Manufacturing and Fatigue Verification of Two Different Components Made by Semi-Solid Processing of Aluminium TX630 Alloy

Blad, Madeleine; Johannesson, Bengt; Nordberg, Patrik; Winklhofer, Johannes

doi:10.4028/www.scientific.net/ssp.256.328

Cited by 12 publications

(14 citation statements)

References 4 publications

(4 reference statements)

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“…This is attributed to its fine-grained structure [10,11]. This grade is commonly used for pressure-tight castings that are susceptible to fatigue loading [8,9]. After heat treatment, it has good corrosion resistance and high strength.…”

Section: Methodsmentioning

confidence: 99%

Comparison of Microstructure, Density and Shrinkage Porosity for Casting and Rheocasting of AlSi7Mg alloy

Abdulrahman

Gonda²,

Réger³

et al. 2023

Preprint

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With the increasing application of aluminum foundry alloys for automotive and aerospace components, the aluminum industry must pay close attention to component quality and dependability. This article focuses on the interpretation of the relative density and porosity of Al foundry casting and rheocasting alloys AlSi7Mg. The most popular Al-Si alloy grain refinement utilized in the casting and rheocasting processes is AlSi7Mg. The limitations are using comparable density findings to determine the quality of a component of casting or rheocasting state. Two approaches are employed to attain this goal, first the theoretical analysis using the JMatPro software, which offers density distribution results depending on the chemical composition of the aluminum alloy. Second,the experimental Archimedes method, which provides density data on actual aluminum castings alloy. This study advances substantial research on microstructure, grain sizes, form shape factors, theoretical and practical density, shrinkage porosity, casting and rheocasting application samples alloy, and potential industrial applications of AlSi7Mg. The results show that the average grain size is significantly more uniform in the rheocasting comparing to casting average grain size results. In addition, the results from the metallographic image analysis of casting and rheocasting application shows five different zones from the bottom to the top of the sample. Finally, the study observed that the shrinkage porosity in the casting application sample is higher than those of rheocasting application sample.

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Section: Methodsmentioning

confidence: 99%

Comparison of Microstructure, Density and Shrinkage Porosity for Casting and Rheocasting of AlSi7Mg alloy

Abdulrahman

Gonda²,

Réger³

et al. 2023

Preprint

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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%

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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“…Al-7Si-Mg alloys are commonly used in the automotive and aerospace industries due to their excellent castability, high specific strength and corrosion resistance [1][2][3][4]. The addition of up to 0.5 wt.% magnesium to these alloys improves the response to precipitation hardening during aging of these alloys [2,[5][6][7]. However, magnesium addition decreases ductility and fracture toughness [8].…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…In the T5 heat treatment, the as-solidified casting is artificially aged, and a moderate increase of strength is obtained without the risk of distortion [5]. Additionally, the T5 heat treatment is less expensive and blistering is prevented compared to T6 heat treatment [5,6]. However, the strength of castings in the T5 condition is generally significantly lower, compared to castings in the T6 condition [9,10].…”

Section: Introductionmentioning

confidence: 99%

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Magnesium Solubility in Primary α-Al and Heat Treatment Response of Cast Al-7Si-Mg

Santos

Dahle

Jarfors

2020

Metals

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Magnesium and silicon concentrations in the interior of primary α-Al of Al-7Si-Mg alloys were studied at temperatures in the liquid-solid range and just after solidification was completed. Analysis of the results showed that the magnesium concentration in the interior of primary α-Al is very low in the temperatures range from the liquidus to the start of the Al-Si eutectic reaction. Formation of silicon-rich phases during eutectic reactions, such as eutectic silicon and β-Al5FeSi, phases trigger a significant increase in the magnesium concentration in the interior of primary α-Al, when sufficient time is allowed for solid-state diffusion to occur. When fast cooling rates are applied during the Al-Si eutectic reaction, most of the magnesium is retained in π-Al8FeMg3Si6 and Mg2Si phases formed during solidification. Semi-solid Al-7Si-Mg castings were produced with varying magnesium contents, and the mechanical properties were evaluated in the as-cast, T5 and T6 conditions. It was found that the 0.2% offset yield strength of the semi-solid Al-7Si-Mg castings in the T5 and T6 conditions increases linearly with the square root of the magnesium concentration in the interior of the α-Al globules formed during the slurry preparation process.

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Manufacturing and Fatigue Verification of Two Different Components Made by Semi-Solid Processing of Aluminium TX630 Alloy

Cited by 12 publications

References 4 publications

Comparison of Microstructure, Density and Shrinkage Porosity for Casting and Rheocasting of AlSi7Mg alloy

Comparison of Microstructure, Density and Shrinkage Porosity for Casting and Rheocasting of AlSi7Mg alloy

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

Magnesium Solubility in Primary α-Al and Heat Treatment Response of Cast Al-7Si-Mg

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