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.     

The grain refinement efficiency of Ni–C on Mg–Al alloys

In this article, two kinds of Ni–C alloys which contain flake-like graphite and spherical graphite were prepared and the alloys were added into Mg–Al alloys in order to bring the C element into them. It is found that C can be easily and stably added into Mg–Al alloys. It is considered that the graphite in Ni–C alloys will react with Al in melt to form Al₄C₃ phase, but the formed Al₄C₃ will aggregate to the particle-like Al–Ni phase, and these duplex particles are powerful nuclei for α-Mg during solidification. It is also found that the morphology of graphite can remarkably influence the refinement, and the refining efficiency of the spherical graphite is much higher than that of the flake-like one.     

Grain refinement in nanostructured Al–Mg alloys subjected to high pressure torsion

Nanostructures of three binary Al–Mg alloys and a commercial AA5182 alloy subjected to high pressure torsion at room temperature were comparatively investigated using transmission electron microscopy, high-resolution transmission electron microscopy, and X-ray line profile analysis. Grain size distributions, dislocation densities, and densities of planar defects including stacking faults and microtwins were quantified. The average subgrain size decreased considerably from 120 to 55 nm as the Mg content increased from 0.5 to 4.1 wt%. The average dislocation density in the alloys first increased to a maximum and then decreased as the Mg content increased and the average subgrain size decreased. The role of Mg solute on these features and the refinement mechanisms associated with the typical nanostructures and faults were interpreted.     

Influence of C/Ti stoichiometry in TiC_x on the grain refinement efficiency of Al–Ti–C master alloy

TiC_x contained Al–Ti–C is a kind of grain refiner for Al alloys. In this work, the influence of C/Ti stoichiometry, i.e. the x value in TiC_x on grain refinement efficiency was investigated. TiC_x particles have been obtained in five Al–5Ti–m C(m = 0.1, 0.5, 0.8, 1, 1.25) master alloys and the x values were measured to be0.72, 0.75, 0.79, 0.81 and 0.8, respectively. It was found that the refinement performance of the master alloys had a close relationship with the x value of TiC_x . The Al–5Ti–m C alloy with lower-x TiC_x shows better refinement efficiency and anti-fading capability. It is supposed that TiC_x particles with lower x are more preferred to release Ti atoms during nucleating process and have a better Ti-absorbing capability.This contributes to the Ti-rich zone formation at TiC_x /melt interface, thus enhancing the refinement and anti-fading capability.     

Study on the grain refinement of A356 alloy by Al–3 wt-% VN master alloy

ABSTRACT

A novel Al–3?wt-% VN master alloy, mainly consisting of α-Al and VN phases, was successfully prepared by stir casting. The grain refinement performance of the master alloy on A356 alloy was then investigated. The results showed that the α-Al grain size of A356 alloy refined by Al–3?wt-% VN master alloy was 350?±?95?µm while that of A356 alloy treated by traditional Al–5Ti–B master alloy was 570?±?105?µm. Moreover, for A356 alloy with Al–3?wt-% VN addition, the good grain refining efficiency did not fade significantly within 30?min. The effectiveness of grain refinement might be attributed to VN particles, which acted as the heterogeneous nuclei of α-Al grains. Owing to the refinement strengthening, the yield strength, ultimate tensile strength and elongation of A356 alloy were improved.     

Effects of processing parameters on the refinement of primary Si in A390 alloys with a new Al–Si–P master alloy

In this study, a new Al–17Si–2.5P master alloy has been successfully prepared to refine primary Si in hypereutectic A390 alloys. By means of electron probe microanalyzer (EPMA), a large number of AlP particles can be found in the Al–17Si–2.5P master alloy. An orthogonal L₉(3³) test was designed to investigate the integrated effects of refining factors including phosphorus addition level, melting temperature and holding time, and subsequently to optimize the processing parameters. It is found that under the optimized conditions, i.e., phosphorus addition of 375 ppm, melting temperature of 800 °C, and holding time of 30 min, the average sizes of primary Si can be most remarkably decreased from 116 μm to 14 μm with sphere-like morphology. Meanwhile, the Brinell hardness and tensile strength can be significantly increased by 14.1 and 27.8%, respectively. In addition, thermal analysis is also performed with differential scanning calorimeter (DSC) to analyze the solidification process of Al–18Si alloys.     

Grain refinement in as cast Al–Mg–Mn alloy during high temperature equal channel angular pressing

Abstract

An as cast Al–Mg–Mn alloy with coarse equiaxed grain structure was processed by equal channel angular pressing (ECAP) at 350°C up to eight passes. Systematic studies were made on the microstructural evolution during ECAP by optical microscopy, electron backscattered diffraction and TEM. Equal channel angular pressing led to a considerable grain refinement, resulting in an average cell size of about 1 μm and a fraction of high angle boundaries of 75% after eight pressing passes. Deformation bands were not developed during the ECAP process, and a reasonably equiaxed substructure was obtained even after one pass. The main mechanism of grain refinement was attributed to the continuous dynamic recrystallisation based on the motion of deformation induced dislocations. Discontinuous recrystallisation at grain boundaries and triple junctions also contributed to the refinement, which played an important role especially at high strain of eight passes.     

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.     

Grain size effect on deformation twinning in Mg–Al–Zn alloy

Abstract

Specimens of Mg–3Al–1Zn alloy with a wide range of grain size distribution were compressed along different directions. The compressed microstructure was examined to clarify the grain size effect on deformation twinning in magnesium alloys. Small strains were used to reveal the twinning behaviour. The results show that the grain size affects the formation of deformation twins in an Mg–Al–Zn alloy. The reason for a different result being previously reported is given. This study also reports the different deformation microstructures in specimens compressed along different directions.     

Effect of Al addition on the grain refinement and mechanical properties of as-cast Mg–5Y–4Sm alloys

Journal of Materials Science - In recent years, the utilization of Al as a grain refiner in Mg–RE alloys has gained widespread attention because of its advantages such as low cost. In this...     

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.     

Microstructural characterization of Mg–Al–Sr alloys

The microstructural details of fourteen Mg–Al–Sr alloys were investigated in the as-cast form by a combination of scanning electron microscopy/energy dispersive spectrometer (SEM/EDS) analysis and quantitative electron probe microanalysis (EPMA). The heat transfer method coupled with the DSC measurement has been utilized to determine the solidification curves of the alloys. The morphology and the chemical composition of the phases were characterized. The microstructure of the alloys is primarily dominated by (Mg) and (Al₄Sr). In the present investigation, ternary solid solubility of three binary compounds extended into the ternary system has been reported and denoted as: (Al₄Sr), (Mg₁₇Sr₂) and (Mg₃₈Sr₉). The (Al₄Sr) phase is a substitutional solid solution represented by Mg_xAl_4–xSr and has a plate-like structure. The maximum solubility of Al in Mg₁₇Sr₂ was found to be 21.3 at%. It was also observed that Mg₃₈Sr₉ dissolved 12.5 at% Al.     

Mechanism of grain refinement of an Al–Zn–Mg–Cu alloy prepared by low-frequency electromagnetic casting

Low-frequency electromagnetic casting (LFEC) process had been developed and is being used for the past several years with the application of an induction coil placed outside the conventional direct chill (DC) casting mould. It has been demonstrated that the LFEC process has a significant grain refining effect on aluminium alloys. In the present study, temperature measurement and direct quenching from liquid and/or semi-solid were carried out to study the temperature field during casting process and to understand the mechanism of the grain-refining effect of the LFEC process. The experimental results showed that in contrast to the conventional DC casting process, the liquid melt from the launder, during the LFEC process, is cooled with very high cooling rate directly to 3–6 °C below the liquidus, and the temperature field of the entire melt in the mould, and the hot top is quite uniform, which results in the enhanced heterogeneous nucleation and improved survival rate of the nuclei. This is believed to be the main reason why the LFEC process can significantly refine the grain size of aluminium alloys.     

Effect of instability of TiC particles ongrain refinement of Al and Al–Mg alloysby addition of Al–Ti–C inoculants

Abstract

Thermodynamic modelling shows that while TiC is a stable phase in Al–Ti–C grain refiners, it should decompose on addition of the refiners to typical Al alloys. The present work assesses the impact of melt composition on TiC stability and on grain refiner performance, which has been tested at various addition levels in Al and Al–Mg alloys. In melts with compositions that stabilise TiC, there is effective grain refinement with little fading of performance on holding the refiner in the melt. In melts with compositions in which TiC is not stable, grain refinement is impaired even at short holding times, and becomes markedly worse at longer holding times. It is concluded that in typical cases progressive decomposition of TiC does occur, and that this can have a significant effect on grain refinement by inoculation with Al–Ti–C master alloys.     

Effect of reverse modification of Al–5Ti–B master alloy on hypoeutectic ZnAl4Y alloy

The present work focuses on reverse modification of Al–5 wt.%Ti–1 wt.%B master alloy on the structural characteristics and mechanical properties of hypoeutectic ZnAl4Y alloy. The results shows that with the increase of the adding amount of master alloy to ZnAl4Y alloy, the morphology and the kind of primary phase as well as the amount of eutectic structure of the modified alloy vary considerably. With the increase of the adding amount of Al–5 wt.%Ti–1 wt.%B, the tensile strength and the hardness of modified ZnAl4Y alloy increase. When the adding amount is 0.5 wt.%, the impact toughness and the elongation of the alloy reach the maximum.     

Grain refinement of Cu–Zn–Al and Cu–Al–Ni by Ti addition

Abstract

To obtain fine grained Cu based shape memory alloys after thermomechanical processing, Ti is added to β-Cu–Zn–Al or β-Cu–Al–Ni as a particle forming element. This work consists of a study of the mechanism that controls the grain growth limiting effect during the final annealing treatment. A critical evaluation of the grain growth models in particle containing materials and comparison with the experimental results lead to the conclusion that the grain growth inhibition is mainly attributable to the effect of the second phase particles but also to the influence of Ti atoms in solid solution.

MST/678     

Thermal properties of Mg–Li and Mg–Li–Al alloys

Abstract

The present work is a study of the thermal properties of Mg–xLi–y Al with x= 4, 8 and 12 wt-% and y= 0, 3 and 5 wt-% as a function of temperature in the range 20–375°C. The thermal diffusivity and coefficient of thermal expansion (CTE) have been measured and the thermal conductivity calculated. The thermal diffusivity of all alloys decreases with an increasing content of lithium. The CTE of the single phase alloys Mg–4Li and Mg–12Li has a linear character, and the CTE of Mg–12Li is higher than that of Mg–4Li. The influence of thermal stresses in the two phase alloy Mg–8Li is perceptible in terms of temperature dependence of the CTE. In Mg–4Li–3Al and Mg–4Li–5Al, an influence of the solution of AlLi phase on all the studied thermal properties has been found.     

Laser shock peening effect on the dislocation transitions and grain refinement of Al–Mg–Si alloy

This paper systematically investigates the effect of laser shock peening without coating parameters on the microstructural evolution, and dislocation configurations induced by ultra-high plastic strains and strain rates. Based on an analysis of optical microscopy, polarized light microscopy, transmission electron microscopy observations and residual stress analysis, the significant influence of laser shock peening parameters due to the effect of plasma generation and shock wave propagation has been confirmed. Although the optical microscopy results revealed no significant microstructural changes after laser shock peening, i.e. no heat effect zone and differences in the distribution of second-phase particles, expressive influence of laser treatment parameters on the laser shock induced craters was confirmed. Moreover, polarized light microscopy results have confirmed the existence of well-defined longish grains up to 455 μm in length in the centre of the plate due to the rolling effect, and randomly oriented smaller grains (20 μm × 50 μm) in the surface due to the static recrystallization effect. Laser shock peening is reflected in an exceptional increase in dislocation density with various configurations, i.e. dislocation lines, dislocation cells, dislocation tangles, and the formation of dense dislocation walls. More importantly, the microstructure is considerably refined due to the effect of strain deformations induced by laser shock peening process. The results have confirmed that dense dislocation structures during ultra-high plastic deformation with the addition of shear bands producing ultra-fine (60–200 nm) and nano-grains (20–50 nm). Furthermore, dislocation density was increased by a factor of 2.5 compared to the untreated material (29 × 10¹³ m^− 2 vs. 12 × 10¹³ m^− 2).     

Compressive creep behaviour of Mg–Li–Al alloy

Abstract

The compressive creep behaviour of as cast Mg–14Li–1·3Al (wt-%) alloy was investigated in the temperature range of 20?85°C and under different compressive stress in the range of 37·3–74·6 MPa with special apparatus. Primary creep deformation and steady creep rate increase with temperature and applied stress. The compressive creep behaviour obeys an empirical equation ln t=C?nln σ + Q/RT, where t is the time to a selected creep strain, σ is the applied stress, T is the absolute temperature, R is the gas constant, and C, n, and Q are constants for the experimental alloy. The average values of the exponent n and the creep activation energy Q are 4·33 and 101·13 kJ mol^?1 respectively. The creep rate controlling mechanism is the dislocation climb and the lattice diffusion of Li in the experimental alloy under the testing conditions.     

Characterisation of interfaces in Al–Zn–Mg alloy reinforced with Sicabo fibres

Abstract

The microstructure of a metal matrix composite consisting of an Al–Zn–Mg alloy reinforced with SiC coated boron fibres has been examined by electron microscopy, electron probe microanalysis, and by optical microscopy. Considerable amounts of Mg₂Si phase were found to be segregated at the fibre/matrix interface. This intermetallic was not formed by a reaction between the fibre and matrix during the fabrication process, a liquid infiltration technique, but as a result of silicon impurities present as contaminants in the melt. It was concluded that the interface phase was precipitated from the metal matrix in the later stages of solidification without any nucleation role being played by the fibre. The Mg₂Si phase appears to be brittle and was present in amounts likely to have a deleterious effect on the strength of the composite.

MST/871