried out to detect the phase constitution before and after modification. It was found that no new phase formed and the lattice of silicon and aluminum increased after modification and most of Nd may exist as solids solute element of silicon and absorb on the surface of silicon. Mechanical property test results showed that after modification with 0.3% Nd, Tensile strength increased about 33% from 138 to 184 MPa, yield strength increased about 15% from 126 to 145 MPa, and elongation change was not obvious. The improvement of mechanical property should attribute to fine grain strength and purification of base metal after modification.

Modification effect of pure rare earth metal La on as-cast hypereutectic Al-17%Si alloys

The modification effect of La addition on the microstructural characteristics of hypereutectic Al 17%Si alloys was studied. Microstructures were examined using conventional optical microscopy and electron probe X ray microanalyzer. The morphology of Si crystal was evaluated by quantitative metallographical analysis. The results indicate that simultaneous modification to both primary and eutectic Si crystals is obtained by the addition of pure rare earth metal La in the hypereutectic Al 17%Si alloys while the optimal effect of La is obtained at a rather large scale. La begins to form intermetallic compound when its concentration exceeds approximately 1%, which appears as dark platelets in etched specimens. Electron probe X ray microanalysis experiment shows that La rich platelet could be represented as Al 1Si 2La 2 consisting of LaSi 2 and some unknown ternary Al x Si y La phase.

Modification mechanism of hypereutectic Al-Si alloy with P-Na addition

Effect of P-Na united modification on Al-22%Si-1.0%Cu-0.5%Mg-0.5%Mn alloy was studied. The results show that the refining effect of P-Na addition on primary silicon is superior to that of P and the former could modify eutectic silicon at the same time. Effects of P-Na modification on crystallization and microstructure of hypereutectic Al-Si alloys were studied with Electron-Scanning Microscope, Electron-Probe and X-ray diffractometer. The modification mechanism represents that on one hand, the primary silicon is refined by AlP as heterogeneous nucleus; on the other hand, when Na is added at the same time, P atoms are difficult to diffuse in the melt, and then enrichs on the growing faces of silicon phase. Moreover, a SiP compound was also discovered in Si crystals, which prevents the growth of silicon phase and refines the primary silicon.

Characteristics and Microstructure of a Hypereutectic Al-Si Alloy Powder by Ultrasonic Gas Atomization Process

A hypereutectic Al-Si alloy powder was prepared by ultrasonic gas atomization process. The morphologies, microstructure and phase constituent of the alloy powder were studied. The results showed that powder of the alloy was very fine and its microstructure was mainly consisted of Si crystals plus intermetallic compound A19FeSi3, which were.very fine and uniformly distributed.

Rapidly solidified hypereutectic Al-Si alloys prepared by powder hot extrusion

Rapidly solidified hypereutectic Al-Si alloys were prepared by powder hot extrusion. By eliminating vacuum degassing procedure, the fabrication routine was simplified. The tensile fracture mechanisms at room temperature and elevated temperature were investigated by SEM fractography. Compared with KS282 casting material, the tensile strength of rapidly solidified Al-Si alloy is greatly improved due to silicon particles refining while its density and coefficient of thermal expansion are lower than those of KS282. The wear resistance of RS AlSi is better than that of KS282.

Effects of ZnS modification on primary Si in hypereutectic Al-Si alloy

A new modifying agent, ZnS, was used as a refiner to modify primary silicon in hypereutectic AlSi alloy. The factors affecting the modification results, including addition level of ZnS and holding time, were investigated. The results showed that the average size of the most effectively modified primary silicon was 28.5 μm when the ZnS mixed powder addition was 0.15 wt.% with a holding time of 10 min. More important, the average size of primary silicon could remain below 40 μm despite the holding time extending to 120 min, which means ZnS is a promising modifying agent of primarySi in industrial applications.