Skip to main content
SpringerLink
Log in

Measurement and interrelation of length scale of dendritic microstructures, tensile properties, and machinability of Al-9 wt% Si-(1 wt% Bi) alloys

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Al-Si alloys are increasingly being employed in the aerospace industry, satellite bearings, and inertial navigation systems. Hypoeutectic compositions are more attractive because of the low material cost and excellent castability. The addition of alloying elements to these alloys is generally used to modify the morphology of Si particles with a view to meeting mechanical strength requirements. Considering manufacturing requirements, to efficiently predict the quality of the machining process, it is essential to analyze the machinability of the material to be used, which depends on several factors, including microstructural features. In the present study, the effects of solidification cooling rate and Bi addition to Al-Si alloys on microstructural features, tensile properties, and rate of heat generation during necking processes are analyzed in samples of directionally solidified Al-9 wt% Si-(1.0 wt% Bi) alloy castings. The microstructure is composed of α-Al dendrites characterized by measured primary, secondary, and tertiary dendritic arm spacings, with a eutectic mixture of α-Al and Si-(Bi) particles. The addition of Bi is shown to attenuate the sharp tips of Si crystals. The dendritic length scale of the Al-rich matrix is correlated with the solidification cooling rate through experimental equations, and the evolution of the ultimate tensile strength with the primary dendritic spacing is experimentally represented by a single Hall-Petch-type equation for both examined alloys. Considering a same primary dendritic arm spacing, the addition of 1 wt% Bi to the Al-9 wt% Si alloy is shown to have the following effects: similar ultimate tensile strength, the elongation to fracture is improved, higher machinability based on significant decrease in the heating rate.

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
Fig. 18
Fig. 19
Fig. 20

Similar content being viewed by others

References

  1. Dwivedi DK, Sharma A, Rajan TV (2008) Machining of LM13 and LM28 cast aluminium alloys: part I. J Mater Process Technol 196:197–204

    Article  Google Scholar 

  2. Santos MC Jr, Machado AR, Sales WF, Barrozo MAS, Ezugwu EO (2016) Machining of aluminum alloys: a review. Int J Adv Manuf Technol 86:3067–3080

    Article  Google Scholar 

  3. Pervaiz S, Kannan S, Kishawy HA (2018) An extensive review of the water consumption and cutting fluid based sustainability concerns in the metal cutting sector. J Clean Prod 197:134–153

    Article  Google Scholar 

  4. Dias OA, Muniz EP, Porto PSS (2019) Electrocoagulation using perforated electrodes: an increase in metalworking fluid removal from wastewater. Chem Eng Process 139:113–120

    Article  Google Scholar 

  5. Madanchi N, Thiede S, Gutowski T, Herrmann C (2019) Modeling the impact of cutting fluid strategies on environmentally conscious machining systems. Proc CIRP 80:150–155

    Article  Google Scholar 

  6. Farahany S, Ourdjini A, Bakar TAA, Idris MH (2014) Role of bismuth on solidification, microstructure and mechanical properties of a near eutectic Al-Si alloys. Met Mater Int 20:929–938

    Article  Google Scholar 

  7. Samuel AM, Doty HW, Gallardo SV, Samuel FH (2016) The effect of Bi-Sr and Ca-Sr interactions on the microstructure and tensile properties of Al-Si-based alloys. Materials-Basel 9:126

    Article  Google Scholar 

  8. Wu X, Zhang GA, Wu FF (2013) Influence of Bi addition on microstructure and dry sliding wear behaviors of cast Al-Mg2Si metal matrix composite. Trans Nonferrous Metals Soc China 23:1532–1542

    Article  Google Scholar 

  9. Farahany S, Ghandvar H, Nordin NA, Ourdjini A, Idris MH (2016) Effect of primary and eutectic Mg2Si crystal modifications on the mechanical properties and sliding wear behaviour of an Al–20Mg2Si–2Cu–xBi composite. J Mater Sci Technol 32:1083–1097

    Article  Google Scholar 

  10. Costa TA, Dias M, Freitas ES, Casteletti LC, Garcia A (2016) The effect of microstructure length scale on dry sliding wear behaviour of monotectic Al-Bi-Sn alloys. J Alloys Compd 689:767–776

    Article  Google Scholar 

  11. Freitas ES, Silva AP, Spinelli JE, Casteletti LC, Garcia A (2014) Inter-relation of microstructural features and dry sliding wear behavior of monotectic Al – Bi and Al – Pb alloys. Tribol Lett 55:111–120

    Article  Google Scholar 

  12. Farahany S, Ourdjini A, Idris MH, Thai LT (2011) Effect of bismuth on microstructure of unmodified and Sr-modified Al-7Si-0.4Mg alloys. Trans Nonferrous Metals Soc China 21:1455–1464

    Article  Google Scholar 

  13. Farahany S, Dahle AK, Ourdjini A, Hekmat-Ardakan A (2016) Flake-fibrous transition of silicon in near-eutectic Al-11.7Si-1.8Cu-0.8Zn-0.6Fe-0.3Mg alloy treated with combined effect of bismuth and strontium. J Alloys Compd 656:944–956

    Article  Google Scholar 

  14. El-Hadad S, Samuel AM, Samuel FH, Doty HW, Valtierra S (2003) Effects of Bi and Ca addition on the characteristics of eutectic Si particles in Sr-modified 319 alloys. Int J Cast Met Res 15:551–564

    Article  Google Scholar 

  15. Zander J, Sandström R (2009) Modelling technological properties of commercial wrought aluminium alloys. Mater Des 30:3752–3759

    Article  Google Scholar 

  16. Barzani MM, Farahany S, Yusof NM, Ourdjini A (2013) The influence of bismuth, antimony, and strontium on microstructure, thermal, and machinability of aluminum-silicon alloy. Mater Manuf Process 28:1184–1190

    Article  Google Scholar 

  17. Talbot DEJ, Ransley CE (1977) The addition of bismuth to aluminum-magnesium alloys to prevent embrittlement by sodium. Metall Trans A 8:1149–1154

    Article  Google Scholar 

  18. Danish M, Ginta TL, Habib K, Rani AMA, Saha BB (2019) Effect of cryogenic cooling on the heat transfer during turning of AZ31C magnesium alloy. Heat Transfer Eng 40:1023–1032

    Article  Google Scholar 

  19. Kaynak Y, Gharibi A, Yılmaz U, Köklü U, Aslantaş K (2018) A comparison of flood cooling, minimum quantity lubrication and high pressure coolant on machining and surface integrity of titanium Ti-5553 alloy. J Manuf Process 34:503–512

    Article  Google Scholar 

  20. Pu Z, Outeiro JC, Batista AC, Dillon OW Jr, Puleo DA, Jawahir IS (2012) Enhanced surface integrity of AZ31B Mg alloy by cryogenic machining towards improved functional performance of machined components. Int J Mach Tool Manu 56:17–27

    Article  Google Scholar 

  21. Danish M, Ginta TL, Habib K, Carou D, Rani AMA, Saha BB (2017) Thermal analysis during turning of AZ31 magnesium alloy under dry and cryogenic conditions. Int J Adv Manuf Technol 91:2855–2868

    Article  Google Scholar 

  22. Astakhov VP (2012) Environmentally friendly near-dry machining of metals. In: Astakhov VP, Joksch S (eds) Metalworking fluids (MWFs) for cutting and grinding. Fundamentals and recent advances. Woodhead Publishing, Cambridge, pp 135–200

    Chapter  Google Scholar 

  23. Farahany S, Ourdjini A, Bakhsheshi-Rad HR (2016) Microstructure, mechanical properties and corrosion behavior of Al-Si-Cu-Zn-X (X=Bi, Sb, Sr) die cast alloy. Trans Nonferrous Metals Soc China 26:28–38

    Article  Google Scholar 

  24. Reyes RV, Bello TS, Kakitani R, Costa TA, Garcia A, Cheung N, Spinelli JE (2017) Tensile properties and related microstructural aspects of hypereutectic Al-Si alloys directionally solidified under different melt superheats and transient heat flow conditions. Mater Sci Eng A 685:235–243

    Article  Google Scholar 

  25. Silva CAP, Leal LRM, Guimarães EC, Júnior PM, Moreira AL, Rocha OL, Silva AP (2018) Influence of thermal parameters, microstructure, and morphology of Si on machinability of an Al–7.0 wt.% Si alloy directionally solidified. Adv Mater Sci Eng:9512957 1–12

  26. Septimio RS, Costa TA, Vida TA, Garcia A, Cheung N (2017) Interrelationship of thermal parameters, microstructure and microhardness of directionally solidified Bi–Zn solder alloys. Microelectron Reliab 78:100–110

    Article  Google Scholar 

  27. Brito C, Costa TA, Vida TA, Bertelli F, Cheung N, Spinelli JE, Garcia A (2015) Characterization of dendritic microstructure, intermetallic phases, and hardness of directionally solidified Al-Mg and Al-Mg-Si alloys. Metall Mater Trans A 46:3342–3355

    Article  Google Scholar 

  28. Goulart PR, Spinelli JE, Osório WR, Garcia A (2006) Mechanical properties as a function of microstructure and solidification thermal variables of Al-Si castings. Mater Sci Eng A 421:245–253

    Article  Google Scholar 

  29. Peres MD, Siqueira CA, Garcia A (2004) Macrostructural and microstructural development in Al-Si alloys directionally solidified under unsteady-state conditions. J Alloys Compd 381:168–181

    Article  Google Scholar 

  30. Rocha OL, Siqueira CA, Garcia A (2003) Heat flow parameters affecting dendrite spacings during unsteady-state solidification of Sn-Pb and Al-Cu alloys. Metall Mater Trans A 34:995–1006

    Article  Google Scholar 

  31. Gündüz M, Çadırlı E (2002) Directional solidification of aluminium–copper alloys. Mater Sci Eng A 327:167–185

    Article  Google Scholar 

  32. Kakitani R, Reyes RV, Garcia A, Cheung N, Spinelli JE (2019) Effects of melt superheating on the microstructure and tensile properties of a ternary Al-15 Wt Pct Si-1.5 wt pct Mg alloy. Metall Mater Trans A 50:1308–1322

    Article  Google Scholar 

  33. Reyes RV, Kakitani R, Costa T, Spinelli JE, Cheung N, Garcia A (2016) Cooling thermal parameters, microstructural spacing and mechanical properties in a directionally solidified hypereutectic Al-Si alloy. Philos Mag Lett 96:228–237

    Article  Google Scholar 

  34. Sullivan DO, Cotterell M (2001) Temperature measurement in single point turning. J Mater Process Technol 118:301–308

    Article  Google Scholar 

  35. Abukhshim NA, Mativenga PT, Sheikh MA (2006) Heat generation and temperature prediction in metal cutting: a review and implications for high speed machining. Int J Mach Tool Manu 46:782–800

    Article  Google Scholar 

  36. Tadeu E, Gandini S (2013) The effects of microstructure and hardness of hypoeutectic Al-Si alloy over their machinability, in: 22nd International Congress of Mechanical Engineering, COBEM, Ribeirão Preto, Brazil, November 3-7, 2199–2209

  37. Chand M, Mehlta A, Sharma R, Ojha VN, Chaudhary KP (2011) Roughness measurement using optical profiler with self-reference lase and stylus instrument – a comparative study. Indian J Pure Appl Phys 49:335–339

    Google Scholar 

  38. Chinga G, Johnssen PO, Dougherty R, Lunden-Berli E, Walter J (2007) Quantification of the 3-D micro-structure of SC surfaces. J Microsc 227:254–265

    Article  MathSciNet  Google Scholar 

  39. Ferreira IL, Moreira ALS, Aviz JAS, Costa TA, Rocha OL, Barros AS, Garcia A (2018) On an expression for the growth of secondary dendrite arm spacing during non-equilibrium solidification of multicomponent alloys: validation against ternary aluminum-based alloys. J Manuf Process 35:634–650

    Article  Google Scholar 

  40. Mazahery ALI, Shabani MO (2012) A356 reinforced with nanoparticles: numerical analysis of mechanical properties. JOM-J Met 64:323–329

    Article  Google Scholar 

Download references

Funding

This study received financial support from the National Council for Scientific and Technological Development (CNPq) and FAPESP (São Paulo Research Foundation—Grant: 2018/11791-2.

Author information

Authors and Affiliations

  1. Federal Institute of Education, Science and Technology of Pará, IFPA, Belém, PA, 66093-020, Brazil

    Thiago A. Costa

  2. Department of Manufacturing and Materials Engineering, University of Campinas, UNICAMP, Campinas, SP, 13083-860, Brazil

    Marcelino Dias, Cassio Silva, Noé Cheung & Amauri Garcia

  3. Federal University of São Paulo, UNIFESP-Baixada Santista, Santos, SP, 11070100, Brazil

    Emmanuelle Freitas

  4. Federal University of Pará, UFPA, Belém, PA, 66075-110, Brazil

    Adrina P. Silva

Authors
  1. Thiago A. Costa
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Marcelino Dias
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Cassio Silva
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Emmanuelle Freitas
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Adrina P. Silva
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Noé Cheung
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Amauri Garcia
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Noé Cheung.

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

Costa, T.A., Dias, M., Silva, C. et al. Measurement and interrelation of length scale of dendritic microstructures, tensile properties, and machinability of Al-9 wt% Si-(1 wt% Bi) alloys. Int J Adv Manuf Technol 105, 1391–1410 (2019). https://doi.org/10.1007/s00170-019-04211-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04211-1

Keywords

Search

Navigation