Investigation of the microstructure and thermo-mechanical properties of functionally graded materials fabricated by the vibrating centrifugal solid particle method

In this research, SiC/Al A413.1 functionally graded materials (FGMs) were fabricated by the vibrating centrifugal solid particle method (VCSPM), and the effects of the SiC particles on the microstructure and thermo-mechanical properties of an A413.1 aluminium alloy were investigated. The benefits of a vibration during centrifugal casting of FGMs are illustrated. After designing and fabricating the centrifugal casting machine, cylindrical FGM specimens were produced using the centrifugal solid particle method (CSPM) and VCSPM. This study used SiC particles with an average particle size from 50 to 62 μm as reinforcements to fabricate A413.1-10 wt% SiC functionally gradient composites at three annular mould speeds (900–1500 and 2100 rpm) and with or without a vibration of the mould. The Brinell hardness was measured; the yield strength (YS), ultimate tensile strength (UTS) and Young’s modulus (E) were determined by tensile testing; the density was determined by the Archimedes method; and the thermal expansion coefficients were measured with a dilatometer. A comparison of the samples produced by the conventional method and VCSPM shows a significant reduction in the porosity and an increase in the distribution gradient of the reinforcing particles for the VCSPM case. It can be concluded that in both processes, the mechanical and thermal properties improved in most cases by moving from the inner radius to the outer radius because of the movement of particles towards the outer radius from the centrifugal force. The results also show that the use of a vibration dramatically increased the rate and speed of migration of gas bubbles towards the inner radius, and the mechanical properties (hardness, YS, UTS and E) improved by moving from the inner to outer radius due to an increase in the percentage of silicon carbide particles. Upon increasing the velocity and using the VCSPM, the slope of these changes becomes steeper than those for the vibration-free mode and at low rotation speeds.

Effects of Heat Treatment on the Microstructure and Hardness of A356 (AlSi7Mg0.3) Manufactured by Vertical Centrifugal Casting

The A356 alloy has been widely used in automotive components, such as wheels and brake disks, because it is an excellent lightweight material with high corrosion resistance and good mechanical properties. Recently, to reduce the weight of brake disks, the Fe-A356 hybrid brake disk has been suggested. Because brake disk quality is directly related to driving safety, the T4/T6 heat treatment of centrifugally cast A356 alloys were performed to enhance the mechanical properties and reduce micro-segregation. The solid-solution heat treatment followed by annealing caused the formation of Mg-rich intermetallic compounds on the grain boundaries of the Al matrix, decreasing the average hardness of the alloys by 13 HV. In contrast, the solid solution followed by water quenching (T4) reduced the area fractions of the intermetallic compounds and increased the average hardness by 11 HV. The T6 heat-treated A356 alloys, which were influenced by the formation of the Guinier–Preston zone exhibited a relatively higher average hardness, by 18 HV, compared to T4 heat-treated A356 alloys.

Enhancing the tensile strength of SiC reinforced aluminium- based functionally graded structure through the mixture design approach

PurposeThis article aims to study the tensile properties of a functionally graded composite structure with Al–18wt%Si alloy as the matrix material and silicon carbide (SiC) particles as the reinforcing element. More specifically, the study's primary objective is to optimize the composition of the material elements using a robust statistical approach.Design/methodology/approachIn this research, the composite material is fabricated using a combination of stir casting and the centrifugal casting technique. Moreover, the test specimen required to study the tensile strength are prepared according to the ASTM (American Society for Testing and Materials) standards. Eventually, optimal composition to maximize the tensile property of the material is determined using the mixture design approach.FindingsThe investigation results imply that the addition of the SiC plays a crucial role in increasing the tensile strength of the composite. The optical microstructural images of the composite show the adequate distribution of the reinforcing particles with the matrix. The proposed regression model shows better predictability of tensile strength. In addition, the methodology aids in optimizing the mixture component values to maximize the tensile strength of the produced functionally graded composite structure.Originality/valueLittle work has been reported so far where a hypereutectic Al–Si alloy is considered the matrix material to produce the composite structure. The article attempts to make a composite structure by using a combination of stir casting and centrifugal casting. Furthermore, it employs the mixture design to optimize the composition and predict the model of the study, which is one of a kind in the field of material science.

Numerical Simulation of Solidification Structure of Al Alloy During Centrifugal Casting

The centrifugal casting process of 6082 Al alloy was simulated by ProCAST software. The effects of rotation speed and heat transfer coefficient on the filling and solidification behaviour were analysed. The porosity of the cast pipe increases with the increase of the rotation speed and decreases with the increase of heat transfer coefficient. The CAFE model was used to simulate the grain structure of centrifugal cast Al alloy under different process conditions. When the rotation speed and heat transfer coefficient increase, the length of columnar crystal region will increase and the grain will be refined.

Dry wear behavior of A356-SiCp functionally graded composite in unidirectional and reciprocating contacts

Purpose The purpose of this study is to distinguish the difference in tribological behavior of functionally graded composites in two sliding modes, namely, unidirectional and reciprocating. Design/methodology/approach A356-(10 Wt.%)SiCp functionally graded composite material (FGM) was prepared by vertical centrifugal casting and then a comparison was made between the tribological characteristics using pin-on-disk and pin-on-reciprocating plate configurations under identical operating conditions (sliding distance (s): 350 m; load (W): 30 = W = 120 N, in steps of 30 N; and velocity (v): 0.2 = v = 1.2 m/s, in steps of 0.2 m/s). Two types of test pins were considered, namely, a test pin taken from the outer zone of the FGM with maximum particle concentration and a test pin taken from the inner zone of the FGM in a matrix-rich region. Findings The study revealed that, for the test pin taken from the outer zone of the FGM in the low-velocity range (0.2–0.4 m/s), the reciprocating wear of the friction pair was dominant, while unidirectional wear was dominant in the velocity range of 0.6–0.8 m/s for the entire load range investigated. However, when the velocity was increased from 1.0 to 1.2 m/s, conflicting nature of dominancy in the wear characteristics of the friction pair was observed, depending on the loading condition. In addition, the inner zone FGM pin underwent seizure in the reciprocating mode, whereas this phenomenon was not seen in the unidirectional mode. Originality/value Differences in wear and friction characteristics of FGM friction pairs in two different sliding modes were investigated over a wide range of operating parameters.

Numerical Simulation and Rapid Centrifugal Casting of Large Complex Thin-Walled Titanium Alloy Intermediate Casing Based on 3D Printed Pattern

Titanium alloy intermediate casing is a typical large casting, with many thin-walled and complex structures. It is a high cost and time-consuming process in the trial stage to manufacturing the wax pattern of the intermediate casing by metal mold. Rapid investment casting based on 3D printed patterns is the development direction of casting technology which integrates digitization and intelligence. In this study, selective laser sintering (SLS) technology was used to realize the rapid prototyping of polystyrene pattern in the precision casting of intermediate casing. A numerical simulation method was used to predict the filling process, solidification and casting defects of the intermediate casing. The simulation results show that the gating system for the casting of intermediate casting was reasonable, the number and size of gating risers met the open design requirements, and a sequential solidification of the casting could be realized. The titanium alloy intermediate casing with excellent metallurgical quality and size accuracy CT7 was successfully produced using centrifugal rapid casting technology.

Experiment On Fluid Regime Under Different Rotate Velocity In Physical Simulation of Titanium Vertical Centrifugal Casting

In this paper, the physical simulation of filling process of vertical centrifugal casting (VCC) of complex titanium alloy casting was studied. Combined with the mature PTV particle tracking technology, the high-speed photography pictures of the filling process of VCC at different rotational speeds were obtained. The trajectory and velocity information of tracer particles in the rotating flow field were obtained by the corresponding analysis software. Then, through the analysis and modeling of quantitative experimental data, the flow behavior characteristics and movement law of titanium alloy melt in the mold cavity under different mold speeds were studied. The results show that: 1. When the mold is still, the front edge of the filling fluid forms a curved surface with the curvature center pointing to the outside of the mold; when the mold rotates, the front edge of the liquid flow forms a curved surface with the curvature center pointing to the inside of the mold; 2. With the increase of the mold rotation speed, the speed of the fluid filling the mold increases significantly; when the rotational speed is greater than 120 rpm, the fluid still has a certain driving force in the mold center far away from the gate It is good for filling the inner corner of mold with fluid; 3. When the rotational speed of centrifugal casting of titanium alloy reaches 45 rpm or above, typical turbulent vortices appear in the wake; with the increase of rotating speed to 180 rpm, the average curvature radius of turbulent vortices first increases and then decreases, and reaches the minimum value of 0.67 cm at 120 rpm.