Mechanical properties and microstructures of a modified Al–Si–Cu alloy prepared by thixoforming process for automotive connecting rods

Samat, Saziana; Omar, Mohd Zaidi; Baghdadi, Amir Hossein; Mohamed, Intan Fadhlina; Aziz, Ahmad Muhammad

doi:10.1016/j.jmrt.2020.12.085

Cited by 33 publications

(7 citation statements)

References 48 publications

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“…Automotive connecting rods manufactured by the casting technology have significantly lower mechanical and functional properties compared to elements produced by metal forming methods presented in the literature [ 11 , 18 , 19 , 20 ]. Cast automotive connecting rods have casting defects, which include heterogeneity of structure, coarseness, bubbles, porosity, shrinkage cavities or thinning, which affect their properties [ 21 , 22 ].…”

Section: Introductionmentioning

confidence: 99%

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Dziubińska

2023

Materials

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This article presents a new technology for forming automotive connecting rod forgings by means of die forging from cast performs from EN AB-71100 (EN AB-AlZn10Si8Mg) aluminum alloy. A premise was made that the production process would be carried out on forging presses. The process of forming connecting rod forgings was analyzed considering different deformation rates related to the type of machine used: a crank press and a screw press. The billet in the form of in-house designed, shaped preforms cast into sand molds with two variants of geometry was used in the process. The numerical analysis of the new process was carried out on the basis of the finite element method using Deform 3D, the simulation software for metal forming. The simulations were conducted in the spatial deformation conditions, considering the full thermomechanical analysis. Based on the simulations, certain important findings concerning the novel process were acquired, including the distribution of stress, deformation, temperatures, cracking criterion and energy parameters. The results of numerical tests confirmed the possibility of producing defect-free forgings of connecting rods from EN AB-71100 aluminum alloy on forging presses by means of the proposed technology. The proposed process of forging using crank and screw presses was verified in the course of tests conducted in industrial conditions. The properly formed connecting rod forgings were subjected to quality tests in terms of their structure and mechanical properties.

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Section: Introductionmentioning

confidence: 99%

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Dziubińska

2023

Materials

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“…The technique promotes homogeneous globular microstructures that reduce segregation and porosity [ 10 , 18 ]. SSM has the ability to improve the mechanical properties [ 17 , 19 , 20 ] and corrosion resistance [ 10 , 21 ] of Al alloys.…”

Section: Introductionmentioning

confidence: 99%

Effect of Semisolid and Heat Treatment Process on Microstructural Refinement of Al–7Si Alloy

et al. 2023

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Improving the engineering properties of Al–7Si cast alloys (300 series) provides an attractive alternative to automotive and aircraft engine industries. The solubility limit of silicon (Si) in Al contributes to the precipitation of flake-shaped Si particles with sharp edges, which function as a stress riser and promote crack propagation during the eutectic phase while also weakening the protective layer’s durability. In this study, the impact of microstructure refinement of Al–7Si alloys by using cooling slope, thixoforming and the T6 heat treatment process on hardness and corrosion resistance behavior was investigated. Results showed that the microstructures of the as-cast alloy had a very coarse dendritic shape, whereas the dendritic transferred to the globular α-Al phase, and the Si particles were replaced into a lamellar- or acicular-like shape after the cooling slope and thixoforming process, respectively. The as-cast, cooling slope and thixoformed samples were subjected to the T6 heat treatment process, which enhanced the hardness to 79, 99 and 104 HV, respectively, due to Si particle refinement. The potentiodynamic test revealed that the corrosion rate dropped to 0.00790 and 0.00736 mmpy−1 in the heat-treated cooling slope and thixoforming samples. This finding can be attributed to the substantially refined Si particles and reduced eutectic phase area due to the smaller cathodic to anodic area ratio.

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“…It is a two-step process that involves preparing a feedstock material with a nondendritic microstructure and then partially remelting it to a temperature in the semisolid zone to form a globular microstructure [18][19][20]. Aluminium alloys, which are in demand, are adaptable to thixoforming and possess exceptional properties to exploit the advantages of thixoforming [21,22]. Cast alloys are tailored for thixoforming but need to be developed to improve their properties.…”

Section: Introductionmentioning

confidence: 99%

Effect of Magnesium Addition by Thixoforming Process on Wear Properties of A319 Alloy

Alhawari¹,

Omar

Samat³

et al. 2023

Preprint

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The effect of Mg addition (0.5–2.0%) on the as-cast and thixoformed microstructures, hardness and the tribological properties of A319 aluminium alloy was investigated. The investigations highlight the dry sliding wear test behaviour using a pin-on-disk tester configuration under the applied pressures of three loads of 10, 50 and 100 N at a constant sliding speed of 1 m/s and a sliding distance of 9 km. Detailed microstructural morphology studied for these alloys is correlated with the wear properties obtained. Results in the as-cast A319 alloy revealed that Mg addition transformed the Al2Cu phase and Si particle to form the Al5Cu2Mg3Si5 and Mg2Si intermetallic phases during the solidification. Moreover, the platelet-like morphology of β-Al5FeSi intermetallic completely converted to Chinese script-like morphology, π-Al8Mg3FeSi6 phase with the addition of Mg up to 1.5 wt.%. By adding Mg and performing thixoforming, the microstructure of the α-Al phase shows a fine globular primary phase surrounded by uniformly distributed Si and refined fragmented of intermetallic phases formed. The morphology of Mg2Si particles was modified from large, polygonal particles into relatively smaller and more globular, whereas the Chinese script-like morphology π-Al8Mg3FeSi6 changes to a compact shape. Adding Mg up to 2 wt.% increased the hardness at 100 Hv. The increase in Mg content enhances the wear resistance, friction coefficient and volume loss of thixoformed A319 alloy. A combination of abrasion and adhesion for alloys of low Mg dominates the wear mechanism. In contrast, excessive subsurface fracturing and delamination with minor abrasion are mainly observed for alloys of high Mg.

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Mechanical properties and microstructures of a modified Al–Si–Cu alloy prepared by thixoforming process for automotive connecting rods

Cited by 33 publications

References 48 publications

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms

Effect of Semisolid and Heat Treatment Process on Microstructural Refinement of Al–7Si Alloy

Effect of Magnesium Addition by Thixoforming Process on Wear Properties of A319 Alloy

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