Fatigue Characteristics and Quality Index of A357 Type Semi-Solid Aluminum Castings Used for Automotive Application

Bouazara, Mohamed; Bouaicha, A.; Ragab, Kh. A.

doi:10.1007/s11665-015-1602-2

Cited by 11 publications

(13 citation statements)

References 17 publications

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“…Different researchers have compared high cycle fatigue resistance of SSM alloys (mainly based on Al-Si) with that of conventional casting ones [64,70,[86][87][88][89][90][91][92][93][94][95][96][97]. There is a general consensus in these papers that the SSM samples show higher fatigue resistance, even though the data about the high cycles fatigue strength results is quite scattered (ranging from 60 to 180 MPa) depending on the process route used, casting and heat treatment parameters, as well as the possible presence of defects.…”

Section: Fatigue Behaviormentioning

confidence: 99%

“…Additionally, they provide evidence that fatigue failure is also associated with the presence of oxides as well as slip bands and intermetallic phases. Clearly, as in the case of conventional casting, with the presence of platelet-like and needle-like shapes, Fe-rich intermetallic compounds reduce the fatigue properties, as their morphology is conducive to high stress concentrations, thus making them a source of cracks able to cause failure [95]. Figure 11 shows an example of a fatigue fracture surface [95].…”

Section: Fatigue Behaviormentioning

confidence: 99%

“…Clearly, as in the case of conventional casting, with the presence of platelet-like and needle-like shapes, Fe-rich intermetallic compounds reduce the fatigue properties, as their morphology is conducive to high stress concentrations, thus making them a source of cracks able to cause failure [95]. Figure 11 shows an example of a fatigue fracture surface [95]. A mixed fracture mode can be clearly seen with both cleavage cracks, which induce brittle fracture, and dimples in the α-phase, which denote a ductile fracture.…”

Section: Fatigue Behaviormentioning

confidence: 99%

“…Scanning electron microscope analysis of the fatigue fracture surface of SSM A357 samples after T6 treatment[95].…”

mentioning

confidence: 99%

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Microstructure and Properties of Semi-Solid Aluminum Alloys: A Literature Review

Pola

Tocci

Kapranos

2018

Metals

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Semi-solid processing of aluminum alloys is a well-known manufacturing technique able to combine high production rates with parts quality, resulting in high performance and reasonable component costs. The advantages offered by semi-solid processing are due to the shear thinning behavior of the thixotropic slurries during the mold filling. This is related to the microstructure of these slurries consisting of solid, nondendritic, near-globular primary particles surrounded by a liquid matrix. This paper presents a review on the formation of this nondendritic microstructure, reports on the different proposed mechanisms that might be responsible, and illustrates the relationship between microstructure and properties, in particular, tensility, fatigue, wear, and corrosion resistance.fraction. Unfortunately, all these tend to increase the production costs [8], even though recent investigations have shown that SSM processing is only slightly more expensive than conventional die-casting and cheaper than some other competing foundry processes [9].Since its development in the early 1970s at MIT [10], much research has been performed worldwide, aimed mainly at developing new and alternative routes of feedstock production for different alloys suitable for SSM processing. At present, there are a number of different techniques used to produce semi-solid castings, differentiated by the percentage of liquid/solid fraction they employ and the way they produce the alloy in the semi-solid state. SSM methods can be divided in two main categories according to their processing route, known as rheocasting and thixocasting [11]. In rheocasting, the semi-solid slurry is prepared in situ from the liquid state down to a certain percentage of solid fraction (usually between 10 and 30% [12]), and then directly transferred into the shot sleeve for being injected into the die. In thixocasting, a billet, characterized by an almost globular or rosette-like microstructure developed through some specific route, is reheated in the mushy zone (semi-solid region) to an appropriately chosen solid fraction (usually between 50% and 60% [13]), placed in a modified shot sleeve and finally injected into the die [14]. Another classification methodology distinguishes the SSM methods according to the initial step used for obtaining the semi-solid feedstock, i.e., from the liquid state, by controlled solidification or from the solid state, via heavy plastic deformation and recrystallization [11].Some of the most common routes for feedstock material preparation are: mechanical stirring, such as the SSR [15,16] or GISS [17] processes, electromagnetic stirring (EMS or MHD) [18,19], ultrasonic stirring (UTS) [20,21], New Rheocasting (NRC or UBE) [22,23], cooling slope [24], twin screw [25], Rheometal [26], liquid mixing method [27], SEED [28], thermomechanical [29], and SIMA [14,30].A number of interesting reviews about the different technologies available for obtaining nondendritic slurries can be found in the literature [11,13,14,[31][32][33]. Nevertheless, indep...

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Section: Fatigue Behaviormentioning

confidence: 99%

Section: Fatigue Behaviormentioning

confidence: 99%

Section: Fatigue Behaviormentioning

confidence: 99%

“…Scanning electron microscope analysis of the fatigue fracture surface of SSM A357 samples after T6 treatment[95].…”

mentioning

confidence: 99%

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Microstructure and Properties of Semi-Solid Aluminum Alloys: A Literature Review

Pola

Tocci

Kapranos

2018

Metals

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“…A357-type aluminum (Al-Si-Mg) alloy is mostly known for its excellent strength and quality index value, and is widely used in various engineering applications, particularly in the automotive industry [1][2][3][4]. The vehicle suspension system is the assembly of mechanical components located between the frame (chassis) of the vehicle and road wheels.…”

Section: Introductionmentioning

confidence: 99%

Fatigue Cycles and Performance Evaluation of Accelerating Aging Heat Treated Aluminum Semi Solid Materials Designed for Automotive Dynamic Components

et al. 2020

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The A357-type (Al-Si-Mg) aluminum semi solid casting materials are known for their excellent strength and good ductility, which make them materials of choice, preferable in the manufacturing of automotive dynamic mechanical components. Semi-solid casting is considered as an effective technique for the manufacturing of automotive mechanical dynamic components of superior quality performance and efficiency. The lower control arm in an automotive suspension system is the significant mechanical dynamic component responsible for linking the wheels of the vehicle to the chassis. A new trend is to manufacture this part from A357 aluminum alloy due to its lightweight, high specific strength, and better corrosion resistance than steel. This study proposes different designs of a suspension control arm developed, concerning its strength to weight ratio. Furthermore, this study aims to investigate the effect of accelerating thermal aging treatments on the fatigue life of bending fatigue specimens manufactured from alloy A357 using the Rheocasting semi-solid technology. The results revealed that the multiple aging cycles, of WC3, indicated superior fatigue life compared to standard thermal aging cycles. On the other hand, the proposed designs of automotive suspension control components showed higher strength-to-weight ratios, better stress distribution, and lower Von-Mises stresses compared to conventional designs.

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Determination of Optimum Process Parameters and Residual Stress in Friction Welding of Thixocast A356 Aluminum Alloy

Singh¹,

Chattopadhyay²,

Dutta³

2020

Metall Mater Trans B

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Fatigue Characteristics and Quality Index of A357 Type Semi-Solid Aluminum Castings Used for Automotive Application

Cited by 11 publications

References 17 publications

Microstructure and Properties of Semi-Solid Aluminum Alloys: A Literature Review

Microstructure and Properties of Semi-Solid Aluminum Alloys: A Literature Review

Fatigue Cycles and Performance Evaluation of Accelerating Aging Heat Treated Aluminum Semi Solid Materials Designed for Automotive Dynamic Components

Determination of Optimum Process Parameters and Residual Stress in Friction Welding of Thixocast A356 Aluminum Alloy

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