Abstract
Reported work focuses on the effect of morphology of the Fe-rich intermetallic phases on the machinability of Al-alloy containing >2wt.% Fe, obtained from automotive scrap. Effect of Mo addition on the microstructure, high-temperature impression creep and thereby the machinability of the Al-recycled alloy were studied. The machinability of the recycled alloy was estimated by investigating the built-up-edge (BUE) and surface roughness (R a). SEM-EDS and TEM-SADP studies have shown that the crystal structure (BCC) of the Al8Fe2Si phase remained unchanged; however, Mo replaced few Fe atoms with little effect on the lattice dimension. It has been found that the addition of Mo to the recycled alloy suppresses the formation of β-phase (Al5FeSi) by suppressing the peritectic transformation of α (Al8Fe2Si) phase. Such suppression is found to improve the high-temperature creep resistance and the machinability with the increase in the Mo addition level.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
G. Gaustad, E. Olivetti, and R. Kirchain, Improving Aluminum Recycling: A Survey of Sorting and Impurity Removal Technologies, Resour. Conserv. Recycl., 2012, 58, p 79–87
S. Das, Designing Aluminum Alloys for a Recycle-Friendly World, Mater. Sci. Forum, 2006, 519–521, p 1239–1244
M.A. Moustafa, Effect of Iron Content on the Formation of β-Al5FeSi and Porosity in Al-Si Eutectic Alloys, J. Mater. Process. Technol., 2009, 209(1), p 605–610
Z. Li, M. Samuel, F.H. Samuel, C. Ravindran, S. Valtierra, and H.W. Doty, Parameters Controlling the Performance of AA319-Type Alloys: Part I. Tensile Properties, Mater. Sci. Eng. A, 2004, 367(1–2), p 96–110
L. Hurtalova, E. Tillova, M. Chalupova, Possibilities of Fe-Rich Phases Elimination with Using Heat Treatment in Secondary Al-Si-Cu Cast Alloy, METABK, 2015, 54(1) p 39–42 (UDC—UDK 669.715:66.04:620.17:620.18 = 111)
V. Abouei, H. Saghafian, S.G. Shabestari, and M. Zarghami, Effect of Fe-Rich Intermetallics on the Wear Behavior of Eutectic Al-Si Piston Alloy (LM13), Mater. Des., 2010, 31(7), p 3518–3524
J.Y. Hwang, H.W. Doty, and M.J. Kaufman, The Effects of Mn Additions on the Microstructure and Mechanical Properties of Al-Si-Cu Casting Alloys, Mater. Sci. Eng. A, 2008, 488(1–2), p 496–504
L.F. Mondolfo, Aluminium Alloys: Structure and Properties, Butterworths, London/Boston, 1976
W. Khalifa, F.H. Samuel, and J.E. Gruzleski, Iron Intermetallic Phases in the Al Corner of the Al-Si-Fe System, Metall. Mater. Trans. A, 2003, 34(13), p 807–825
E.R. Wang, X.D. Hui, S.S. Wang, Y.F. Zhao, and G.L. Chen, Improved Mechanical Properties in Cast Al-Si Alloys by Combined Alloying of Fe and Cu, Mater. Sci. Eng. A, 2010, 527(29–30), p 7878–7884
X. Cao and J. Campbell, Morphology of β-Al5FeSi Phase in Al-Si Cast Alloys, Mater. Trans., 2006, 47(5), p 1303–1312
N.A. Belov, A.A. Aksenov, and D.G. Eskin, Iron in Aluminium Alloys: Impurity and Alloying Element, CRC Press, London, 2002 (ISBN 9780415273527—CAT# TF1411)
A.R. Farkoosh, X. Grant Chen, and M. Pekguleryuz, Dispersoid Strengthening of a High Temperature Al–Si–Cu–Mg Alloy via Mo Addition, Mater. Sci. Eng. A, 2015, 620, p 181–189
H. Westengen, Formation of Intermetallic Compounds During DC Casting of a Commercial Purity Al-Fe-Si Alloy, Zeitschrift fur Metallkunde, 1982, 73, p 360–368
Y. Zedan, F.H. Samuel, A.M. Samuel, and H.W. Doty, Effects of Fe Intermetallics on the Machinability of Heat-Treated Al-(7–11)% Si Alloys, J. Mater. Proc. Tech., 2010, 210, p 245–257
C. Lu, Study on Prediction of Surface Quality in Machining Process, J. Mater. Proc. Tech., 2008, 205(1–3), p 439–450
B. Das, R. N. Rai, and S. C. Saha, Analysis of Surface Roughness on Machining of Al-5Cu Alloy in CNC Lathe Machine, Int. J. Res. Eng. Tech, 2013, 2(9), p 2319–2322 (http://esatjournals.net/ijret/2013v02/i09/IJRET20130209044.pdf)
X. Wang and C.X. Feng, Development of Empirical Models for Surface Roughness Prediction in Finish Turning, Int. J. Adv. Manuf. Technol., 2002, 20(5), p 348–356
Acknowledgments
The corresponding author, Dr. Rao, is highly indebted to Prof. Nack J Kim and Mr. Yuni Kwon, GIFT-POSTECH, Korea for their kind help in conducting the TEM characterization presented in this work. Dr. Rao also expresses his deep thankfulness to Dr. Mahesh Kumar Talari and Ms. Widyani Darham, Faculty of Applied Sciences of Universiti Teknologi MARA (UiTM) for assisting in conducting the high-temperature impression creep tests discussed in this work. Prof. M.M. Ratnam of Faculty of Mechanical Engineering, Universiti Sains Malaysia, Malaysia, is highly appreciated for lending his laboratory for conducting the machinability studies. In addition, Dr Rao is also grateful to KBM Affilips B.V, (The Netherlands) for their sponsorship of inoculant master alloy and Malaysian Aluminium Alloys Company (Malaysia) for sponsoring the recycled automotive recycled alloy used in the present work. Ministry of Higher Education (MOHE), Malaysia and Universiti Malaysia Pahang are also highly acknowledged for funding the present work through the FRGS and UMP research Grants (RDU140113 and RDU140363).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Ain, W.Q., Faisal, M.K., Talari, M.K. et al. Effect of Mo on the High-Temperature Creep Resistance and Machinability of a Recycled Al-Alloy with High Iron Impurity. J. of Materi Eng and Perform 25, 4310–4316 (2016). https://doi.org/10.1007/s11665-016-2266-2
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-016-2266-2