Development of an Experimental Setup to Investigate Influences on Component Distortion in Gravity Die Casting and a First Variation of Temperature Control Strategy

Distortion (1), residual stresses and hot cracks can facilitate significant decreases in quality characteristics of casting products. Their reduction by a suitable component design (2) and process control is therefore desirable. In the casting process, these characteristics are assumed as a result of the combination of solidification shrinkage paired with the local self-feeding and the geometric constraints imposed on the component by the mold. In gravity die casting (3) of aluminum (4) with thermally well conducting and rigid metal molds, the control of solidification through a localized adjustment of the heat balance (5) appears to be a suitable approach to minimize these effects. The development of an experimental setup for the assessment of the interdependencies of the alloy, casting geometry and cooling are described in this work. A first series of experiments with A356 aluminum alloy and the introduction to the different methods of evaluation are presented. Furthermore, an approach to improve the understanding of the underlying mechanisms is outlined.

Effect of Si Content on the Properties of A356 Aluminum Alloy

The effects of different Si contents on the microstructure and mechanical properties of A356 aluminum alloy were studied by metallographic microscope analysis and tensile property test. The results show that when the silicon content is between 7% and 11 %, with the increase of silicon content, the eutectic silicon in the matrix increases, and the tensile strength and elongation decrease. When the silicon content increased to 13%, the primary silicon structure appeared in A356 aluminum alloy, and its mechanical properties increased.

Experimental Investigation on Tensile Properties and Yield Strength Modeling of T5 Heat-Treated Counter Pressure Cast A356 Aluminum Alloys

In the present study, experimental investigations on microstructures and tensile properties of an counter-pressure cast (CPC) A356 aluminum alloy under different T5 heat treatment conditions were conducted in the temperature range of 160–200 ∘C for 1–48 h. As the T5 heat treatment time increased, both tensile and yield strength of the CPC A356 alloy either continuously increased at 160 ∘C until 48 h of heat treatment time or increased until the maximum strength values were achieved and then decreased, showing peak aging behavior at 180 and 200 ∘C. Changes in microstructural aspects, such as size and aspect ratio, of the eutectic Si, Mg and Si distribution in the α-Al grain and the stability of intermetallic compounds were found to be negligible during the T5 heat treatments employed in the present study. From high resolution-transmission electron microscope (HR-TEM) analysis, nanosized needle-like β′′ precipitates were identified in the specimens, showing a significant increase in strength after the T5 heat treatment. Based on the measured tensile properties and observed microstructure changes, a yield strength model was proposed to predict yield strengths of CPC A356 alloys at arbitrary T5 heat treatment conditions. The calculation results of the model showed good agreement with the experimental data obtained in the present study. From the model calculations, the optimal T5 heat treatment time or temperature conditions were suggested.

Microstructural and corrosion study of aluminum foams obtained by space holder process using low-cost removable preforms

The space holder process (SHP) is a useful and common technique to obtain metal foams. However, an important question remains unsolved: Would the quality of the salt affect the properties of the aluminum foam obtained? In this paper, removable preforms of two types of salt (refined and unrefined) were infiltrated with A356 aluminum alloy to obtain metal foams with different pore sizes. The interaction preform-metal was studied from analyzing the morphological structure of the foams, the metal microstructure, and the corrosion resistance of the Al356 alloy. It was observed that, although the two types of salt exhibited some differences, they did not show variations in relation to the porous structure and metal microstructure in the aluminum foams obtained. Additionally, the electrochemical analyses did not show significant effects on the corrosion behavior of aluminum foams caused by the interaction with the salt preforms.

Microstructure And Mechanical Properties of Ultrasonically Processed Al-7Si Alloy / Y2O3 Nanocomposite

The aim of the present study is to investigate the microstructure and mechanical properties of the A356 aluminum metal matrix composite reinforced with Y2O3 particles. The composite is synthesized by adding 1 and 2 vol.% of reinforcement via stir casting assisted by ultrasonic treatment (UT). Microstructural contemplates shows improvement in the dispersion of nano Y2O3 particles and decrease in the porosity level due to the ultrasound aided synthesis. The UT refines the size of the Y2O3 particles as well as helps to improve its dispersion. The secondary dendrite arm spacing of 2 vol.% Y2O3 reinforced samples with 5 min UT is found to be significantly reduced to 12 µm as compared to that of the as-cast A356 alloy. Addition of 2 vol.% of nano Y2O3 has significantly improved the hardness of the A356 alloy from 60 HV to 108 HV. A considerable increment in the YS and TS of the A356 alloy is observed with the of Y2O3 and found to further improve with UT. However, small reduction in ductility is observed with the addition of Y2O3 as well as ultrasonic treatment.