Metallurgical and Foundry Parameters for the SSM Forming of High Strength Aluminium-Zinc-Magnesium-Copper (7075) Alloy

2009 ◽  
Vol 618-619 ◽  
pp. 611-614 ◽  
Author(s):  
L.G. Juganan ◽  
Gonasagren Govender ◽  
A.F. Mulaba Bafubiandi
Keyword(s):  
Melting Furnace ◽  
Optical Emission ◽  
High Strength ◽  
Hot Tearing ◽  
Compositional Variation ◽  
Limited Information ◽  
Casting Technique ◽  
Compositional Variations ◽  
Semi Solid ◽  
7075 Alloy

Aluminium-Zinc-Magnesium-Copper, 7075, alloy offers both high strength (comparable with those of alloy steels) and very good ductility which makes this alloy group suitable for many automotive, aerospace and defence applications, however the alloys are difficult to cast because of their tendency for Hot Tearing. The Semi-Solid Metalforming (SSM) casting technique allows for near net shape casting using High-Pressure Diecasting (HPDC). The lower forming temperature reduces the problem of Hot Tearing. The CSIR has developed a rheocasting process which prepares semi-solid slurries from molten metal which can then be formed using HPDC. Since 7075 is a wrought alloy there is limited information on the foundry practice for this alloy. The aim of this study is to determine the foundry practice for 7075 aluminium alloy. Melting trials and optical emission spectroscopy on, AA7075 was conducted to study the effect of metallurgical melting parameters and compositional variations. 7075 Alloy was melted using a resistance melting furnace and compositional variation in the crucible for varying holding times was evaluated to determine the degree of segregation of key alloying elements. Results have shown some compositional variations.

Casting and Heat Treatment of Turbocharger Impellers Thixocast from Alloy 201

2012 ◽  
Vol 192-193 ◽  
pp. 556-561 ◽  
Author(s):  
Qiang Zhu ◽  
Stephen Midson ◽  
Chang Wei Ming ◽  
Helen V. Atkinson
Keyword(s):  
Heat Treatment ◽  
High Strength ◽  
Heat Treatment Condition ◽  
Hot Tearing ◽  
Alloy Casting ◽  
Heat Treated ◽  
Before And After ◽  
Optimum Heat ◽  
Semi Solid ◽  
Optimum Heat Treatment

Commercial semi-solid cast impellers are produced from Al-Si-Cu alloys heat treated to the T6 temper. The study described in this paper involved the identification of casting and heat treatment parameters to produce semi-solid processed turbocharger impellers from a silicon-free, higher strength 201 alloy. Casting parameters were identified which minimized hot tearing in the alloy 201 impellers. A series of heat treatment studies were performed to determine optimum heat treatment parameters. The T71 temper was identified as the preferred heat treatment condition to produce high strength as well as superior elongation. The results from mechanical property measurements conducted on the T71 heat treated impellers are reported. Optical and scanning electron microscopy (SEM) were also used to characterize the microstructure of alloy 201 impellers before and after heat treatment, and representative microstructures are presented.

Hot Tearing Susceptibility and Fluidity of Semi-Solid Gravity Cast Al-Cu Alloy

2006 ◽  
Vol 116-117 ◽  
pp. 76-79 ◽  
Author(s):  
J. Wannasin ◽  
David Schwam ◽  
J.A. Yurko ◽  
C. Rohloff ◽  
G. Woycik
Keyword(s):  
Liquid State ◽  
Copper Alloys ◽  
High Strength ◽  
Hot Tearing ◽  
Gravity Casting ◽  
Aluminum Copper Alloys ◽  
Semi Solid ◽  
High Superheat ◽  
Constrained Rod Casting ◽  
Hot Tearing Susceptibility

Aluminum-copper alloys offer both high strength and excellent ductility suitable for a number of automotive applications to reduce vehicle weight; however, the alloys are difficult to cast because of their tendency for hot tearing. In this work, semi-solid gravity casting of an aluminum-copper alloy, B206, was conducted in constrained rod casting molds to study the feasibility of using the process to reduce or eliminate hot tearing. To demonstrate the feasibility of gravity casting of the metal slurries, a fluidity test was also conducted. Results show that the hot tearing susceptibility of the aluminum-copper B206 alloy cast in semi-solid state is lower than those cast in liquid state with high superheat temperatures. The grain size of the semi-solid cast Al-Cu samples appears to be finer than those cast in liquid state with high superheat temperatures. In addition, the metal slurries had sufficient fluidity to fill the molds even with low gravity pressures. The results suggest that semi-solid gravity casting is a feasible process to help reduce hot tearing.

The Mechanical Properties of Rheo-High Pressure Die Cast Al-Mg-Si-(Cu) 6xxx Series Alloys

2014 ◽  
Vol 217-218 ◽  
pp. 61-66 ◽  
Author(s):  
Heinrich Möller ◽  
Pfarelo Daswa ◽  
Gonasagren Govender
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Hot Tearing ◽  
Limited Information ◽  
Die Cast ◽  
Near Net Shape ◽  
Alloy Castings ◽  
Semi Solid ◽  
Si Content ◽  
6Xxx Series

Near-net shape casting of wrought aluminium alloys has proven to be difficult due to a tendency towards hot tearing during cooling. Rheo-high pressure die casting (R-HPDC), has been shown to be an effective method of producing near-net shape wrought aluminium alloy castings. Limited information is available regarding the mechanical properties of age-hardenable wrought Al-castings produced by semi-solid metal forming. The purpose of this study is to investigate the effects of chemical composition and natural pre-ageing on the hardness and mechanical properties of rheo-HPDC 6xxx series Al-Mg-Si-(Cu) alloys in the T6 temper condition. The effects of the addition of Cu, as well as the (Mg+Si) content and Mg:Si ratio of the alloys are quantified. Alloys that are included are Cu-free 6004 and 6082, as well as Cu-containing 6013, 6111 and 6066. It is shown that the addition of Cu and excess Si result in higher hardness and strength. Natural pre-ageing has a significant effect (positive for 6004 and negative for the others) on the T6 properties. Good strength values can be achieved, but ductility is dependent on factors such as hot tearing during casting and incipient melting during solution heat treatment.

ALCOA 7075

Alloy Digest ◽  
1998 ◽  
Vol 47 (7) ◽  
Keyword(s):  
Corrosion Resistance ◽  
Physical Properties ◽  
Surface Treatment ◽  
Stress Corrosion ◽  
Tensile Properties ◽  
Stress Corrosion Cracking ◽  
High Strength ◽  
Structural Parts ◽  
7075 Alloy ◽  
Very High

Abstract Alcoa 7075 alloy has very high strength and is used for highly stressed structural parts. The T7351 temper offers improved stress-corrosion cracking resistance. The alloy’s strength level equals or exceeds mild steels. This datasheet provides information on composition, physical properties, and tensile properties. It also includes information on corrosion resistance as well as machining and surface treatment. Filing Code: AL-350. Producer or source: ALCOA Wire, Rod & Bar Division.

scholarly journals Application of Commercial Surface Pretreatments on the Formation of Cerium Conversion Coating (CeCC) over High-Strength Aluminum Alloys 2024-T3 and 7075-T6

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 930
Author(s):  
Juan Jesús Alba-Galvín ◽  
Leandro González-Rovira ◽  
Francisco Javier Botana ◽  
Maria Lekka ◽  
Francesco Andreatta ◽  
...  
Keyword(s):  
Electrochemical Impedance ◽  
Salt Spray ◽  
Aluminum Matrix ◽  
Optical Emission ◽  
High Strength ◽  
Chemical Conversion ◽  
Conversion Coating ◽  
Neutral Salt ◽  
Corrosion Properties ◽  
Surface Pretreatment

The selection of appropriate surface pretreatments is one of the pending issues for the industrial application of cerium-based chemical conversion coatings (CeCC) as an alternative for toxic chromate conversion coating (CrCC). A two-step surface pretreatment based on commercial products has been successfully used here to obtain CeCC on AA2024-T3 and AA7075-T6. Specimens processed for 1 to 15 min in solutions containing CeCl3 and H2O2 have been studied by scanning electron microscopy coupled with energy-dispersive X-ray analysis (SEM-EDX), glow discharge optical emission spectroscopy (GDOES), potentiodynamic linear polarization (LP), electrochemical impedance spectroscopy (EIS), and neutral salt spray (NSS) tests. SEM-EDX showed that CeCC was firstly observed as deposits, followed by a general coverage of the surface with the formation of cracks where the coating was getting thicker. GDOES confirmed an increase of the CeCC thickness as the deposition proceed, the formation of CeCC over 7075 being faster than over 2024. There was a Ce-rich layer in both alloys and an aluminum oxide/hydroxide layer on 7075 between the upper Ce-rich layer and the aluminum matrix. According to LP and EIS, CeCC in all samples offered cathodic protection and comparable degradation in chloride-containing media. Finally, the NSS test corroborated the anti-corrosion properties of the CeCC obtained after the commercial pretreatments employed.

Effect of Fe Content on Hot Tearing of High-Strength Al-Mg-Si Alloy

2007 ◽  
Vol 539-543 ◽  
pp. 380-385 ◽  
Author(s):  
Hiromi Nagaum ◽  
Satoru Suzuki ◽  
T. Okane ◽  
T. Umeda
Keyword(s):  
Crack Initiation ◽  
Electromagnetic Induction ◽  
High Strength ◽  
Solidification Path ◽  
Hot Tearing ◽  
Temperature Range ◽  
Fe Content ◽  
Calculation Results ◽  
Electromagnetic Induction Heating ◽  
Calculation Software

The effect of Fe content on hot tearing of the high-strength Al-Mg-Si alloy was systematically investigated. In this study, a thermodynamic calculation software Thermo-Calc was used to calculate the solidification path under the non-equilibrium condition, and the mechanical properties of this alloy have also been investigated during solidification using an electromagnetic induction heating tensile machine. In order to confirm the calculation results of solidification path, a quenching test also was carried out. By using the Thermo-Calc, the sequence of crystallization, crystallization temperature of formed phases and their crystallized amount were systematically investigated for each alloy in which Fe content was changed. Furthermore, by comparing the fracture surfaces of the tensile testing sample and DC billet, the temperature range of crack initiation of the alloy was examined. Comparing the temperature range of crack initiation with the crystallization phase and its crystallization order, Fe content of high-strength Al-Mg-Si alloy influenced hot tearing significantly owing to the crystallization behavior of α(AlFeMn).

Characterizing the Effect of Processing Parameters on Temperature Distribution of 7075 Aluminum Alloy Slurry Prepared by Enthalpy Control Process

2022 ◽  
Vol 327 ◽  
pp. 263-271
Author(s):  
Gan Li ◽  
Jin Kang Peng ◽  
En Jie Dong ◽  
Juan Chen ◽  
Hong Xing Lu ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Temperature Difference ◽  
Initial Temperature ◽  
Control Process ◽  
Processing Parameters ◽  
Heating Time ◽  
7075 Aluminum Alloy ◽  
Semi Solid ◽  
7075 Alloy ◽  
Slurry Preparation

There is a strong demand for high-strength aluminum alloys such as 7075 aluminum alloy to be applied for rheocasting industry. The overriding challenge for the application of 7075 alloy is that its solid fraction is very sensitive to the variation of temperature in the range of 40% ~ 50% solid fraction, which inevitably narrows down the processing window of slurry preparation for rheocasting process. Therefore, in this work, a novel method to prepare semi-solid slurry of the 7075 alloy, so called Enthalpy Control Process (ECP), has been developed to grapple with this issue. In the method, a medium-frequency electromagnetic field was applied on the outside of slurry preparation crucible to reduce the temperature difference throughout the slurry. The effect of processing parameters, including heating power, heating time, the initial temperature of crucible and melt weight, on the temperature field of the semi-solid slurry was investigated. The results exhibited that although the all the processing parameters had a great influence on the average temperature of the slurry, heating time was the main factor affecting the maximum temperature difference of the slurry. The optimum processing parameters during ECP were found to be heating power of 7.5 KW, the initial temperature of crucible of 30 °C ~ 200 °C and melt weight of 2 kg.

scholarly journals Rinkite–nacareniobsite-(Ce) solid solution series and hainite from the Ilímaussaq alkaline complex: occurrence and compositional variation

2014 ◽  
Vol 62 ◽  
pp. 1-15
Author(s):  
Jørn G. Rønsbo ◽  
Henning Sørensen ◽  
Encarnacion Roda-Robles ◽  
François Fontan ◽  
Pierre Monchoux
Keyword(s):  
Solid Solution ◽  
Electron Microprobe ◽  
Compositional Variation ◽  
Solid Solution Series ◽  
Alkaline Complex ◽  
Full Extension ◽  
X Ray ◽  
Solution Series ◽  
Compositional Variations ◽  
A Minor

In the Ilímaussaq alkaline complex, minerals from the rinkite–nacareniobsite-(Ce) solid solution series have been found in pulaskite pegmatite, sodalite foyaite, naujaite and naujaite pegmatite from the roof sequence, and in marginal pegmatite, kakortokite and lujavrite from the floor sequence. The electron microprobe analyses embrace almost the full extension of the solid solution series and confirm its continuity. The solid solution series shows similar compositional variations in the roof and floor sequences: Rinkite members of the series are found in the less evolved rocks in the two sequences, whereas nacareniobsite-Ce members occur in the most evolved rocks and pegmatites in the two sequences. The REE (+Y) content varies from 0.83 atoms per formula unit (apfu) in rinkite from pulaskite pegmatite to 1.31 apfu in nacareniobsite-(Ce) from naujaite pegmatite. The main substitution mechanisms in the solid solution series investigated in this work are 2Ca2+ = Na+ + REE3+ and Ti4+ + Ca2+ = Nb5+ + Na+. The increased contents of Nb5+ and REE3+ are only to a minor degree compensated through the F1– = O2– substitution. The chondrite normalised REE patterns of the minerals develop in a similar way in the two sequences, showing relative La-enrichment and Y-depletion from the less to the most evolved rocks. Hainite has not previously been found in the Ilímaussaq complex. It was here identified in a pulaskite pegmatite sample by a combination of X-ray diffraction giving the unit cell dimensions a = 9.5923(7) Å, b = 7.3505(5) Å, c = 5.7023(4) Å, α = 89.958(2)°, β = 100.260(1)°, γ = 101.100(2)°, and X-ray powder pattern and electron microprobe data giving the empirical formula (Ca1.62 Zr0.16Y 0.22) (Na0.87Ca1.11) (Ca 1.65 REE0.35)Na(Ti0.81Nb0.09Fe0.08 Zr0.02)(Si2O7)2O0.99F2.96. Based on published and the present data it is documented that minerals from the hainite-götzenite solid solution series show a compositional variation between the ideal end members (Y,REE,Zr)Na2Ca4Ti(Si2O7)2OF3 and NaCa6Ti(Si2O7)2OF3.

Continuous Casting of Magnesium Billets for Semi-Solid Processing

2005 ◽  
Vol 475-479 ◽  
pp. 517-520
Author(s):  
Hwa Chul Jung ◽  
Kwang Seon Shin
Keyword(s):  
Aluminum Alloys ◽  
Continuous Casting ◽  
Magnesium Alloys ◽  
Casting Process ◽  
Az91 Alloy ◽  
Attractive Alternative ◽  
Limited Information ◽  
Continuous Casting Process ◽  
Dendritic Microstructure ◽  
Semi Solid

Semi-solid processing is recognized as an attractive alternative method for the near net-shape production of engineering components. Although there has been a significant progress in semi-solid processing of aluminum alloys, very limited information is available on semi-solid processing of magnesium alloys, except for the thixomolding process. Continuous casting process has been utilized to produce the billets with the desirable cross-section at a reduced production cost for many metals, such as steel, copper and aluminum alloys. It has also been commercially utilized to produce the aluminum billets with non-dendritic microstructure for subsequent thixocasting process. However, continuous casting of magnesium billets for semi-solid processing has not yet been commercialized due to the difficulties involved in casting of magnesium alloys. In the present study, a continuous casting process has been developed for the production of the cylindrical billets of magnesium alloys for the subsequent thixocasting process. In order to obtain the desired non-dendritic microstructure with an excellent degree of homogeneity both in microstructure and composition, an electromagnetic stirring system has been utilized. A continuous casting process has been proven to be an efficient way to produce the high quality billets of magnesium alloys for semi-solid processing. A prototype air conditioner cover was produced using the continuously cast billets of AZ91 alloy.

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