Comparative Study of the Metallurgical Quality of Primary and Secondary AlSi10MnMg Aluminium Alloys

Bakedano, A.; Niklas, Andrea; Fernández-Calvo, Ana Isabel; Plata, Gorka; Lozares, Jokin; Labari, Carlos Berlanga

doi:10.3390/met11071147

Cited by 10 publications

(5 citation statements)

References 18 publications

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“…The chemical reactivity leading to the formation of non-metallic inclusions, their decomposition and size is mainly due to small changes in the chemical composition of the alloy and the conditions under which the process of preparing the liquid metal for casting is carried out [6,17]. Therefore, in the current research to achieve a zero waste effect, it is extremely valuable to know how to remelt scrap with maximum contributions.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Inclusions and Impurities Present in Typical HPDC, Stamping and Extrusion Alloys Produced with Different Scrap Levels

da Silva,

Pujante,

Hrabia-Wiśnios

et al. 2024

Metals

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The European Green Deal poses a two-pronged challenge for the automotive industry: migrating to solutions based on light structures, requiring lightweight concepts and light materials, while at the same time avoiding dependence on the importation of these advanced materials. Aluminium alloys are lightweight and cost-effective materials that can successfully meet the requirements of many structural applications; however, their production requires bauxite and other Critical Raw Materials (CRMs), such as Si and Mg. Aluminium alloys are fully recyclable, but scrap is usually contaminated and its use is related to an increment of impurities, tramp elements and undesired inclusions. Traditionally, the use of secondary alloys has been restricted to low-performance applications. The present work analyses the effect that the use of scrap has on the quantity of inclusions present in the alloy and on other properties relevant for material processing. This study was carried out using common alloys associated with three of the most common aluminium processes used in the car manufacturing industry: high-pressure die casting (HPDC) (AB-43500), extrusion (6063) and sheet metal forming (5754 and 6181). The reference alloys were mixed with different levels of scrap (0, 20, 40, 60, 80 and 100%), with an aim to keep the chemical composition as unaffected as possible. The inclusion level of the alloy was characterized using the Prefil Footprinter® test. In addition, the obtained materials, after being cast in an open mould, were subjected to metallographic characterization. Relevant properties were measured to assess the processability of the alloys for the corresponding transforming process using the flowability test for the HPDC alloy and high-temperature compression for the extrusion alloys. The results obtained suggest that the number of inclusions present in the melt highly increase with the amount of scrap used to produce the alloy. These inclusions are also related to a significant loss of flowability, but do not have a noticeable impact on microstructure.

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Section: Introductionmentioning

confidence: 99%

Analysis of Inclusions and Impurities Present in Typical HPDC, Stamping and Extrusion Alloys Produced with Different Scrap Levels

da Silva,

Pujante,

Hrabia-Wiśnios

et al. 2024

Metals

View full text Add to dashboard Cite

show abstract

“…The chemical reactivity leading to the formation of impurities, their decomposition and size is mainly due to small changes in the chemical composition of the alloy and the conditions under which the process of preparing the liquid metal for casting is carried out [6,17]. Therefore, in the current research to achieve a zero waste effect, it becomes extremely valuable to know how to remelt scrap with maximum contribution.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Inclusions and Impurities Present in Typical Hpdc, Stamping and Extrusion Alloys Produced with Different Scrap Levels

Da Silva,

Pujante,

Hrabia-Wisnios

et al. 2024

Preprint

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The European Green Deal poses a two-pronged challenge for the automotive industry: migrating to solutions based in light structures, requiring light weight concepts and light materials, while at the same time avoiding dependence towards the importation of these advanced materials. Aluminium alloys are lightweight and cost-effective materials that can successfully cover the requirements of many structural applications, however their production requires from bauxite and other Critical Raw Materials (CRM), such as Si and Mg. Aluminium alloys are fully recyclable, but scrap is usually contaminated and its use is related to an increment of impurities, tramp element and undesired inclusions. Traditionally, the use of secondary alloys has been restricted to low performance applications. The present work analyses the effect that the use of scrap has in the quantity of inclusions present in the alloy and in other properties relevant for the material processing. The study was carried out for common alloys belonging to 3 of the most common aluminium processes used in the car manufacturing industry: High Pressure Die Casting (HPDC) (EN AC-43500), extrusion (6063) and sheet metal forming (5754 and 6181). Reference alloy were mixed with different level of scrap (0, 20, 40, 60, 80 and 100%) trying to keep the chemical composition as unaffected as possible. The inclusions level of the alloy was characterized with the Prefil Foot-printer® test. In addition, the obtained materials, after being cast in an open mould, were subjected to metallographic characterization. Relevant properties to assess the formability quality of the alloys for the corresponding transforming process, were obtained: flowability test for HPDC alloy and high temperature compression for extrusion alloys. The results obtained suggest that the number of inclusions present in the melt highly increase with the amount of scrap used to produce the alloy. These inclusions are also related with an important lost of flowability, but do not have a noticeable impact on microstructure.

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“…Recycling represents increased environmental care in the aluminium industry, which is related to reducing the consumption of resources such as energy, materials, water, and soil, extending the lifetime of products, etc. [3][4][5][6]. The producers of such aluminum casts have worried about the effect of chemical composition (especially higher Fe content) on strength, hardness, wear resistance, creep, stress relaxation, or fatigue since these are influenced by the size, volume, and morphology of microstructural parameters or intermetallic [7].…”

Section: Introductionmentioning

confidence: 99%

Influence of Corrosive Environment on Fatigue and Mechanical Properties of Al Cast Alloy with Higher Fe Content

Kuchariková¹,

Pastierovičová²,

Tillová³

et al. 2023

Preprint

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Al has very good corrosion resistance and corrosion properties. The corrosion resistance of Al cast alloys is different because these alloys contain a lot of elements. Especially in secondary alloys which contain more impurity elements from which Fe is the most common. This study deals with secondary AlSi7Mg0.3 cast alloys which contain more Fe and are affected by a chloride corrosion environment. This environment was selected based on the application of castings in the automo-tive industry. The main object was to research the effect of such an environment on basic me-chanical properties and fatigue properties. The results show that a higher Fe content does not lead to a significant reduction in the properties of the casting and the chloride environment is not so harmful. Therefore, can be stated that the investigated secondary sand-cast experimental materials can replace the primary alloys without losing the required corrosion and mechanical properties.

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Comparative Study of the Metallurgical Quality of Primary and Secondary AlSi10MnMg Aluminium Alloys

Cited by 10 publications

References 18 publications

Analysis of Inclusions and Impurities Present in Typical HPDC, Stamping and Extrusion Alloys Produced with Different Scrap Levels

Analysis of Inclusions and Impurities Present in Typical HPDC, Stamping and Extrusion Alloys Produced with Different Scrap Levels

Analysis of Inclusions and Impurities Present in Typical Hpdc, Stamping and Extrusion Alloys Produced with Different Scrap Levels

Influence of Corrosive Environment on Fatigue and Mechanical Properties of Al Cast Alloy with Higher Fe Content

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