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Development of Cast Hypereutectic Al-Si-X Alloys with Ultrafine–Si Phase Part 1: As-cast Structure Development

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Abstract

A strontium-modified experimental Al20Si3Cu alloy was processed using the squeeze casting/high pressure die casting universal metallurgical simulator and analyzer (SC/HPDC UMSA) under impact and cyclic loading. Sample pressure and temperature vs. time were monitored during solidification, allowing thermal analysis to identify key solidification parameters. The application of pressure to the melt region improves the contact between the melt and the steel mold, which increases the initial melt cooling rate to ~100 °C/s and heat extraction by 40%. Metallographic analysis techniques including LOM, SEM/EDS, STEM/EDS were used to characterize the as-cast microstructure and microchemistry of selected samples. Metallographic data were collected from the polished and deep-etched surfaces as well as from STEM thin foils. This data allowed for the gathering of complementary information for determination of the relationship between the process and the thermal analysis parameters. The best processing parameters produced as-cast composite colonies that had a high fraction (~38 vol. %) dispersion of nanosized, individual, amorphous, Si-rich SiAl clusters and whiskers in a face-centered cubic (FCC) α-Al matrix. The clusters and whiskers had an average diameter of 220 nm with a standard deviation of 48 nm and whiskers were ~2 µm long. This nanocomposite structure was in the form of ~500 µm cauliflower-florets-shaped colonies of radial cells of ~30 µm in diameter that accounted for >85% of the material volume. We describe the process of formation of these newly discovered glassy SiAl nanophase clusters and whiskers in an FCC α-Al matrix. This ultrafine phase is a main, dominant feature of the as-cast ultrafine microstructure of Sr-modified, hypereutectic Al20Si3CuX alloy solidified under non-equilibrium conditions controlled by rapid heat extraction.

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Availability of Data and Material

All data are published in the PhD dissertation.5 Experimental materials were donated by Yamaha Motors Company, Japan. Software applications such as SC/HPDC UMSA were developed by Dr. Al Conle and Dr. Marcin Kasprzak, while concept and hardware design by Dr. Jerry Sokolowski.

Code Availability

UMSA SC/HPDC Control/Monitoring Software and HT UMSA Thermal Analysis Software (both proprietary software), commercial Octave routines, and open source fatigue test control software consisting of C++, FORTRAN, Linux Bash scripts, and commercial Microstar DAP platform software and hardware.

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Funding

This research was supported by AUTO 21 and the University of Windsor. This research concept was developed and executed at the University of Windsor and the Silesian University of Technology facilities under regular conditions.

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Authors and Affiliations

  1. Department of Mechanical, Automotive & Materials Engineering, University of Windsor, Windsor, Ontario, Canada

    P. Guba, J. Sokolowski, A. Sobiesiak & A. Conle

  2. Gesing Consultants Inc., Kingston, Ontario, Canada

    A. Gesing

  3. Faculty of Electrical Engineering, Silesian University of Technology, Gliwice, Poland

    M. Kasprzak

Authors
  1. P. Guba
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  2. J. Sokolowski
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  3. A. Gesing
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  4. A. Sobiesiak
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  5. A. Conle
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  6. M. Kasprzak
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Contributions

PG, JS and AS were involved in conceptualization. PG, JS, AG, AC, AS and MK were involved in methodologies. PG and AC were involved in experimental execution. PG, JS, AG, AC and MK were involved in formal analysis and investigation. PG, JS, AG and AS were involved in writing—original draft preparation. PG, JS, AG and AS were involved in writing review and editing. AUTO 21, University of Windsor was involved in funding acquisition. JS and AS were involved in supervision.

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Correspondence to P. Guba.

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Guba, P., Sokolowski, J., Gesing, A. et al. Development of Cast Hypereutectic Al-Si-X Alloys with Ultrafine–Si Phase Part 1: As-cast Structure Development. Inter Metalcast 17, 1535–1557 (2023). https://doi.org/10.1007/s40962-022-00888-5

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