EFFECT OF CU CONTENT AND GROWTH VELOCITY ON THE MICROSTRUCTURE PROPERTIES OF THE DIRECTIONALLY SOLIDIFIED AL-MN-CU TERNARY ALLOYS

In this work, influences of composition (Cu content) and growth velocity (V) on the microstructure (dendritic spacing) of Al–Mn–Cu ternary alloys have been investigated. Al–1.9Mn–xCu (x=0.5, 1.5 and 5 wt. %) alloys were prepared using metals of 99.90% high purity in the vacuum atmosphere. These alloys were directionally solidified upwards under various growth velocities (8.3–978 m/s) using a Bridgman-type directional solidification furnace at a constant temperature gradient (7.1 K/mm). Measurements of primary dendrite arm spacing () of the samples were carried out and then expressed as functions of growth velocity and Cu content. Especially, cell-dendritic transition was detected for low growth velocity (41.6 m/s) for alloys containing 0.5 and 1.5Cu. It has been found that the values of  decrease with increasing V and decreasing Cu content. Keywords: Aluminum alloys, Solidification, Cell-dendritic transition, Dendrite arm spacing

Emphasis of Weld Time, Shielding Gas and Oxygen Content in Activated Fluxes on the Weldment Microstructure

The activated-TIG (A-TIG) process is a recognised process for achieving higher depth-of- penetration (DoP) and it could be used for various stainless-steel grades welding. The oxygen content of oxide based activated fluxes provide the extra heat during decomposition of flux and result into deep penetration. This study reveals the effect of short weld time of 2 sec in stationary arc, shielding environment (Ar and Ar + 2.5 % H2) and an effect of oxygen element in activated flux (CrO3 and SiO2) on the microstructure and weld metal micro-hardness. Use of hydrogen mix shielding gas during A-TIG process has significant impact on the dilution rate, grain size and dendrite arm spacing. The fraction of oxygen in the flux and the presence of silicon in SiO2 flux play a significant role in achieving higher DoP. To evaluate the impact of different shielding environment on grain growth, the samples were investigated with weld pool morphology, depth of penetration, weld chemistry, optical microscopy and SEM analysis. The extra heat produced due to oxygen fraction in activated flux and H2 induced shielding have been quantified in the study. The ferrite and austenite grain growth as well as the dendrite arm spacing found to be increased due to presence of H2 in shielding gas.

Automatic Determination of Secondary Dendrite Arm Spacing in AlSi-Cast Microstructures

A new procedure for the automatic measurement of the secondary dendrite arm spacing (SDAS) from microscopic images is presented. The individual primary and secondary dendrite arms are identified through suitable segmentation techniques and clustered in such a way that dendritic structures are obtained suitable for SDAS measurement. The algorithms are applied to two different hypoeutectic aluminum cast alloys, and the quality of the measurements obtained is assessed through a comparison to manually measured SDAS values. A good agreement between the automated measurements and the distribution of manual measurements is found for both cast structures considered. In addition, a decrease in computation time is observed which allows for an increase in measurement density that is used to characterize the microstructures.

Influence of some Chemical Elements on SDAS of A357 Alloy

A solidification model of coarsening coefficient for the criterion of secondary dendrite arm spacing has been established in this paper. When the model is applied to aluminum cast alloy, it is found that the model is in good agreement with the experiment results. Experiments and analysis show that addition of some chemical elements is conducive to the refinement of the secondary dendrite arm spacing under the same solidification condition. Different chemical elements have different refining effects, and Zr and Ti have better refining effect on A357 aluminum cast alloy than Cu.

Simulation and Experimental Validation of Secondary Dendrite Arm Spacing for AlSi7Mg0.3 Chassis Parts in Low Pressure Die Casting

The structural properties of cast aluminum parts are strongly affected by the solidification in the production process. The solidification dynamics determines the Secondary Dendrite Arm Spacing (SDAS), directly affecting the structural strength of the alloy. Simulation techniques enable the integrated design of chassis parts and their production equipment. However, in order to effectively predict the SDAS formation, the simulation models need to be investigated and calibrated. The present research investigates the SDAS formation models and identifies a robust relation to be used in Design by Simulation phases for AlSi7Mg0.3 parts.

Generation and Relaxation of Residual Stresses in Automotive Cylinder Blocks

There is direct proportionality between ultimate tensile stress (UTS) and residual stresses (RS). Residual stresses gradually decrease with decreasing cooling/quenching rates. Quenching in cold water develops highest, whereas air cooling produces lowest, residual stresses. Significant increase in RS is observed in specimens with low dendrite arm spacing (high solidification rate), while lower residual stresses are measured in specimens with high dendrite arm spacing (low solidification rate). For I-4 and V-6 engine blocks, there is refinement in microstructure due to the increase in solidification rate along the cylinder length. The developed residual stresses are normally tensile in both engine types. Air cooling following solution heat treatment produces higher RS compared to warm water and cold water quenching. Solution heat treatment and freezing lead to maximum RS relaxation where 50% of the stresses are reduced after the solution heat treatment step. Aging time and temperature are directly proportional to the residual stresses relaxation. Relaxation of RS also depends on the geometry and size of the workpiece. It should be mentioned here that the I-4 and V-6 cylinder blocks were provided by Nemak-Canada (Windsor-Ontario-Canada). Residual stress measurements technique and procedure are typical of those used by the automotive industry in order to provide reliable data for industrial applications supported by intensive experiments.