Effect of Ablation Casting Process on the Microstructural Parameters and Tensile Properties of A413 and A356 Alloys
International Journal of Metalcasting - Trang 1-14 - 2023
Tóm tắt
The process of ablation casting (AC) is a novel sand casting technique that not only offers the benefits of conventional sand casting (CSC), but also offers opportunities to overcome some of its shortcomings. In this research, A413 and A356 alloys were cast via CSC and AC processes. The CSC simulation process showed that the solid fraction parameter at different times indicated A413 to be more suitable than A356 for the AC process. The experimental results showed that AC process increased the cooling rate of both alloys (4–6% times for A413 and 9–10 times for A356), compared to CSC. Moreover, prolonging water spray delay time led to decrease in the cooling rate. Indeed, the AC has a more significant impact on reducing SDAS in A413 (60–75%) compared to A356 (45–61%). Moreover, decreasing the Si content in hypo-eutectic Al–Si binary systems limits the water spray delay time at a similar superheat. Besides, the reduction of eutectic silicon aspect ratio is nearly equal in both A413 (77–81%) and A356 (80–83%) alloys, through the AC compared to CSC. Furthermore, through the use of AC, the UTS of A413 and A356 increased by 112–130% and 78–100%, the YS of A413 and A356 increased by 8–21% and 31–42%, and the elongation of A413 and A356 increased by 333–620% and 110–252%, respectively, compared to CSC. These experimental results confirmed the simulation results. Finally, the transition of fracture from cleavage plane to dimple form occurred through AC for both A413 and A356 alloys, compared to CSC. In sound casting, it was found that the role of eutectic silicon in fracture was more prominent than Fe-containing intermetallic compounds.
Tài liệu tham khảo
J.R. Davis, Aluminum and Aluminum Alloys (ASM international, 1993)
E. Georgantzia, M. Gkantou, G.S. Kamaris, Aluminium alloys as structural material: a review of research. Eng. Struct. 227, 111372 (2021)
Handbook, A., Introduction to Aluminum-Silicon Casting Alloys, vol. 2 (2004), pp. 1–9
R. Ahmad, M. Asmael, Influence of cerium on microstructure and solidification of eutectic Al–Si piston alloy. Mater. Manuf. Process. 31(15), 1948–1957 (2016)
A. Dahle et al., Eutectic modification and microstructure development in Al–Si Alloys. Mater. Sci. Eng. A 413, 243–248 (2005)
S. Farahany et al., Evaluation of the effect of Bi, Sb, Sr and cooling condition on eutectic phases in an Al–Si–Cu alloy (ADC12) by in situ thermal analysis. Thermochim. Acta 559, 59–68 (2013)
O. Gursoy, G. Timelli, Lanthanides: a focused review of eutectic modification in hypoeutectic Al–Si alloys. J. Market. Res. 9(4), 8652–8666 (2020)
S. Jigajinni, K. Venkateswarlu, S. Kori, Computer aided cooling curve analysis for Al-5Si and Al-11Si alloys. Int. J. Eng. Sci. Technol. 3(6), 257–272 (2011)
J. Li et al., Modification of eutectic Si in Al–Si alloys with Eu addition. Acta Mater. 84, 153–163 (2015)
H. Liao et al., Eutectic solidification in near-eutectic Al–Si casting alloys. J. Mater. Sci. Technol. 26(12), 1089–1097 (2010)
H. Liao et al., Refinement of eutectic grains by combined addition of strontium and boron in near-eutectic Al–Si alloys. Scripta Mater. 57(12), 1121–1124 (2007)
P. Ma et al., Mechanism of formation of fibrous eutectic Si and thermal conductivity of SiCp/Al-20Si composites solidified under high pressure. J. Alloys Compd. 709, 329–336 (2017)
M. Mahmoud, A. Samuel, H. Doty, S. Valtierra, F. Samuel, Effect of rare earth metals, Sr, and Ti addition on the microstructural characterization of A413. 1 alloy. Adv. Mater. Sci. Eng. 2017, 4712946 (2017). https://doi.org/10.1155/2017/4712946
M. Mahta et al., Precipitation of Fe rich intermetallics in Cr-and Co-modified A413 alloy. Int. J. Cast Met. Res. 18(2), 73–79 (2005)
G. Mao et al., The varied mechanisms of yttrium (Y) modifying a hypoeutectic Al–Si alloy under conditions of different cooling rates. J. Alloy. Compd. 806, 909–916 (2019)
A. Mazahery, M.O. Shabani, Modification mechanism and microstructural characteristics of eutectic Si in casting Al–Si alloys: a review on experimental and numerical studies. JOM 66(5), 726–738 (2014)
J. Rao et al., Modification of eutectic Si and the microstructure in an Al-7Si alloy with barium addition. Mater. Sci. Eng. A 728, 72–79 (2018)
A. Samuel, H. Doty, S. Valtierra, F. Samuel, Effect of Sr-P interaction on the microstructure and tensile properties of A413. 0 type alloys. Adv. Mater. Sci. Eng. 2016, 7691535 (2016). https://doi.org/10.1155/2016/7691535
S. Shabestari, S. Ghodrat, Assessment of modification and formation of intermetallic compounds in aluminum alloy using thermal analysis. Mater. Sci. Eng. A 467(1–2), 150–158 (2007)
S. Valtierra, J. Lacaze, Effect of strontium and cooling rate upon eutectic temperatures of A319 aluminum alloy. Scripta Mater. 52(6), 439–443 (2005)
J. Grassi et al., Ablation Casting. Aluminum Alloys Fabrication, Characterization and Applications (TMS, 2008)
M. Taghipourian et al., The effect of waterjet beginning time on the microstructure and mechanical properties of A356 aluminum alloy during the ablation casting process. J. Mater. Process. Technol. 238, 89–95 (2016)
M. Tiryakioglu, P. Eason, J. Campbell. Fatigue life of ablation cast 6061-T6 components. in 13th International Conference on Aluminum Alloys (ICAA 13): Conference Proceedings. (Springer, 2017)
J. Grassi, J. Campbell, M. Hartlieb, F. Major, The ablation casting process. in Materials Science Forum, vol. 618 (2009), pp. 591–594. https://doi.org/10.4028/www.scientific.net/MSF.618-619.591
S.M.A. Boutorabi, P. Torkaman, J. Campbell et al., Structure and properties of carbon steel cast by the ablation process. Inter Metalcast 15, 306–318 (2021). https://doi.org/10.1007/s40962-020-00466-7
T.J. Williams, D. Galles, C. Beckermann. Translating water spray cooling of a steel bar sand casting. in 67th SFSA Technical and Operating Conference, Iowa (2013)
A.H. Fazeli, S.M.A. Boutorabi, H. Saghafian, Ablation casting of high-aluminum ductile cast iron (Fe-C-Al-Mg). Inter Metalcast 17, 1778–1790 (2023). https://doi.org/10.1007/s40962-022-00851-4
E. Heidari et al., Ablation casting of thin-wall ductile iron. Int. J. Metalcast. 16(1), 166–177 (2022)
M. Arabpour, S.M.A. Boutorabi, H. Saghafian, Effect of casting thickness on the solidification characteristics and microstructural parameters of near-eutectic Al–Si alloy produced by ablation casting process. Metallogr. Microstruct. Anal. 11, 1–13 (2022)
V. Bohlooli, M. Shabani Mahalli, S. Boutorabi, Effect of ablation casting on microstructure and casting properties of A356 aluminium casting alloy. Acta Metall. Sin. 26(1), 85–91 (2013)
A. Kheirabi, M. Divandari, S.M.A. Boutorabi et al. Effect of the modified ablation casting process on the mechanical properties and microstructure of near eutectic Ai–Si alloy. Inter Metalcast 16, 1557–1574 (2022). https://doi.org/10.1007/s40962-021-00672-x
S. Puzio, J. Kamińska, M. Angrecki, K. Major-Gabryś, Effect of the type of inorganic binder on the properties of microwave-hardened moulding sands for ablation casting technology. Arch. Metall. Mater. 65(4), 1385–1390 (2020). https://doi.org/10.24425/amm.2020.133704
S. Puzio et al., The use of phosphate binder for ablation casting of AlSi7Mg modified TiB alloy. Arch. Found. Eng. 22, 1 (2022)
M. Arabpour, H. Saghafian, S.M.A. Boutorabi, Effect of ablation casting on the microstructural parameters and tensile properties of aluminum matrix composite reinforced by SiC particles. Metallogr. Microstruct. Anal. 11, 1–13 (2022)
D. Weiss et al., Ablation of hybrid metal matrix composites. Trans. Am. Found. Soc. 119, 35–42 (2011)
D. Emadi, L.V. Whiting, M. Diurdjevic, W.T. Kierkus, J. Sokolowski, Comparison of newtonian and fourier thermal analysis techniques for calculation of latent heat and solid fraction of aluminum alloys. Metall. Mater. Eng. (2018). https://doi.org/10.30544/379
Q. Han, Ablation casting: solidification characteristics, microstructure formation, and mechanical properties. Inter Metalcast 15, 1213–1222 (2021). https://doi.org/10.1007/s40962-020-00544-w
D. Sui, Q. Han, Modeling ablation casting. Int. J. Metalcast. 16(1), 132–142 (2022)
A. Verma et al., Influence of cooling rate on the Fe intermetallic formation in an AA6063 Al alloy. J. Alloys Compd. 555, 274–282 (2013)
J. Campbell, Complete Casting Handbook: Metal Casting Processes, Metallurgy, Techniques and Design (Butterworth-Heinemann, 2015)
D. Wankhede et al., Influence of pouring temperature and external chills on mechanical properties of aluminum silicon alloy castings. Mater. Today Proc. 5(9), 17627–17635 (2018)
M.T. Di Giovanni et al., How slight solidification rate variations within cast plate affect mechanical response: a study on as-cast A356 alloy with Cu additions. Adv. Mater. Sci. Eng. 2018, 1–11 (2018)
Z. Liu, L. Zhou, G. Li, Effects of cooling rate on the microstructure and tensile strength of A356 alloy wheels. in 3rd International Conference on Material, Mechanical and Manufacturing Engineering (IC3ME 2015) (Atlantis Press, 2015)
M.O. Shabani, A. Mazahery, Prediction of mechanical properties of cast A356 alloy as a function of microstructure and cooling rate. Arch. Metall. Mater. 56(3), 671–675 (2011)