铸造Al-Si系合金中的合金元素的作用

对铸造Al-Si系合金中杂质元素Fe,合金元素Mg、Cu、Sn、Mn、Be、Pb和变质元素稀土、Sr、P、B、Na等的作用进行了分析和概述。Fe能提高合金硬度和耐磨性,但会降低合金的力学性能。Mg能提高合金强度,但Fe、Mg共同作用会降低合金的力学性能。Cu和Mn对脆性Al-Fe-Si相有变质作用,并能提高合金力学性能,Cu与Ni复合作用,可提高Al-Si合金的高温强度和硬度。Sn能提高合金的力学性能。Be降低富铁相有害作业,提高合金力学性能。Pb能提高合金的机加工性能和耐磨性能。Na、Ca都对共晶硅有变质作用,P、B可细化初晶Si,稀土元素和Sr对共晶Si和初晶Si都有变质作用。     

Ca在铝合金中的作用

Ca在铝合金中的作用具有两面性,一方面表现出抑制P变质、降低流动性、增加氧化物夹杂等有害作用,另一方面体现出改善Al-Si合金中β-Fe相形态、细化初晶硅、变质共晶硅等有益影响。首先综述了Ca对铝合金显微组织、铸造性能、变质作用等的影响;其次系统归纳了Ca与Si、Fe、P、Sr、Cu等元素的二元交互作用规律,其中Ca-Si、Ca-Fe、Ca-Sr、Ca-Cu等元素二元交互均表现出协同作用,而Ca-P的抑制作用可以通过添加B或C2Cl6来消除;最后,开发含Ca的二元、多元联合变质剂,深化Ca对铝合金微合金化作用机理以及再生循环过程中Ca对其他元素的影响等都是今后重点研究的思路与方向。     

杂质元素对铝硅合金Si相形核影响的探讨

Si相的尺寸和形貌对Al-Si合金的性能具有重要的影响。如何在增加Si相的有效形核基底数量以显著提高Si相形核率、细化初晶Si的同时,不削弱共晶Si的细化和变质效果,是提高铝硅合金性能的关键。添加适量的合金元素和微量元素是调节Si相形核率的重要手段之一,特别是在不影响主合金元素成分要求的前提下,通过添加变质剂或细化剂,结合除杂技术和浇铸工艺可以明显细化共晶Si尺寸。但是,废杂铝中的杂质元素对Si相形核率的影响规律及其作用机理尚未达成共识,这是废杂铝再生铸造铝硅合金研究中的热点和难点。废杂铝再生因其具有原料来源广、可再生利用、节能减排效果显著等优点成为生产铸造铝合金的重要工艺。然而,由于废杂原料含有多种杂质元素,并且它们对铝硅合金中Si相的交互作用关系不确定,所以很难制定相应的技术措施以同时细化共晶Si和初生Si相。目前已经确证AlP为Si相形核的主要基底,β-Fe相为次要基底,氧化膜对二者的形成具有促进作用。近年来,除深入研究常见元素对Si相形核的作用机理外,两种及两种以上元素之间的相互作用对Si相形核的作用机理也开始受到广泛关注。在充分研究AlP、β-Fe相、氧化膜等可作为Si相形核基底物质的结构特性基础上,针对P-X、Fe-X、Ca-X等二元交互作用对Si相形核的影响研究也取得了显著成果。Sr、Ca、B、Mg等元素一般通过钝化AlP、β-Fe相等Si相形核基底的活性或与AlP反应生成更稳定的化合物这两种机制降低Si相的形核率。当三种或三种以上杂质元素通过直接或间接的交互作用对共晶硅形核率产生影响时,作用机理和作用效果将更为复杂。其主要表现为两种杂质元素单独存在时均有助于发挥第三元素的作用,但同时存在时会反应生成化合物,反而弱化第三元素促进Si相形核的作用。本文描述了Al-Si合金凝固过程中Si相形核基底的作用,重点讨论了常见杂质元素对Si相形核基底的影响。文末就如何进一步掌握杂质元素对Si相形核的交互作用规律以避免杂质元素的有害影响和充分发挥有益微量元素的积极作用提出了新的建议。     

动态复合细化变质对A356铝合金显微组织的影响

为弥补Al-10Sr中间合金对A356铝合金变质处理的不足,采用自制的Al-5Ti-1B-1RE中间合金与A1-10Sr中间合金对A356铝合金进行动态复合细化变质处理,研究变质处理后合金的显微组织,并与理论计算结果进行了比较。结果表明:采用JJ-1型精密增力电动搅拌器对熔体进行强力搅拌、振动,动态复合细化变质不仅能使共晶硅相由粗大的板片状转变为细密的颗粒状,并在α-Al边界均匀析出,而且使α-Al相明显细化,力学性能显著提高,与约翰逊-梅尔方程理论对组织晶粒尺寸控制研究结果相一致;同时A356铝合金熔体吸气倾向显著减轻,与热力学近似计算方程和斯托克斯定律对除气机制进行定量计算研究结果相一致。     

快速凝固和直流电处理对铝硅合金中硅形态的影响

用氮气雾化法制取了Al-12.54%Si合金微粒并进行700℃重熔处理,对加Sr变质的Al-13.23%Si合金熔体进行了直流电处理.用扫描和透射电镜研究了不同处理条件对Al-Si合金中共晶硅生长形态的影响.结果表明,快速凝固法制取的合金微粒与重熔处理试样中,共晶硅呈球状和条状.加Sr变质的共晶硅为弯扭的纤维状,直流电熔体处理后共晶硅转变为圆球状,其颗粒尺寸为50～200nm.     

Al-Si合金中富铁相形态及其影响因素研究进展

综述了Al-Si合金中富铁相的存在形态、形成条件以及富铁相影响因素的研究进展,重点讨论了Al-Si合金中合金元素、熔炼铸造工艺对富铁相形态与分布影响的最新研究现状。研究现状表明,针状富铁相对Al-Si合金性能危害极大,而汉字状富铁相对合金性能的危害要小得多,合金元素和熔铸工艺对富铁相形态具有重要的影响;因此,研究合金元素与熔铸工艺对富铁相形态的交互作用及其影响规律,从而获得有益的富铁相形态,或减少合金中Fe含量是Al-Si合金中减缓富铁相危害的重要研究趋势。     

铝硅合金变质的研究进展

综述了当前国内外铝硅合金变质处理及其变质机理的研究进展。变质元素Na、Sr、Sb、Ba、Te、Bi、P、S、Ca、As、稀土等已取得了良好的变质效果,通过对比分析其变质机理以及绿色无污染、经济长效等方面的优缺点,比较了这些变质元素单一变质、二元变质和多元变质的优势与局限性,并展望了铝硅合金变质方法的发展趋势。     

稀土元素Gd对Al-Si-Mg铸造合金微观组织和力学性能的影响

为了系统地研究稀土Gd对铸造Al-Si-Mg(A357)合金组织和性能的影响,采用OM,SEM,EPMA,XRD,DSC,TEM及拉伸实验等方法对不同Gd含量A357合金进行研究。结果表明:Gd的添加可以细化A357合金的晶粒并减小二次枝晶间距。此外,Gd可以有效地细化合金中的共晶硅,但是对片状共晶硅的形貌影响不大。晶粒和共晶硅的细化及二次枝晶间距的减小使添加Gd后的A357合金的力学性能有了显著的提高。其中,A357-0.5Gd(质量分数/%)合金热处理态抗拉强度为355MPa,相对于未添加Gd元素的A357合金提高了37MPa。当Gd质量分数为1.0%时,尽管组织得到进一步细化,但是大量粗大Al 2Si 2Gd第二相的形成导致了合金力学性能的下降。同时对Gd的细化机制进行探究,结合TEM分析结果可以推断,Gd变质处理后共晶硅上的孪晶密度并不足以引起共晶硅形貌的转变,使得Gd变质效果较弱。而Gd对共晶硅的细化作用可能与Gd增加成分过冷以及形成纳米相阻碍共晶硅生长有关。     

钠盐变质及振动对Zn - 27Al - Si合金组织和性能的影响

为了提高锌铝合金在干摩擦条件下的耐磨性以进一步拓宽其应用范围,在Zn-27Al合金中加入3%～4%Si,并通过钠盐变质及振动处理,制得Zn-27Al-Si合金.利用显微镜和电镜观察分析了试验合金中硅相形貌,并对合金的力学性能进行了测定.研究结果表明:钠吸附在硅晶体的生长台阶上使初晶硅产生大量分枝,最终生长成为球团状;振动一方面改变了结晶的温度场,抑制了共晶硅的析出,另一方面产生的"扰动"作用使硅球表面辐射生长的杆状共晶硅机械碎断,从而减少了硅相对基体的割裂作用,使试验合金在其他性能不变的情况下耐磨性提高3～4倍.     

Mg对共晶Al-2%Fe合金显微组织的影响

为了消除粗大针状富铁相对Al-Fe合金组织和性能的不良影响,在金属型铸造共晶Al-2?合金中添加了质量分数为0.2%一0.8%的合金元素Mg,利用光学显微镜和电子探针研究了Mg对共晶合金组织以及富铁相形态的影响.研究结果表明:共晶Al-2?合金组织为针状Al3Fe相与(α-Al)相所组成的非规则共晶组织;添加Mg后,合金组织转变为由树枝状初生(α-Al)和枝晶间网状分布共晶体所组成的亚共晶组织,富铁相尺寸显著降低;随着Mg添加量的增加,初生(α-Al)枝晶二次枝晶间距增大,一次枝晶出现熔断.     

Effect of Al-5Ti-1B on the microstructure of near-eutectic Al-13.0%Si alloys modified with Sr

The addition of Sr in Al-Si alloys as a modifier causes a transition of the morphology of eutectic silicon from coarse plate-like or acicular to fine fibrous. However, it may also lead to the formation of long columnar dendritic -Al phase. Al-5Ti-1B master alloy is often used as a grain refiner to achieve the fine equaixed grains in aluminum and aluminum alloys. The aim of the present study is to highlight the effect of Al-5Ti-1B master alloy additions on the microstructure of near-eutectic Al-Si alloys modified with Sr. When the addition of Al-5Ti-1B master alloy was below 0.82 mass%, the dendritic -Al phase changed from long columnar to equiaxed, and there were no noticeable changes of the morphology and size of eutectic silicon, while the size of eutectic cells decreased slightly. However, when the addition was above 0.82 mass%, the deleterious influence of Al-5Ti-1B master alloy on the modification effect of Sr emerged and with further increases in addition level a fully unmodified microstructure was finally produced. The results indicate that the effective Sr in the melt decreases with increased addition of Al-5Ti-1B. The poisoning event of Al-5Ti-1B master alloy on the modification of Sr is supposed to be related with the interaction between Sr and Ti.     

半固态铝硅合金中共晶硅的形貌

利用扫描电镜研究了未变质和锶变质半固态铝硅合金中共晶硅的形貌,实验结果表明,未变质半固态合金中晶硅的形貌较常规铸态合金有较硅变化,从成簇的细长片状过渡到以粗短片状或碎块状为主,锶变质半固态合金中的共晶硅仍以细长片状为主,但有一部分为粗短片状或碎块状,上述结果与旋转磁场引起的熔体流动对凝固过程的影响有关。     

Influence of Ti,B and Sr on the microstructure and mechanical properties of A356 alloy

In the present investigation, the microstructural and mechanical properties study of A356 alloy have been discussed. The microstructural aspect of cast A356 alloy employed in the present study is strongly dependent on the grain refinement (Ti and B) and modification (Sr). The mechanical properties such as PS, UTS, %E, %R, YM and VHN have been investigated. This paper deals with the combined effect of grain refinement and modification, which improves the overall mechanical properties of the alloy. It is also a well-known fact that the mechanical properties of cast A356 alloy were improved by subjecting suitable melt treatment such as grain refinement, modification and mould vibration, etc. The quality of castings and their properties can be achieved by refining of α-Al dendrites in A356 alloy by means of the addition of elements such as Ti and B which reduces the size of α-Al dendrites, which otherwise solidifies with coarse columnar α-Al dendritic structure. In addition, modification is normally adopted to achieve improved mechanical properties. Metallographic studies reveal that the structure changes from coarse columnar dendrites to fine equiaxed ones on the addition of grain refiner and further, plate like eutectic silicon to fine particles on addition of 0.20% of Al–10Sr modifier. The present result shows that a reduction in the size of α-Al dendrites, modification of eutectic Si and improvement in the mechanical properties were observed with the addition of grain refiner Al–3Ti, Al–3B and modifier Al–10Sr either individual addition or in combination. The change in the microstructure from coarse columnar α-Al dendrites to fine equiaxed dendrites and plate like eutectic silicon to rounded particles leads to improved mechanical properties.     

Influence of boron on the microstructure and mechanical properties of Al-11.6Si-0.4Mg casting alloy modified with strontium

Abstract

The influence of the addition of Al-1B master alloy on the microstructure and mechanical properties of Al-11.6%Si-0.4%Mg alloy modified with 0.030%Sr has been investigated. The mechanical properties and fracture behaviour of the alloys as cast and after T6 heat treatment with three different melt treatments (no treatment; 0.030%Sr modifying treatment; and 0.030%Sr + 0.028%B combined melt treatment) were also compared. Al-1B master alloy has a strong action in refining the dendritic structure in near eutectic Al-Si casting alloys modified with Sr. The Sr+B combined melt treatment can improve considerably the mechanical properties of the alloys, both as cast and after T6 heat treatment. Fracture modes of the alloys with the Sr modifying treatment and the Sr+B combined melt treatment are typically ductile. However, fractographs indicate that the alloy with combined melt treatment suffered greater ductile deformation before fracture. The Sr+B combined melt treatment significantly improves the mechanical properties of near eutectic Al-Si casting alloys.     

Effect of modification and ceramic particles on solidification behavior of aluminum-matrix composites

Thermal analysis is used to establish the relationship between solidification history and the microstructure of SiC particulate reinforced Al-Si alloy-matrix composites. The results show that cooling curves are influenced by the presence of SiC particles and by strontium modification. The eutectic growth temperature of SiC_P/359 composites modified with Sr lies in the range of 840 to 843 K, i.e., about 5 to 7 K higher than that of Sr-modified unreinforced 359. For the same composite, the eutectic undercooling is higher with Sr modification than without. The eutectic solidification time of the composites is shorter than that of the unreinforced base alloy because of the presence of the ceramic particles. Strontium modification has the tendency to extend the eutectic solidification time. Microstructure analysis reveals that Sr modification has a refining effect on eutectic silicon for the composites, and SiC particles in the composite melt serve as the substrates for eutectic Si phase nucleation.     

Structural modification of Al-Si eutectic alloy by Sr and its effect on tensile and fracture characteristics

Modification of the commercial A-S13 alloy and high purity Al-Si eutectic alloy has been successfully achieved using Al-5 Sr master alloy. The refined structure showed more fine and uniformly distributed eutectic silicon in the high purity alloy. The incidence of Al-dendrites due to modification was related to the movement of the eutectic point to the higher-silicon side. The chill-cast alloys showed better refined structure and higher mechanical properties in comparison with the sand-cast alloys. The modified chill-cast alloy exhibited the best mechanical properties. The ultimate. tensile strength of which reached 280 M Pa and the elongation was 9.2%. The fracture patterns changed from well faceted brittle appearance to smooth silky and dimple-like for the normal and modified alloys respectively. This reflects the change from brittle to ductile behaviour after modification. A model for the fracture mechanism was proposed to explain the observed higher ductility for the modified alloy.     

Formation of hypoeutectic microstructure in a rapidly solidified Al–5 wt-%Sr alloy

Abstract

The microstructure and thermal analysis of the melt spun Al-5 wt-%Sr alloy have been investigated using X-ray diffraction, TEM, and differential scanning calorimetry (DSC). The experimental results show that rapid solidification makes the eutectic composition shift to a higher Sr content exceeding 5 wt-%Sr. The microstructure of the melt spun Al-5Sr alloy is hypoeutectic and composed of primary α-Al cells and the α-Al/Al₄Sr eutectic; quite different from that of the ingot like alloy comprising coarse primary Al₄Sr phase embedded in the eutectic. In the melt spun Al-5Sr alloy, some areas comprise equiaxed or elongated α-Al cells with intercellular irregular α-Al/Al₄Sr eutectic. Moreover, some areas fully comprise coupled α-Al/Al₄Sr eutectic. The eutectic Al₄Sr phase is lamellar strip like or vermiform in morphology. The size of the eutectic Al₄Sr phase is less than 50 nm in width. Furthermore, the very fine microstructure of the melt spun Al-5Sr alloy has a marked effect on the DSC trace in heating process.     

Preparation of Al–Ti–C–Sr master alloys and their refining efficiency on A356 alloy

Al–Ti–C–Sr master alloys with various amounts of Sr were prepared through a method of liquid solidification reactions. The as-prepared Al–Ti–C–Sr master alloys were then used as grain refiners to modify A356 alloy. The microstructures of the Al–5Ti–0.25C–2Sr, Al–5Ti–0.25C–8Sr alloys and modified A356 alloy were investigated. The results showed that the Al–5Ti–0.25C–2Sr alloy consisted of phases of α-Al, lath-shaped or tiny blocky TiAl₃, granular TiC, and blocky or rim AlTiSr, while the Al–5Ti–0.25C–8Sr alloy contained an irregular blocky Al₄Sr phase besides the above-mentioned phases. Satisfactory grain refining and modifying effects were obtained by the addition of Al–Ti–C–Sr alloys (0.5 wt.%) to the A356 alloy. Meanwhile, the sizes of the α-Al dendrites / SDAS(40 µm) decreased to 32.7 µm (or 30 µm).The morphology of eutectic silicon was changed from needle-/platelike form to fibrous/globular form. The grain refinement and modification effects of Al–Ti–C–Sr alloys on A356 alloys were mutually promoted. Compared with the Al–5Ti–0.25C–2Sr alloy, the Al–5Ti–0.25C–8Sr alloy possessed higher efficiency in grain refinement and modification of the A356 alloys.