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Microstructure, Macrosegregation, and Thermal Analysis of Direct Chill Cast AA5182 Aluminum Alloy

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Abstract

The variation in microstructure, macrosegregation, and solidification behavior during aluminum alloy Direct Chill casting is investigated with respect to geometry. Optical microscopy, energy-dispersive analysis, and differential scanning calorimetry were employed to study the grain size evolution, distribution of alloying elements, and solidification sequence across the cross section of DC cast AA5182 aluminum alloy. The results show that (1) grain size increases from the surface to center of the ingot, corresponding to a decrease in the heat extraction rate; (2) there is a considerable macrosegregation of Mg, Mn, and Cr, with Mg showing negative segregation at the center and positive segregation at the surface, Mn showing negative segregation both at center and surface and positive segregation elsewhere, and Cr showing positive segregation at the center and negative segregation at the surface; (3) the solidus and the reaction temperatures vary as a function of position due to the local chemical composition and cooling rate. These findings, which show the interconnectivity of grain size, segregation, and solidification sequence, are useful in further analysis of the DC casting process and in predicting casting-related defects, specifically hot tear formation.

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Notes

  1. The nominal composition, Al-3.92 wt.%Mg-0.38 wt.%Mn-0.18 wt.%Cr, was determined by averaging the EDS measurements at individual locations presented in Table 2. The values of Mn and Cr fall within the alloy’s specification. The value for Mg is below what is expected for AA 5182, 4-5 wt.%Mg.

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Acknowledgments

The authors would like to thank the financial support of the Natural Sciences and Engineering Research Council (NSERC) of Canada.

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Authors and Affiliations

  1. School of Engineering, The University of British Columbia, Kelowna, Canada

    N. Jamaly, N. Haghdadi & A. B. Phillion

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  1. N. Jamaly
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  2. N. Haghdadi
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  3. A. B. Phillion
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Correspondence to A. B. Phillion.

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Jamaly, N., Haghdadi, N. & Phillion, A.B. Microstructure, Macrosegregation, and Thermal Analysis of Direct Chill Cast AA5182 Aluminum Alloy. J. of Materi Eng and Perform 24, 2067–2073 (2015). https://doi.org/10.1007/s11665-015-1480-7

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  • DOI: https://doi.org/10.1007/s11665-015-1480-7

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