Skip to main content
SpringerLink
Log in

Comparative Study of Grain Size and Mechanical Properties of Die-cast and Spray Formed Al-4.5 wt. % Cu Alloys Deposit

  • Peer Reviewed
  • Published:
Metallography, Microstructure, and Analysis Aims and scope Submit manuscript

Abstract

An Al-4.5 wt. % Cu alloy was prepared by die casting and spray forming process. The grain size, grain size distribution, porosity of the alloys were measured using optical metallurgical microscope and influence of grain refinement on mechanical properties of Al-4.5 wt. % Cu alloy was investigated in the present paper by performing a tensile test. The optical micrographs of die-cast alloy revealed the coarse equiaxed and dendritic structure, whereas spray formed alloy exhibits finer microstructure with equiaxed grain morphology. The average percentage of porosity in spray formed and die-cast alloy was quantified using image analysis. An evaluation of the YS and UTS of the spray formed alloy inferred excellent YS and UTS compared to its conventional die-cast counterpart. The analysis of the data showed that YS is influenced by the grain size and the distribution of the θ phase (CuAl2).

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

Similar content being viewed by others

References

  1. H.J. Lavernia, N.J. Grant, Spray deposition of metals a review. Mater. Sci. Eng. 98, 381–394 (1988)

    Article  CAS  Google Scholar 

  2. S. Annavarapu, R.D. Doherty, Evolution of microstructure in spray casting. Int. J. Powder Metall. 29, 331–343 (1993)

    CAS  Google Scholar 

  3. M. M. Sharma Material characterization, microstructural and mechanical characterization of various modified 7XXX series spray formed alloys 59, 91-99 (2008)

  4. G. Alan, Leatham and Alan Lawley, the osprey process: principles and applications. Int J Powder Metall. 29, 321–329 (1993)

    Google Scholar 

  5. G. B. Gauthama, Rudrakshi and S. N. Ojha Spray forming of liquid immiscible alloys and their wear characteristics J. Mater. Process. Techn. 198, 224-230 (2007)

  6. S. Komura, Z. Horita, M. Furukawa, M. Remoto, T.G. Langdon, Metall. Trans. 32A, 707 (2001)

    CAS  Google Scholar 

  7. W.J. Kim, S.I. Hong, Y.S. Kim, S.H. Min, H.T. Jeong, J.D. Lee, Acta Mater. 51, 3293 (2003)

    Article  CAS  Google Scholar 

  8. M. Eddahbi, M. Carsi, A. Ruano, Mater. Sci. Eng. 361A, 36 (2003)

    Article  Google Scholar 

  9. E.J. Lavernia, E.M. Gutierrewz, J. Szekely, N.J. Grant, Int. J. Rapid Solidific. 4, 89–124 (1988)

    CAS  Google Scholar 

  10. F.W. Kang, G.Q. Zhang, J.F. Sun, Z. Li, J. Shen, Hot deformation behavior of a spray formed super alloy. J. Mater. Process Tech. 204, 147–151 (2008)

    Article  CAS  Google Scholar 

  11. P. Mathur, S. Annavarapu, D. Appelian, A. Lawley, Process control, modeling, and applications of spray casting. J Meta. 41, 23–28 (1989)

    CAS  Google Scholar 

  12. G.M. Janowski, F.S. Biancaniello, G.E. Hicho, R.J. Fields and S.D. Ridder and F. H. Froes, P/M in aerospace, defense and demanding applications, MPIF. Princeton, 363-370 (1993)

  13. S. Hariprasad, S.M.L. Sastry, K.L. Jerina, R.J. Lederich, Microstructure and mechanical properties of dispersion-strengthened high-temperature Al-85 Fe 1.2 V 1.7 Si alloys produced by atomized melt deposition process. Metall. Trans. A. 24, 865–873 (1993)

    Article  Google Scholar 

  14. H. Liu, E.J. Levernia, R.H. Rangel, Modeling of molten droplet impingement on non-flat surface. Acta Metall. Mater. 43, 2053–2072 (1995)

    Article  CAS  Google Scholar 

  15. H. Liu, R.H. Rangel, E.J. Lavernia, Modeling of droplet-gas interactions in spray atomization of Ta-2.5 W alloy. Mater. Sci. Eng. A. 191, 171–184 (1995)

    Article  Google Scholar 

  16. A. Upadhyaya, N.S. Mishra, S.N. Ojha, Microstructural control by spray forming and wear characteristics of a babbit alloy. J. Mat. Sci. 32, 3227–3235 (1997)

    Article  CAS  Google Scholar 

  17. P.S. Grant, B. Cantor, L. Katgerman, Modeling of droplet dynamic and thermal histories during spray forming-ll. Effect Process Parameters Acta Metall. Mater. 41, 3109–3118 (1993)

    Article  CAS  Google Scholar 

  18. P. Mathur, S. Annavarapu, D. Apelian, A. Lawley, Spray casting an integral model for process understanding and control. Mater. Sci. Eng. A. 142, 261–276 (1991)

    Article  Google Scholar 

  19. E.J. Lavernia, Y. Wu, Spray atomization and deposition (Wiley, New York, 1996)

    Google Scholar 

  20. P.S. Grant, Prog, spray forming. Mater. Sci. 39, 497–545 (1996)

    Google Scholar 

  21. P. Mathur, D. Apelian, A. Lawley, Analysis of the spray deposition process. Acta Metall. 37, 429–443 (1989)

    Article  CAS  Google Scholar 

  22. W.D. Cai, E.J. Lavernia, Modeling of porosity during spray forming. Mater. Sci. Eng. A. 226, 8–12 (1997)

    Article  Google Scholar 

  23. P.S. Grant, W.T. Kim, B. Cantor, Spray forming of Aluminum-copper alloys. Mater. Sci. Eng. A. 134, 1111–1114 (1991)

    Article  Google Scholar 

  24. Prashant Shukla, R.K. Mondal and S.N. Ojha, Microstructural modifications induced by spray forming of Al-Cu alloys Mater. Sci. Eng. A 304-306, 583-586 (2001)

  25. ASTM. E8-04. Standard Test Methods for tension testing of Metallic Materials., Annual Book of ASTM Standards 03-01-3.06 (2004)

  26. A.K. Srivatasava, S.N. Ojha, S. Ranganathan, Microstructural features and heat flow analysis of atomized and spray formed Al-Fe-V-Si Alloy. Met. Mater. Trans. A. 29(1), 2205–2219 (1998)

    Article  Google Scholar 

  27. S.N. Singh, S.N. Ojha, Microstructural investigation on rapidly solidified cast iron powders. Int. J. Rapid Solidification. 7, 201–217 (1992)

    CAS  Google Scholar 

  28. V.C. Srivastava, A. Upadhyay, S.N. Ojha, Microstructural features induced by spray forming of a ternary Pb-Sn-Sb alloy. Bull. Mater. Sci. 23, 73–78 (2000)

    Article  CAS  Google Scholar 

  29. M.C. Flemings, Solidification processing, vol 58 (McGraw-Hill, New York NY, 1974)

    Google Scholar 

  30. G. Baumeister, B. Okolo, J. Rögner, Microcasting of Al bronze: influence of casting parameters on the microstructure and the mechanical properties. Microsyst. Techn. 14, 1647–1655 (2008)

    Article  CAS  Google Scholar 

  31. M. Eddahbi, F. Carreño, O.A. Ruano, Deformation behavior of an Al-Cu-Mg-Ti alloy obtained by spray forming and extrusion. Mater. Lett. 60, 3232–3237 (2006)

    Article  CAS  Google Scholar 

  32. F.W. Kang, G.Q. Zhang, J.F. Sun, Z. Li, J. Shen, Hot deformation behavior of a spray formed super alloy. J. Mater. Process. Tech. 204, 147–151 (2008)

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, REVA University, Bengaluru, Karnataka, 560 064, India

    K. S. Narayana Swamy

  2. School of Mechanical Engineering, REVA University, Bengaluru, Karnataka, 560 064, India

    S. Devaraj

  3. Department of Mechanical Engineering, SJC Institute of Technology, B.B. Road, Post Box. No. 20, Chickballapur, Karnataka, 562 101, India

    H. K. Chandra Mohan

Authors
  1. K. S. Narayana Swamy
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. S. Devaraj
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. H. K. Chandra Mohan
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to H. K. Chandra Mohan.

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

Narayana Swamy, K.S., Devaraj, S. & Chandra Mohan, H.K. Comparative Study of Grain Size and Mechanical Properties of Die-cast and Spray Formed Al-4.5 wt. % Cu Alloys Deposit. Metallogr. Microstruct. Anal. 11, 191–198 (2022). https://doi.org/10.1007/s13632-022-00839-w

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13632-022-00839-w

Keywords

Search

Navigation