Abstract
The process of melt treatment (grain refining and modification) is a routine practice for conventional Al–Si alloys casting. For SSM processes, it is worthwhile to see the effect of grain refiner and modification on the primary α-Al dendrites and eutectic silicon. This chapter provides a detailed analysis to verify the effect of melt treatment on the microstructure of as-cast SSM billets. The mechanism of grain refining and modification is examined through thermal analysis, rheological studies, and quantitative metallographic characterization for a range of grain refining master alloys and Sr-based modifiers in different rheocasting processes.
Notes
- 1.
FactSage is a commercial thermodynamic-based software package (http://www.crct.polymtl.ca/factsage)
- 2.
An isopleth is a type of phase diagram which may come from ternary or higher degree system where the phase relationship is identified for the elements of interest at different temperatures with variation of one element.
References
D.G. McCartney, Grain refining of Aluminum and its alloys using inoculants. Int. Mater. Rev. 34(5), 247–260 (1989)
J.P. Gabathuler, D. Barras, Y. Krahenbuhl, Evaluation of various processes for the production of Billet with thixotropic properties. in 2nd International Conference on Semi-Solid Processing of Alloys and Composites (MIT, Cambridge, 1992), 33–46
G. Wan, T. Witulski, G. Hirt, Thixoforming of Al alloys using modified chemical grain refinement for Billet production. La Metallurgia Italiana 86, 29–36 (1994)
G. Wan, T. Witulski, G. Hirt, Thixoforming of Al alloys using modified chemical grain refinement for Billet production. in Conference on Aluminum Alloys: New Process Technologies (Italy, June 1993), 129–141
H.P. Mertens, R. Kopp, T. Bremer, D. Neudenberger, G. Hirt, T. Witulski, P. Ward, D.H. Kirkwood, Comparison of different feedstock materials for thixocasting, EUROMAT 97. in Proceedings of the 5th European Conference on Advanced Materials and Processes and Applications (1997), 439–444
S.C. Bergsma, M.C. Tolle, M.E. Kassner, X. Li, E. Evangelista, Semi-solid thermal transformations of Al-Si alloys and the resulting mechanical properties. Mater. Sci. Eng. A237, 24–34 (1997)
S.C. Bergsma, Casting, thermal transforming and semi-solid forming aluminum alloys. U.S. Patent 5571346, 5 Nov 1996
K. Tahara, H. Tezuka, T. Sato, A. Kamio, Semi-solid solidification in grain refined Al-7%Si-3%Cu alloy. in 6th International Conference on Aluminum Alloys (1998), 303–308
H. Wang, C.J. Davidson, J.A. Taylor, D.H. St. John, Semisolid casting of AlSi7Mg0.35 alloy produced by low-temperature pouring. Mater. Sci. Forum 396–402, 143–148 (2002)
H. Wang, C.J. Davidson, D.H. St. John, Semisolid microstructural evolution of AlSi7Mg alloy during partial remelting. Mater. Sci. Eng. A368, 159–167 (2004)
H. Wang, Semisolid processing of aluminium alloys. Ph.D. Thesis, The University of Queensland, Australia, Sep 2001
Q.Y. Pan, M. Arsenault, D. Apelian, M.M. Makhlouf, SSM processing of AlB2 grain refined Al-Si alloys. AFS Trans. (2004), Paper 04-053
Q.Y. Pan, D. Apelian, M.M. Makhlouf, AlB2 grain refined Al-Si alloys: rheocasting/thixocasting applications. in 8th International Conference on Semi-Solid Processing of Alloys and Composites (Limassol, Cyprus, 2004)
R.S. Rachmat, H. Takano, N. Ikeya, S. Kamado, Y. Kojima, Application of semi-solid forming to 2024 and 7075 wrought Aluminum Billets fabricated by the EMC process. Mater. Sci. Forum 329–330, 487–492 (2000)
T. Grimmig, J. Aguilar, M. Fehlbier, A. Bührig-Polaczek, Optimization of the rheocasting process under consideration of the main influence parameters on the microstructure. in 8th International Conference on Semi-Solid Processing of Alloys and Composites (Limassol, Cyprus, 2004)
R. Shibata, T. Kaneuchi, T. Souda, H. Yamane, Formation of spherical solid phase in die casting shot sleeve without any agitation. in 5th International Conference on Semi-Solid Processing of Alloys and Composites (Golden, 1998), 465–469
K. Sukumaran, B.C. Pai, M. Chakraborty, The effect of isothermal stirring on an Al-Si alloy in the semisolid condition. Mater. Sci. Eng. A369, 275–283 (2004)
L. Yu, X. Liu, The relationship between viscosity and refinement efficiency of pure aluminum by AlTiB refiner. J. Alloys Compd. 425, 245–250 (2006)
R. Elliot, Eutectic Solidification Process (Butterworth, London, 1983)
N. Fat-Halla, Microstructure and mechanical properties of modified and nonmodified stir-cast Al-Si hypoeutectic alloys. J. Mater. Sci. 23, 2419–2423 (1988)
W.R. Loué, M. Suéry, Microstructural evolution during partial remelting of Al-Si7Mg alloys. Mater. Sci. Eng. A203, 1–13 (1995)
B.I. Jung, C.H. Jung, T.K. Han, Y.H. Kim, Electromagnetic stirring and Sr modification in A356 alloy. J. Mater. Proc. Tech. 111, 69–73 (2001)
R.J. Kissling, J.F. Wallace, Grain refinement of Aluminum castings. Foundry (June 1963), 78–82
S. Nafisi, R. Ghomashchi, Grain refining of conventional and semi-solid A356 Al-Si alloy. J. Mater. Proc. Tech. 174, 371–383 (2006)
S. Nafisi, R. Ghomashchi, Boron-based refiners: implications in conventional casting of Al-Si alloys. Mater. Sci. Eng. A452–453, 445–453 (2007)
ASTM International Standard Worldwide, Volume 02.02, Aluminum & Magnesium Alloys (2004), 78–92
L. Backerud, G. Chai, J. Tamminen, Solidification Characteristics of Aluminum Alloys, Volume 2, Foundry Alloys (American Foundry Society, Des Plaines, 1990)
D. Apelian, G.K. Sigworth, K.R. Whaler, Assessment of grain refinement and modification of Al-Si foundry alloys by thermal analysis. AFS Trans. 92, 297–307 (1984)
P.A. Tøndel, G. Halvorsen, L. Arnberg, Grain refinement of hypoeutectic Al-Si foundry alloys by addition of Boron containing silicon metal, in Light Metals, ed. by S.K. Das (TMS, Denver, 1993), 783–790
J.A. Marcantonio, L.F. Mondolfo, Grain refinement in Aluminum alloyed with titanium and Boron. Metal. Trans. B 2, 465–471 (1971)
P.S. Mohanty, J.E. Gruzleski, Mechanism of grain refinement in Aluminum. Acta Mater. 43(5), 2001–2012 (1995)
D. Apelian, Semi-solid processing routes and microstructure evolution. in 7th International Conference on Semi-Solid Processing of Alloys and Composites (Tsukuba, Japan, 2002), 25–30
BORAL, Aluminum Boron Master Alloy, Information sheet, KBAlloys, Inc. (www.kballoys.com)
W.C. Setzer, G.W. Boone, The use of Aluminum/Boron master alloys to improve electrical conductivity, in Light Metals, ed. by E.R. Cutshall (TMS, San Diego, 1992), 837–844
I. Barin, F. Sauert, E.S. Rhonhof, W.S. Sheng, Thermochemical Data for Pure Substances (VCH Verlagsgesellschaft mbH, Germany, 1993)
A.E. Karantzalis, A.R. Kennedy, Nucleation behavior of TiB2 particles in pure Al and effect of elemental additions. J. Mater. Sci. Tech. 14, 1092–1096 (1998)
S. Nafisi, R. Ghomashchi, Boron-based refiners: advantages in semi-solid-metal casting of Al-Si alloys. Mater. Sci. Eng. A452–453, 437–444 (2007)
B. Chalmers, Principles of Solidification (Wiley, New York, 1964)
T.E. Quested, A.T. Dinsdale, A.L. Greer, Thermodynamic modeling of growth restriction effects in Aluminum alloys. Acta Mater. 53, 1323–1334 (2005)
I. Maxwell, A. Hellawell, A simple model for grain refinement during solidification. ACTA Metal 23, 229–237 (1975)
M. Johnsson, L. Backerud, Z. Metallkde. 87, 216–220 (1996)
L. Backerud, M. Johnsson, The relative importance of nucleation and growth mechanisms to control grain size in various aluminum alloys. TMS Light Metals (1996), 679–685
M.A. Easton, D.H. St. John, A model of grain refinement incorporating alloy constitution and potency of heterogeneous nucleant particles. Acta Mater. 49, 1867–1878 (2001)
S. Nafisi, R. Ghomashchi, The effect of dissolved Ti on the primary α-Al grain and globule size in the conventional and semi-solid casting of 356 Al-Si alloy. J. Mater. Sci. 41, 7954–7963 (2006)
W. Kurz, D.J. Fisher, Fundamental of Solidification (Trans Tech, Switzerland, 1989)
S. Nafisi, R. Ghomashchi, Effects of modification during conventional and semi-solid metal processing of A356 Al-Si alloy. Mater. Sci. Eng. A 415, 273–285 (2006)
S. Nafisi, D. Emadi, R. Ghomashchi, Impact of Mg addition on solidification behaviour of Al-7%Si alloy. J. Mater. Sci. Technol. 24(6), 718–724 (2008)
FactSage. http://www.crct.polymtl.ca/factsage
A. Joenoes, J. Gruzleski, Magnesium effects on the microstructure of unmodified and modified Al-Si alloys. Cast Metals 4, 62–71 (1991)
A.P. Bates, D.S. Calvert, Refinement and foundry characteristics of hypereutectic aluminum-silicon alloys. Br. Foundry Man 59, 113–119 (1966)
S. Shankar, Y.W. Riddle, M.M. Makhlouf, Nucleation mechanism of the eutectic phases in Aluminum-Silicon hypoeutectic alloys. Acta Mater. 52, 4447–4460 (2004)
S. Nafisi, R. Ghomashchi, S.M.A. Boutorabi, J. Hedjazi, New approaches to melt treatment of Al-Si alloys: application of thermal analysis technique. AFS Trans. 112 (2004), Paper 04-018
S.-Z. Lu, A. Hellawell, The mechanism of silicon modification in Aluminum-Silicon alloys: impurity induced twinning. Metal. Trans. A 18A, 1721–1733 (1987)
L.M. Hogan, M. Shamsuzzoha, Crystallography of the flake-fiber transition in the Al-Si eutectic. Mater. Forum 10, 270–277 (1987)
S. Argyropoulos, B. Closset, J.E. Gruzleski, H. Oger, The quantitative control of modification of Al-Si foundry alloys using a thermal analysis technique. AFS Trans. 91, 351–357 (1983)
R. DasGupta, C.G. Brown, S. Marek, Analysis of overmodified 356 Aluminum alloy. AFS Trans. 92, 297–310 (1984)
J. Charbonnier, Microprocessor assisted thermal analysis of Aluminum alloys structure. AFS Trans. 92, 907–922 (1984)
K. Nogita, A.K. Dahle, Eutectic solidification in hypoeutectic Al–Si alloys: electron backscatter diffraction analysis. Mater. Charact. 46, 305–310 (2001)
G.K. Sigworth, Theoretical and practical aspects of the modification of Al-Si alloys. AFS Trans. 91, 7–16 (1983)
L. Heusler, W. Schneider, Influence of alloying elements on the thermal analysis results of Al-Si cast alloys. J. Light Metals 2, 17–26 (2002)
J.P. Anson, J.E. Gruzleski, M. Stucky, Effect of strontium concentration on microporosity in A356 Aluminum alloy. AFS Trans. 108, 01-009 (2001)
D. Emadi, J.E. Gruzleski, M. Toguri, The effect of Na and Sr modification on surface tension and volumetric shrinkage of A356 alloy and their influence on porosity formation. Metal. Trans. B 24B, 1055–1063 (1993)
S. Nafisi, R. Ghomashchi, Combined grain refining and modification of conventional & Rheo-Cast A356 Al-Si alloy. Mater. Charact. 57, 371–385 (2006)
S. Nafisi, Effects of grain refining and modification on the microstructural evolution of semi-solid 356 alloy. Ph.D. Thesis, University of Quebec, 2006
S. Nafisi, O. Lashkari, R. Ghomashchi, F. Ajersch, A. Charette, Microstructure and rheological behavior of grain refined and modified semi-solid A356 Al-Si slurries. Acta Mater. 54, 3503–3511 (2006)
G. Chai, T. Roland, L. Arnberg, L. Backerud, Studies of dendrite coherency in solidifying aluminum alloy melts by rheological measurements. in 2nd International Conference, Semi-Solid Processing of Alloys and Composites (Cambridge, 1992), 193–201
V. Laxmanan, M.C. Flemings, Deformation of semi-solid Sn-15%Pb alloy. Metal. Trans. A 11A, 1927–1937 (1980)
J.A. Yurko, M.C. Flemings, Rheology and microstructure of semi solid aluminum alloys compressed in drop forge viscometer. Metal. Trans. A 33A, 2737–2746 (2002)
L. Azzi, F. Ajersch, Development of aluminum-base alloys for forming in semi solid state. in TransAl Conference (Lyon, France, June 2002), 23–33
A. Beaulieu, L. Azzi, F. Ajersch, S. Turenne, Numerical modeling and experimental analysis of die cast semi-solid A356 alloy. in Proceeding of M. C. Flemings (TMS, 2001), 261–265
O. Lashkari, R. Ghomashchi, F. Ajersch, Deformation behavior of semi-solid A356 Al-Si alloy at low shear rates: the effect of sample size. Mater. Sci. Eng. A444, 198–205 (2007)
S. Nafisi, O. Lashkari, R. Ghomashchi, J. Langlais, B. Kulunk, The SEED technology: a new generation in rheocasting. Light Metals, CIM (2005), 359–371
A. Figueredo, Science and Technology of Semi-Solid Metal Processing (North American Die Casting Association, Rosemont, 2001)
Author information
Authors and Affiliations
Rights and permissions
Copyright information
© 2016 Springer International Publishing Switzerland
About this chapter
Cite this chapter
Nafisi, S., Ghomashchi, R. (2016). Rheocasting-Melt Treatment. In: Semi-Solid Processing of Aluminum Alloys. Springer, Cham. https://doi.org/10.1007/978-3-319-40335-9_6
Download citation
DOI: https://doi.org/10.1007/978-3-319-40335-9_6
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-40333-5
Online ISBN: 978-3-319-40335-9
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)