Grain refining aluminium foundry alloys with commercial Al–B master alloys

Abstract

In Al–3B master alloy, a higher fraction of borides is of the AlB₂ variety, while in Al–8B alloy, the predominant species is the AlB₁₂ phase. AlB₁₂ is less stable than AlB₂ and is engaged in exchange reactions, leading to the formation of transition metal diborides that subsequently settle at the bottom of the melt. Hence, AlB₁₂ is involved more in precipitating transition elements than in refining the grain structure. With predominantly AlB₁₂ particles, Al–8B master alloys are better suited for the removal of transition metal impurities in the manufacture of aluminium conductors. Al–3B, on the other hand, is a better grain refiner as the majority of its borides are of the AlB₂ variety. Which of the two master alloys is used in grain refinement does not make a difference once the transition metal impurities have been precipitated. B is dedicated to grain refinement in an impurity free aluminium melt and produces exceptionally small equiaxed grains across the section of the samples.     

Effect of grain refining and Sr-modification interactions on the impact toughness of Al–Si–Mg cast alloys

The present work investigates the effects of various types of grain refiners on the impact properties of Sr-modified A356.2 alloys in both the as-cast and heated-treated conditions. The results showed that the addition of Ti and B greatly improves the alloy toughness, but only when the alloy was in a fully modified state; moreover, the right type of master alloy and addition levels must be used. The highest values of the total absorbed energy recorded for T6-tempered alloys were obtained using Al–5%Ti–1%B and Al–10%Ti master alloys in addition to 0.04%Ti. A significant deterioration in the impact properties is observed due to the Sr–B interaction (in some cases). The improvements in toughness may be attributed to the change in Si particle morphology as well as to the dissolution and fragmentation of a number of the intermetallics formed during the T6 temper.     

Modification of eutectic silicon in Al–Si alloys

The mechanical properties of Al–Si alloys are strongly related to the size, shape and distribution of eutectic silicon present in the microstructure In order to improve mechanical properties, these alloys are generally subjected to modification melt treatment, which transforms the acicular silicon morphology to fibrous one resulting in a noticeable improvement in elongation and strength. Improper melt treatment procedures, fading and poisoning of modifiers often result in the structure which is far from the desired one. Hence it is essential to assess the effectiveness of melt treatment before pouring. A much investigated reliable thermal analysis technique is generally used for this purpose. The deviation from the standard curve in thermal analysis helps in assessing the level of refinement of the Si structure. In the present review an attempt is made to discuss various aspects of modification, including mechanism, interaction of defects and non-destructive assessment by thermal analysis.     

Effect of Si content on microstructure and mechanical properties of Al–Si–Mg alloys

Microstructure and mechanical properties of as-cast and as-extruded Al–Si–Mg alloys with different Si content are investigated by tensile test, microstructure observation. High density of Si particles in the Al alloys can induce dynamic recrystallization during hot extrusion and it becomes more matured with an increase in the density of Si particles. The tensile strength of as-cast and as-extruded alloys can be improved with the increase of Si content and hot extrusion make the elongation of alloys increase dramatically. Considerable grain refining effect caused by recrystallization occurred during hot extrusion of S2 (equivalently commercial A356 alloy) and S3 (near eutectic alloy) alloys plays an important role in the improvement of elongation. A good combination of strength and elongation for the as-extruded S3 alloy indicates that near eutectic Al–Si alloys can be hot-extruded to produce aluminum profiles with high performance.     

Production of Al–Ti–B grain refining master alloys

Abstract

In the present work the interfacial phenomena observed when an Al-Ti-B master alloy is produced have been studied using a modified sessile drop technique.The effect of emulsification has been demonstrated and the influence of small levels of CaF₂ and MgF₂ seen. The Al-Ti-B master alloys were made by the addition of potassium fluotitanate, K₂TiF₆, and potassium fluoborate, KBF₄, to molten aluminium at 750°C. The product was an Al-5Ti-1B(wt-%) master alloy and a KF-AlF₃ flux of eutectic composition. Problems can occur with the production of such alloys by first, emulsification of the liquid Al-Ti-B alloy and KF-AlF₃ flux and second, agglomeration of titanium diboride particles by the wetting and engulfment of the KF-AlF₃ flux. It has been found that levels of CaF₂ and MgF₂ in the fluoride salts greater than 50 ppm and 70 ppm, respectively, can prevent the above emulsification and boride agglomeration occurring.     

Effects of combinative addition of lanthanum and boron on grain refinement of Al–Si casting alloys

In this paper, with the combinative addition of La and B elements, the grain refinement of Al–Si alloys with different contents of Si was achieved. Compared to individual addition of B element, the combinative addition of La and B elements can effectively refine the grains of Al–Si alloys. The addition of La element suppresses the mutual poisoning between Sr and B elements, benefiting the formation of a fully modified eutectic silicon structure in the Al–Si alloys. This work also indicates that the tensile properties, especially the elongation, of Al–Si alloys are enhanced with the addition of La element.     

Effect of calcium on primary silicon particle size in hypereutectic Al–Si alloys

Abstract

Modification of hypereutectic Al-Sialloy, B390 alloy for the refinement of primary silicon particles, and its effects on tensile and impact properties were examined. Calcium was found to have an effect on the size of primary silicon particles. Primary silicon particle size was refined as calcium content decreased. Control of calcium content by the addition of Ti₂Cl₆ to the melt resulted in successful refinement of primary silicon particles. The minimum size of primary silicon particles was 20.3 μmwitha residual calcium content of 16 ppm. The microstructure was composed of very fine 20.3 μm primary silicon particles, compared to 24.5 μm primary silicon particles obtained using the AlCuP method, previously reported as the most effective method. Refinement of primary silicon particles led to an improvement in the mechanical properties of the alloy, especially elongation.     

Effect of cooling rate and Mg content on the Al–Si eutectic for Al–Si–Cu–Mg alloys

This study investigates and clarifies the qualitative and quantitative effects of Mg content and cooling rate (ranging from 0.5 to 4 °C/s), on the modification of the silicon eutectic structure and on the undercooling of the silicon eutectic growth temperature (ΔT_Si-eut) in the series of Al–Si–Cu–Mg alloys. The critical Mg content to produce a notable improvement in the silicon eutectic by 1.5 modification levels (regardless of the cooling rate) is 0.6 wt.% Mg. A similar increase in the modification level was also observed when the cooling rate was increased to a maximum of 4 °C/s, regardless of the Mg content. Measurements of the area and roundness of the silicon particles showed a good correlation with the modification level. The undercooling (ΔT_Si-eut) increased by up to ~ 23 °C at a relatively high Mg content and cooling rate and up to ~ 14 °C when the Mg content was increased from 0.4 to 0.6 wt.%.     

Real time synchrotron X-ray observations of solidification in hypoeutectic Al–Si alloys

This paper demonstrates how recent advances in synchrotron technology have allowed for the real-time X-ray imaging of solidification in Al–Si alloys, despite the small difference in atomic number of these elements. The experiments performed at the SPring-8 synchrotron, involved imaging the solidification of Al–1wt.%Si and Al–4wt.%Si alloys under a low-temperature gradient and a cooling rate of around 0.3 °C/s. The nucleation and growth of the primary aluminum grains as well as the onset of eutectic solidification were clearly observed. In the alloys containing Al–4wt.%Si, contrast was sufficient to characterize the nucleation rate and growth velocity of the aluminum grains. The importance of improving observation of solidification in the Al–Si system by increasing the time resolution during critical events is discussed.     

A study of high-temperature precipitation in Al–Mg–Si alloys with an excess of silicon

The high-temperature decomposition phenomena were examined for two Al–Mg–Si alloys with an excess of silicon. The kinetics of precipitation were studied by transmission electron microscopy and by measurement of the thermoelectric power in the temperature range from 300 to 525 °C. It was shown that decomposition occurs either at 300–400 °C by the precipitation of intermediate phase (different structures are possible depending on the alloy), which is then gradually replaced by the equilibrium phase or, between 400 and 500 °C, by direct precipitation of the phase from the supersaturated solid solution. The precipitation of silicon was also observed. At 300–350 °C, a near equilibrium in composition solid solution can coexist with Mg2Si phases out of equilibrium. Structures of intermediate phases and their orientation relationships with the matrix are given. The diagram of isothermal precipitation is constructed as an S-curve.     

Effect of grain refiner on the tensile and impact properties of Al–Si–Mg cast alloys

The present study aims to investigate the influence of the addition of Ti and B in the form of five different grain refiners/aluminium master alloys (Al–10%Ti, Al–5%Ti–1%B, Al–2.5%Ti–2.5%B, Al–1.7%Ti–1.4%B and Al–4%B) in conjunction with that of Sr (as modifier) added in the form of Al–10%Sr master alloy to A356.2 alloy. Grain refinement of an A356.2 alloy with Ti and B additions in the ranges of 0.02–0.5% and 0.01–0.5%, respectively, was examined using these different types of grain refiners. Strontium additions of 30 and 200 ppm were made. All alloys were T6-heat treated before mechanical testing. Tensile and impact tests were conducted to evaluate the influence of the interaction between grain refiner and modifier on the mechanical properties. The properties were determined for both the as-cast and heat-treated conditions.     

Effects of Si and Cu contents on grain size of Al–Si–Cu alloys

The influence of the silicon and copper contents on the grain size of high-purity Al–Si, Al–Cu, and Al–Si–Cu alloys was investigated. In the Al–Si alloys, a poisoning effect was observed and a poor correlation between the grain size and growth restriction factor was obtained. A possible cause of the poisoning effect in these alloys is the formation of a TiSi₂ monolayer on the particles acting as nucleation sites or another poisoning mechanism not associated with TiSi₂ phase formation. In the Al–Cu alloys, a good correlation between the grain size and growth restriction factor was found, whereas in the Al–Si–Cu alloys, the correlation between these two parameters was inferior.     

Effect of Fe content on the fracture behaviour of Al–Si–Cu cast alloys

Castings were prepared from 319.2 alloy melts, containing Fe levels of 0.2–1.0 wt%. Sr-modified (∼200 ppm) melts were also prepared for each alloy Fe level. The end-chilled refractory mold used provided directional solidification and a range of cooling rates (or dendrite arm spacings, DAS) within the same casting. Impact test samples were machined from specimen blanks sectioned from the castings at various heights above the chill end provided DASs of 23–85μm. All samples were T6-heat-treated before testing keeping with Aluminum Association recommendations. The results show that at low Fe levels and high cooling rates (0.4% Fe, 23 μm DAS), crack initiation and propagation in unmodified 319 alloys occurs through the cleavage of β-Al₅FeSi platelets (rather than by their decohesion from the matrix). The morphology and the size of the platelets (individual or branched) are important in determining the direction of crack propagation. Increasing the DAS to 83μm leads to cleavage fracture. In this case, the fracture path follows a transgranular plane that is usually a well-defined crystallographic plane as judged by the relatively large smooth surfaces of the β-Al₅FeSi phase platelets. Cracks also propagate through the fracture of undissolved CuAl₂ or other Cu-intermetallics, as well as through fragmented Si particles. In Sr-modified 319 alloys, cracks are mostly initiated by the fragmentation or cleavage of perforated β-phase platelets, in addition to that of coarse Si particles and undissolved Cu-intermetallics.The amount of undissolved Cu- intermetallics is directly related to the applied cooling rate. Slow cooling rate (DAS ≈83µm) results in the precipitation of Cu- containing phases on the β-platelets, amplifying the likehood for crack propagation through these loacations.     

Evolution of nickel-rich phases in Al–Si–Cu–Ni–Mg piston alloys with different Cu additions

Evolution of nickel-rich phases (Ni-phases) in Al–Si–Cu–Ni–Mg piston alloys is investigated. The qualitative results show that, with the increasing of Cu content, Ni-phases translate from Al₃Ni (ε-phase) or Al₃CuNi (δ-phase) to Al₇Cu₄Ni (γ-phase), and their morphologies change from short-strip to reticular and then annular or semi-annular shape. Moreover, the quantitative calculations by Thermo-Calc software are in accordance with that of experiments’. The evolutions have a great effect on the mechanical properties. The tensile strength at room temperature decreases from 263.8 MPa to 229.6 MPa, and then increases to 278.9 MPa. Otherwise, the elevated temperature tensile strength increases about 19.7%. But the coefficient of linear expansion decreases constantly.     

Influence of Si content on thermal expansion characteristic of Al–Si alloys

ABSTRACT

The objective of this study was to find out how Si precipitation affects the linear thermal expansion behaviors of Al–Si alloys with various Si content. These Al–Si alloys were manufactured by gravity casting using 99.98?wt-% pure Al and 98.5?wt-% Si pellets. Solution treatment was carried out at 530°C for 10 h for each specimen. As-quenched specimens were subjected to microstructure observation and linear thermal expansion analysis. Si precipitation and additional linear thermal expansion occurred at lower temperature when Si content was increased to 9.5?wt-%. The activation energy of Si precipitation was also lower when Si content was higher. Eutectic Si reduced diffusion distance and acted as a nucleation site of dissolved Si atoms in the Al matrix during aging. These Si phases decreased Si precipitation temperature and activation energy of Si precipitation.     

Effect of heat treatment and Fe content on the microstructure and mechanical properties of die-cast Al–Si–Cu alloys

The effect of solution and ageing heat treatment on the microstructure and mechanical properties of the die-cast Al–9 wt.%Si–3.5 wt.%Cu alloys containing 0.1–1.0 wt.% Fe was investigated. The results showed that the dendritic primary α-Al phase was varied from 20 to 100 μm in size and the globular α-Al grains were smaller than 10 μm in size. The Fe-rich intermetallics exhibited coarse compact or star-like shapes with the sizes from 10 to 20 μm and the fine compact particles at an average size of 0.75 μm. The solution treatment of the alloys could be achieved in a short period of time, typically 30 min at 510 °C, which dissolved the Cu-rich intermetallics into the primary α-Al phase and spheroidised the eutectic Si phase. During the subsequent ageing treatment, numerous fine precipitates of θ′ and Q′ phases were formed to provide effective strengthening to the α-Al phase, significantly improving the mechanical properties. Therefore, Fe content in the die-cast Al–Si–Cu alloys needs to be controlled at a low level in order to obtain the improved ductility and strength under solution and aged condition.     

Effect of silicon content on the microstructure and properties of Fe–Cr–C hardfacing alloys

In this study, the surface of St52 steel was alloyed with preplaced powders 55Fe39Cr6C, 49Fe39Cr6C6Si, and 45Fe39Cr6C10Si using a tungsten-inert gas as the heat source. Following surface alloying, conventional characterization techniques, such as optical microscopy, scanning electron microscopy, and X-ray diffraction were employed to study the microstructure of the alloyed surface. Microhardness measurements were performed across the alloyed zone. Room-temperature dry sliding wear tests were used to compare the coatings in terms of their tribological behavior. It was found that the as-deposited coatings contained higher volume fractions of carbides (Cr₇C₃). The presence of 6%Si in the preplaced powders caused an increase in microhardness and wear resistance.     

Effect of aging and dispersoid content on tensile properties of Al–0·6Mg–1 Si alloys

Abstract

Slip distribution was varied in a series of Al–Mg–Si alloys by changing the amount of manganese-bearing dispersoid present and by under- and overaging, which also altered the grain–boundary precipitate-free zones and hence the grain–boundary strength. Dispersoids are shown to increase ductility by slip homogenization. Slip is more heterogeneous in underaged alloys, but these show greater ductility than overaged alloys because the grain boundaries are stronger. Work-hardening rates increase with dispersoid content, although for a given dispersoid content, the underaged alloys have higher work-hardening rates. This effect is interpreted in terms of the effect of aging upon the properties of the grain-boundary regions.

MST/340     

Characterization of silicon phases in spray-formed and extruded hypereutectic Al–Si alloys by image analysis

The silicon phases in the spray-formed and extruded hypereutectic Al–Si alloys (AlSi18, AlSi25 and AlSi35) have been quantitatively evaluated by means of image analysis technique. The influence of silicon content in the alloys, thermal conditions during spray forming of the alloys and hot extrusion of the spray-formed alloys on the size, shape, dispersion and orientation of the silicon phases have been studied and discussed. In general, the silicon phases are greatly refined and uniformly distributed in the spray-formed Al–Si alloys. This improvement in the silicon phases is further facilitated by low thermal input as well as fast cooling conditions during spray forming. The silicon particles in the as-extruded Al–Si alloys appear more homogeneous and regular than those in the as-deposited Al–Si alloys but exhibit a certain amount of anisotropy and a tendency to preferred orientation. The silicon particles, depending on the particle size and shape, may fracture or coarsen during extrusion.