Skip to main content
SpringerLink
Log in

A Statistical Assessment of Casting Quality–Tribological Properties of Eutectic Al-12Si Alloy: Effect of Mg

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

This work was carried out to evaluate the relationship between casting quality and wear properties of Al-12Si eutectic alloy with various Mg contents. Mg additions were selected as 0, 2, 3, and 4 wt.%. A permanent die tensile test mold, step-type mold, and RPT sand mold were used in the characterization of the properties of the castings. The bifilm index was measured for the determination of the casting quality. Mechanical properties such as hardness, UTS, YS, e (%), toughness, impact, and wear rate were investigated. All the results obtained in this study were evaluated via statistical analysis software. It was found that melt quality and bifilm index is the dominant factor that determines the mechanical properties. As Mg content was increased, the size of oxides was getting smaller and their number was increased. The highest wear properties were obtained with the highest Mg addition (4 wt.%) for ball-on-disk tests. According to the pin-on-disk test, in the lubricated conditions, there was no change in wear properties with Mg content. In the dry tests, as the bifilm index was increased, the friction coefficient was decreased due to the higher oxide content of the alloy.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17

Similar content being viewed by others

References

  1. J.G. Kaufman and E.L. Rooy, Aluminum Alloy Castings: Properties, Processes, and Applications, ASM International, Cleveland, 2004

    Google Scholar 

  2. E. Sjölander and S. Seifeddine, The Heat Treatment of Al-Si-Cu-Mg Casting Alloys, J. Mater. Process. Technol., 2010, 210(10), p 1249–1259

    Google Scholar 

  3. K. Pratheesh et al., Effects of Sr and Pressure on Microstructure, Mechanical and Wear Properties of Near Eutectic Al-Si Piston Alloys, Int. J. Cast Met. Res., 2015, 28(5), p 301–309

    CAS  Google Scholar 

  4. M.M. Haque and A. Sharif, Study on Wear Properties of Aluminium–Silicon Piston Alloy, J. Mater. Process. Technol., 2001, 118(1), p 69–73

    CAS  Google Scholar 

  5. M. Harun, I.A. Talib, and A.R. Daud, Effect of Element Additions on Wear Property of Eutectic Aluminium-Silicon Alloys, Wear, 1996, 194(1), p 54–59

    CAS  Google Scholar 

  6. H. Murat Lus et al., Wear Properties of Squeeze Cast İn Situ Mg2Si-A380 Alloy, Int. J. Cast Met. Res., 2015, 28(1), p 59–64

    CAS  Google Scholar 

  7. T. Yasmin, A.A. Khalid, and M.M. Haque, Tribological (Wear) Properties of Aluminum–Silicon Eutectic Base Alloy Under Dry Sliding Condition, J. Mater. Process. Technol., 2004, 153–154, p 833–838

    Google Scholar 

  8. R.A. Al-Samarai, K.R.A. Haftirman, and Y. Al-Douri, The Tribological Behavior of Hypo-and Hyper-Eutectic Al-Si Alloys under Dry Sliding Conditions, International Journal of Mechanical and Production Engineering Research and Development (IJMPERD), 2013, 3(1), p 111–124

    Google Scholar 

  9. D.E. Lozano et al., Tribological Behaviour of Cast Hypereutectic Al-Si-Cu Alloy Subjected to Sliding Wear, Wear, 2009, 267(1), p 545–549

    CAS  Google Scholar 

  10. S. Hussain et al., Tribological Characteristics of Modified Hypo Eutectic Al-Si Alloy, in Key Engineering Materials. Trans Tech Publ. (2018)

  11. Sunder Barangea, Sudhir Tiwarib, and Gautam Yadav, Tribological Investigations of Aluminum-Silicon (Al-Si) Alloys, International Journal for Scientific Research & Development, 2016, 4(08), p 398–401

    Google Scholar 

  12. R.A. Al-Samarai, A.K. Haftirman, and Y. Al-Douri, Effect of Load and Sliding Speed on Wear and Friction of Aluminum-Silicon Casting Alloy, Int. J. Sci. Res. Publ., 2012, 2(3), p 1–4

    Google Scholar 

  13. A. Sinha and Z. Farhat, Effect of Surface Porosity on Tribological Properties of Sintered Pure Al and Al 6061, Mater. Sci. Appl., 2015, 6(06), p 549

    CAS  Google Scholar 

  14. J. Campbell, Complete Casting Handbook: Metal Casting Processes, Metallurgy, Techniques and Design, Butterworth-Heinemann, Oxford, 2015

    Google Scholar 

  15. G.E. Bozchaloei et al., Effect of Oxide Bifilms on the Mechanical Properties of Cast Al-7Si-0.3 Mg Alloy and the Roll of Runner Height after Filter on Their Formation, Mater. Sci. Eng. A, 2012, 548, p 99–105

    Google Scholar 

  16. J. Campbell, An Overview of the Effects of Bifilms on the Structure and Properties of Cast Alloys, Metall. Mater. Trans. B, 2006, 37(6), p 857–863

    Google Scholar 

  17. D. Dispinar and J. Campbell, Use of Bifilm İndex as an Assessment of Liquid Metal Quality, Int. J. Cast Met. Res., 2006, 19(1), p 5–17

    CAS  Google Scholar 

  18. I.K. Duygun et al., Change in Sr Modification by Duration and Its Effect on Mechanical Properties of A360 and A413 Alloy, in Shape Casting. Springer. p. 353–361 (2019)

  19. M. El-Sayed and W. Griffiths, Hydrogen, Bifilms and Mechanical Properties of Al Castings, Int. J. Cast Met. Res., 2014, 27(5), p 282–287

    CAS  Google Scholar 

  20. G. Gyarmati et al., The Effects of Rotary Degassing Treatments on the Melt Quality of an Al-Si Casting Alloy, Int. J. Metalcast., 2020, 2020, p 1–11

    Google Scholar 

  21. P. Ingle and B. Narkhede, Influence of Taguchi-Grey Relational Analysis of Gating System Design on Mechanical Properties of Casting. Archives of Foundry Engineering (2019)

  22. H.S. Jang et al., Effects of Mg Content on Hydrogen Content and Melt Quality of Al-Mg Alloys, Metals, 2019, 9(11), p 1235

    CAS  Google Scholar 

  23. M.C. Mehta, D. Mandal, and S.K. Chaudhury, Microstructural Changes and Quality Improvement of Al7Si0.2Mg (356) Alloy by Die Vibration, Int. J. Metalcast., 2020, 2020, p 1–12

    Google Scholar 

  24. M. Tiryakioğlu and J. Campbell, Quality İndex for Aluminum Alloy Castings, Int. J. Metalcast., 2014, 8(3), p 39–42

    Google Scholar 

  25. T. Tunçay et al., Microstructure–Bifilm İnteraction and its Relation with Mechanical Properties in A356, Int. J. Cast Met. Res., 2017, 30(1), p 20–29

    Google Scholar 

  26. M. Uludağa et al., Mechanical Properties and Melt Quality Relationship of Sr-Modified Al-12Si Alloy, Arch. Foundry Eng., 2015, 15(4), p 134–140

    Google Scholar 

  27. C. Yüksel et al., Melt Cleaning Efficiency of Various Fluxes for A356 Alloy, in Shape Casting. Springer. p. 273–280 (2019)

  28. E. Efzan et al., Effect of Alloying Element on Al-Si Alloys, in Advanced Materials Research. Trans Tech Publ. (2014)

  29. Y. Liu and S. Kang, The Solidification Process of Al-Mg-Si Alloys, J. Mater. Sci., 1997, 32(6), p 1443–1447

    CAS  Google Scholar 

  30. A. Joenoes and J. Gruzleski, Magnesium Effects on the Microstructure of Unmodified and Modified Al-Si Alloys, Cast Met., 1991, 4(2), p 62–71

    Google Scholar 

  31. M. Tash et al., Effect of Metallurgical Parameters on the Hardness and Microstructural Characterization of As-Cast and Heat-Treated 356 and 319 Aluminum Alloys, Mater. Sci. Eng. A, 2007, 443(1), p 185–201

    Google Scholar 

  32. S. Kori, M. Prabhudev, and T. Chandrashekharaiah, Studies on the Microstructure and Mechanical Properties of A356 Alloy with Minor Additions of Copper and Magnesium, Trans. Indian Inst. Met., 2009, 62(4–5), p 353–356

    CAS  Google Scholar 

  33. M. Yıldırım and D. Özyürek, The Effects of Mg Amount on the Microstructure and Mechanical Properties of Al-Si-Mg Alloys, Mater. Des., 2013, 51, p 767–774

    Google Scholar 

  34. H.R. Ammar et al., Influences of Alloying Elements, Solution Treatment Time and Quenching Media on Quality İndices of 413-Type Al–Si Casting Alloys, Mater. Sci. Eng. A, 2008, 489(1), p 426–438

    Google Scholar 

  35. J. Parida et al., Effect of Heat Treatment on Wear Behaviour of Al-7wt%Si-X wt% Mg alloys. Materials Today: Proceedings (2020)

  36. A. Hekmat-Ardakan et al., Wear Behaviour of Hypereutectic Al-Si-Cu-Mg Casting Alloys with Variable Mg Contents, Wear, 2010, 269(9), p 684–692

    CAS  Google Scholar 

  37. D.K. Dwivedi, Adhesive Wear Behaviour of Cast Aluminium–Silicon Alloys: Overview (1980-2015), Mater. Des., 2010, 31(5), p 2517–2531

    CAS  Google Scholar 

  38. B.P. Bai, E. Dwarakadasa, and S. Biswas, Subsurface DAMAGE in dry Wear of Al-Si Alloys, Wear, 1981, 71(3), p 381–384

    CAS  Google Scholar 

  39. J. Clarke and A.D. Sarkar, Wear Characteristics of as-Cast Binary Aluminium-Silicon Alloys, Wear, 1979, 54(1), p 7–16

    CAS  Google Scholar 

  40. Y. Sun and H. Ahlatci, Mechanical and Wear Behaviors of Al-12Si-XMg Composites Reinforced with İn Situ Mg2Si Particles, Mater. Des., 2011, 32(5), p 2983–2987

    CAS  Google Scholar 

  41. V. Abouei, S.G. Shabestari, and H. Saghafian, Dry Sliding Wear Behaviour of Hypereutectic Al-Si Piston Alloys Containing İron-Rich İntermetallics, Mater. Charact., 2010, 61(11), p 1089–1096

    CAS  Google Scholar 

  42. M.S. Kaiser, Solution Treatment Effect on Tensile, Impact and Fracture Behaviour of Trace Zr Added Al-12Si-1Mg-1Cu Piston Alloy, J. Inst. Eng. (India) Ser. D, 2018, 99(1), p 109–114

    CAS  Google Scholar 

  43. M. Gupta and S. Ling, Microstructure and Mechanical Properties of Hypo/hyper-Eutectic Al-Si Alloys Synthesized USİNG a near-Net Shape Forming Technique, J. Alloys Compd., 1999, 287(1–2), p 284–294

    CAS  Google Scholar 

  44. L. Pedersen and L. Arnberg, The Effect of Solution Heat Treatment and Quenching Rates on Mechanical Properties and Microstructures in AlSiMg Foundry Alloys, Metall. Mater. Trans. A, 2001, 32(3), p 525–532

    Google Scholar 

  45. R.X. Li et al., Age-Hardening Behavior of Cast Al-Si Base Alloy, Mater. Lett., 2004, 58(15), p 2096–2101

    CAS  Google Scholar 

  46. D. Apelian, S. Shivkumar, and G. Sigworth, Fundamental Aspects of Heat Treatment of Cast Al-Si-Mg Alloys, AFS Trans., 1989, 97, p 727–742

    Google Scholar 

  47. V. Shivaprasad, P.S. Dixit, and H. Nalatore, Changes in Structural Features of Al-12Si-3Cu Alloy Due to Age Hardening (2017)

  48. G.-S. Ham et al., Effect of Heat Treatment on Tensile and Fatigue Deformation Behavior of Extruded Al-12 wt% Si Alloy, Met. Mater. Int., 2017, 23(1), p 35–42

    CAS  Google Scholar 

  49. R. Chen et al., Correlation of Solidification Microstructure Refining Scale, Mg Composition and Heat Treatment Conditions with Mechanical Properties in Al-7Si-Mg Cast Aluminum Alloys, Mater. Sci. Eng. A, 2017, 685, p 391–402

    CAS  Google Scholar 

  50. J.-H. Peng et al., Effect of Heat Treatment on Microstructure and Tensile Properties of A356 Alloys, Trans. Nonferr. Met. Soc. China, 2011, 21(9), p 1950–1956

    CAS  Google Scholar 

  51. R. Sharma, Anesh, and D.K. Dwivedi, Influence of Silicon (wt.%) and Heat Treatment on Abrasive Wear Behaviour of cast Al-Si-Mg Alloys, Mater. Sci. Eng. A, 2005, 408(1), p 274–280

    Google Scholar 

  52. D. Dispinar and J. Campbell, Determining Aluminium Melt Quality, Aluminium in India, 2005, 4(4), p 3–11

    Google Scholar 

  53. D. Dispinar and J. Campbell, Reduced Pressure Test (RPT) for Bifilm Assessment, in Shape Casting: 5th International Symposium 2014. Springer (2014)

  54. M. Uludağ, L. Gemi, and D. Dispinar, Statistical Analysis on the Effect of the Solidification Rate and Quenching Mediums on Mechanical Properties in ETIAL 221 Alloy, in Uludağ University Journal of The Faculty of Engineering (2020)

  55. H. Dvorak and E. Schwegtier, Statistical Distribution of Flaw Sizes, Int. J. Fract.Mech., 1972, 8(1), p 110–111

    Google Scholar 

  56. A.P. Hekimoğlu, M. Çalış, and G. Ayata, Effect of Strontium and Magnesium Additions on the Microstructure and Mechanical Properties of Al-12Si Alloys, Met. Mater. Int., 2019, 25(6), p 1488–1499

    Google Scholar 

  57. T. Gao et al., Phase Evolution of β-Al 5 FeSi During Recycling of Al-Si-Fe Alloys by Mg Melt, Int. J. Metalcast., 2019, 13(2), p 473–478

    CAS  Google Scholar 

  58. Y.C. Lin et al., Effects of Solution Treatment on Microstructures and Micro-hardness of a Sr-Modified Al-Si-Mg Alloy, Mater. Sci. Eng., A, 2018, 725, p 530–540

    CAS  Google Scholar 

  59. W. Kurz and D. Fisher, Fundamentals of Solidification; 1992. Trans Tech Publications (1989)

  60. M. Uludağ, R. Çetin, and D. Dispinar, Freezing Range, Melt Quality, and Hot Tearing in Al-Si Alloys, Metall. Mater. Trans. A, 2018, 49(5), p 1948–1961

    Google Scholar 

  61. M. Uludağ et al., On the İnterpretation of Melt Quality Assessment of A356 Aluminum Alloy by the Reduced Pressure Test: The Bifilm İndex and its Physical Meaning, Int. J. Metalcast., 2018, 12(4), p 853–860

    Google Scholar 

  62. M. Uludağ et al., Characterization of the Effect of Melt Treatments on Melt Quality in Al-7wt% Si-Mg Alloys, Metals, 2017, 7(5), p 157

    Google Scholar 

  63. J. Campbell, Discussion of “Investigation of Oxide Bifilms in Investment Cast Superalloy IN100 Parts I, and II”, Metall. Mater. Trans. A, 2017, 48(10), p 5151–5153

    CAS  Google Scholar 

  64. M. El-Sayed, H. Hassanin, and K. Essa, Bifilm Defects and Porosity in Al Cast Alloys, Int. J. Adv. Manuf. Technol., 2016, 86(5–8), p 1173–1179

    Google Scholar 

  65. M. Uludağ et al., Change in Porosity of A356 by Holding Time and its Effect on Mechanical Properties, J. Mater. Eng. Perform., 2018, 27(10), p 5141–5151

    Google Scholar 

  66. M. Uludağ et al., The Effect of Holding Time and Solidification Rate on Porosity of A356, Am. J. Eng. Res, 2016, 5(12), p 271–275

    Google Scholar 

  67. M. Uludağ et al., Relationship Between Machinability, Microstructure, Mechanical Properties of Al-7Si Alloy, J. Test. Eval., 2018, 46(6), p 2592–2603

    Google Scholar 

  68. J.T. Staley, Jr., M. Tiryakioğlu, and J. Campbell, The Effect of İncreased HIP Temperatures on Bifilms and Tensile Properties of A206-T71 Aluminum Castings, Mater. Sci. Eng. A, 2007, 460, p 324–334

    Google Scholar 

  69. X. Cao and J. Campbell, Oxide İnclusion Defects in Al-Si-Mg Cast Alloys, Can. Metall. Q., 2005, 44(4), p 435–448

    CAS  Google Scholar 

  70. S.M. Miresmaeili et al., Precipitation of Sr-Rich İntermetallic Particles and Their İnfluence on Pore Formation in Sr-Modified A356 Alloy, Metall. Mater. Trans. A, 2005, 36(9), p 2341–2349

    Google Scholar 

  71. M. Divandari and J. Campbell, Mechanisms of Bubble Damage in Castings (2001)

  72. B.N. Sutrisno, and H.C.K. Agustin, Effects of Bifilm on the Response of Artificial Aging of Aluminium Alloy ADC12, in AIP Conference Proceedings. AIP Publishing LLC (2019)

  73. P. Davami, S. Kim, and M. Tiryakioğlu, The Effect of Melt Quality and Filtering on the Weibull Distributions of Tensile Properties in Al-7% Si-Mg Alloy Castings, Mater. Sci. Eng. A, 2013, 579, p 64–70

    Google Scholar 

  74. M.A. El-Sayed et al., Effect of Holding Time Before Solidification on Double-Oxide Film Defects and Mechanical Properties of Aluminum Alloys, Metall. Mater. Trans. B, 2011, 42(6), p 1104–1109

    CAS  Google Scholar 

  75. D. Lee, J. Park, and S.W. Nam, Enhancement of Mechanical Properties of Al-Mg-Si Alloys by Means of Manganese Dispersoids, Mater. Sci. Technol., 1999, 15(4), p 450–455

    CAS  Google Scholar 

  76. Y. Liu et al., Effect of Mg on Microstructure and Mechanical Properties of Al-Mg Alloys Produced by High Pressure Torsion, Scripta Mater., 2019, 159, p 137–141

    CAS  Google Scholar 

  77. A.S. Anasyida, A.R. Daud, and M.J. Ghazali, Dry Sliding Wear Behaviour of Al-12Si-4Mg Alloy with Cerium Addition, Mater. Des., 2010, 31(1), p 365–374

    CAS  Google Scholar 

  78. B.K. Yen and T. Ishihara, Effect of Humidity on Friction and Wear of Al-Si Eutectic Alloy and Al-Si Alloy-Graphite Composites, Wear, 1996, 198(1), p 169–175

    CAS  Google Scholar 

  79. P. Davami et al., Effect of Oxide Films, İnclusions and Fe on Reproducibility of Tensile Properties in Cast Al-Si-Mg Alloys: Statistical and İmage Analysis, Mater. Sci. Eng. A, 2012, 558, p 134–143

    Google Scholar 

  80. M. Tiryakioğlu, Fracture Toughness Potential of Cast Al-7% Si-Mg Alloys, Mater. Sci. Eng. A, 2008, 497(1–2), p 512–514

    Google Scholar 

  81. G. Timelli, G. Camicia, and S. Ferraro, Effect of Grain Refinement and Cooling Rate on the Microstructure and Mechanical Properties of Secondary Al-Si-Cu Alloys, J. Mater. Eng. Perform., 2014, 23(2), p 611–621

    CAS  Google Scholar 

  82. M.A. Nozari et al., Effect of Be Modification on the Oxide Bifilms and Tensile Strength Reliability of Al-Si-Mg Alloys Containing Excess Fe, Metall. Mater. Trans. B, 2018, 49(3), p 1236–1245

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Bursa Technical University, Metallurgical and Materials Engineering, Bursa, 16310, Turkey

    Muhammet Uludağ

Authors
  1. Muhammet Uludağ
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Muhammet Uludağ.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Uludağ, M. A Statistical Assessment of Casting Quality–Tribological Properties of Eutectic Al-12Si Alloy: Effect of Mg. J. of Materi Eng and Perform 29, 7526–7543 (2020). https://doi.org/10.1007/s11665-020-05225-7

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-020-05225-7

Keywords

Search

Navigation