Skip to main content
SpringerLink
Log in
Book cover

Light Metals 2017 pp 227–234Cite as

Secondary Aluminum Alloys Processed by Semisolid Process for Automotive Application

  • Conference paper
  • First Online:

  • 2835 Accesses

Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

Abstract

OEMs manufacturers of aluminum based safety components for automotive sector are used to require low percentage of Fe as contaminant, since it can be responsible of very high brittle microstructure due to formation of acicular Fe-compounds. Lowest Fe percentage is achieved by alloying primary aluminum, instead of secondary aluminum obtained on recycling marketplace. On the other hand, any aluminum alloys fabricated starting from primary aluminum achieves very high environmental impact, due to very high CO2 equivalent emitted during the early extractive stage. In order to reduce total global warming potential of finished components, recycling alloys would be preferred, but metallurgy solutions are necessary to control Fe-contaminants. According to recent advancements, Fe-compounds in recycled aluminum could be controlled throughout semisolid processes, where the stirring phase of a semisolid slurry would produce fragmentation Fe-compounds. In this work, investigation about key process parameters has been performed to correlate microstructural features to mechanical properties in presence of Fe-compound. Among various process parameters, stirring time and solid fraction are most important key parameters to control to obtain fine globular microstructure. Tensile tests have been performed showing promising results (yield strength about 300 MPa and ultimate tensile stress about 330 MPa). Stirring stage in semisolid process allows reduction of average size of Fe-compounds, thus producing an increase in percentage elongation and toughness, namely the main requirements in automotive sector for widespread use of low-cost and low-environmental impact aluminum alloys.

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

References

  1. S. Das, The life-cycle impacts of aluminum body-in-white automotive material. JOM 52(8), 41–44 (2000)

    Article  Google Scholar 

  2. Das, S., Life cycle energy and environmental assessment of aluminum-intensive vehicle design. SAE Int. J. Mater. Manuf. 7(3) (2014)

    Google Scholar 

  3. M. Raugei et al., A coherent life cycle assessment of a range of lightweighting strategies for compact vehicles. 108, 1168–1176 (2015)

    Google Scholar 

  4. L. Bushi, T. Skszek, D. Wagner, Comparative LCA study of lightweight auto parts of MMLV MACH-I vehicle as per ISO 14040/44 LCA standards and CSA group: 2014 LCA guidance document for auto parts. Paper presented at TMS Annual Meeting 2015, 18–19 Mar 2015, pp. 193–208

    Google Scholar 

  5. R. Modaresi et all. Global carbon benefits of material substitution in passenger cars until 2050 and the impact on the steel and aluminum industries. Environ. Sci. Technol. 48(18), 10776–10784 (2014)

    Google Scholar 

  6. F. Karakoyun, D. Kiritsis, K. Martinsen, Holistic life cycle approach for lightweight automotive components. Metall. Res. Technol. 111(3), 137–146 (2014)

    Google Scholar 

  7. Q.G. Wang, D. Apelian, D.A. Lados, Fatigue behavior of A356/357 aluminum cast alloys. Part II—Effect of microstructural constituents. J. Light Met. 1(1), 85–97 (2001)

    Article  Google Scholar 

  8. A. Fabrizi et all., Evolution of Fe-rich compounds in a secondary Al–Si–Cu alloy: influence of cooling rate. Int. J. Mater. Res. 106(7), 719–724 (2015)

    Google Scholar 

  9. L.A. Narayanan, F.H. Samuel, J.E. Gruzleski, Crystallization behavior of iron-containing intermetallic compounds in 319 aluminum alloy. Metall. Mater. Trans. A 25(8), 1761–1773 (1994)

    Article  Google Scholar 

  10. G. Gustafsson, T. Thorvaldssons, G.L. Dunlop, Influence of Fe and Cr on the microstructure of cast Al–Si–Mg alloys. Metall. Trans. A Phys. Metall. Mater. Sci. 17A(1), 45–52 (1986)

    Google Scholar 

  11. L. Sweet et al., The effect of iron content on the iron-containing intermetallic phases in a cast 6060 aluminum alloy. Metall. Mater. Trans. A Phys. Metall. Mater. Sci. 42(7), 1737–1749 (2011)

    Google Scholar 

  12. S. Kumar, N. Hari Babu, G.M. Scamans, Z. Fan, Influence of intensive melt shearing on the microstructure and mechanical properties of an Al–Mg alloy with high added impurity content. Metall. Mater. Trans. A Phys. Metall. Mater. Sci. 42(10), 3141–3149 (2011)

    Google Scholar 

  13. D.R. Gunasegaram, A. Tharumarajah, Impacts of high-pressure diecasting process parameters on greenhouse gas emissions. Metall. Mater. Trans. B 40(4), 605–614 (2009)

    Article  Google Scholar 

  14. R.B.H. Tan, H.H. Khoo, An LCA study of a primary aluminum supply chain. J. Clean. Prod. 13(6), 607–618 (2005)

    Article  Google Scholar 

  15. B.J. Welch, M.M. Hyland, B.J. James, Future materials requirements for the high-energy-intensity production of aluminum. JOM 53(2), 13–18 (2001)

    Article  Google Scholar 

  16. T.E. Norgate, W.J. Rankin, Greenhouse gas emissions from aluminium production—a life cycle approach. Paper presented at International Symposium on Greenhouse Gases in the Metallurgical Industries: Policies, Abatement and Treatment (2001), pp. 275–290

    Google Scholar 

  17. J.A. Taylor, Iron-containing intermetallic phases in Al–Si based casting alloys. Mater. Sci. 1, 19–33 (2012)

    Google Scholar 

  18. A. Couture, Iron in aluminium casting alloys—a literature survey. Am. Foundryman’s Soc. Int. Cast Metals J. 6(4), 9–17 (1981)

    Google Scholar 

  19. P.N. Crepeau, Effect of iron in Al-Si alloys: a critical review. Trans. Am. Foundryman’s Soc. 103, 361–366 (1995)

    Google Scholar 

  20. G. Chen, Growth mechanisms of intermetallic phases in DC cast AA1xxx alloys. Paper presented at Light Metals 1998, San Antonio, Texas (1998), pp. 1071–1076

    Google Scholar 

  21. S. Nafisi et all., Microstructure and rheological behavior of grain refined and modified semi-solid A356 Al–Si slurries. Acta Materialia 54(13), 3503–3511 (2006)

    Google Scholar 

  22. O. Lashkari, R. Ghomashchi, The implication of rheology in semi-solid metal processes: an overview. J. Mater. Process. Technol. 182(1–3), 229–240 (2007)

    Article  Google Scholar 

  23. H.V. Atkinson, Modelling the semisolid processing of metallic alloys. Prog. Mater Sci. 50(3), 341–412 (2005)

    Article  Google Scholar 

  24. J. Koke, M. Modigell, Flow behaviour of semi-solid metal alloys. J. Nonnewton. Fluid Mech. 112(2–3), 141–160 (2003)

    Article  Google Scholar 

  25. M. Jeyakumar, M. Hamed, S. Shankar, Rheology of liquid metals and alloys. J. Nonnewton. Fluid Mech. 166(14–15), 831–838 (2011)

    Article  Google Scholar 

  26. A. Pola, R. Roberti, M. Modigell, L. Pape, Rheological characterization of a new alloy for thixoforming. Solid State Phenom. 141–143, 301–306 (2008)

    Article  Google Scholar 

  27. S. Tahamtan et al., Microstructure and tensile properties of thixoformed A356 alloy. Mater. Charact. 59 (2008), 223–228

    Google Scholar 

  28. S. Nafisi, R. Ghomashchi, Grain refining of conventional and semi-solid A356 Al–Si alloy. J. Mater. Process Technol. 174, 371–383 (2006)

    Article  Google Scholar 

  29. Y. Yu, S. Kim, Y. Lee, J. Lee, Phenomenological observation on mechanical and corrosion properties of thixoformed 357 alloys: a comparison with permanent mold cast 357 alloys. Metall. Mater. Trans. A Phys. Metall. Mater. Sci. 33, 1399–1412 (2002)

    Article  Google Scholar 

  30. S. Cecchel, G. Cornacchia, A. Panvini, Cradle-to-gate impact assessment of a high-pressure die-casting safety-relevant automotive component. JOM

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Politecnico di Milano, Milano, Italy

    F. D’Errico

  2. InnSight, Milano, Italy

    D. Mattavelli

Authors
  1. F. D’Errico
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. D. Mattavelli
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to D. Mattavelli .

Editor information

Editors and Affiliations

  1. SINTEF , Trondheim, Norway

    Arne P. Ratvik

Rights and permissions

Reprints and permissions

Copyright information

© 2017 The Minerals, Metals & Materials Society

About this paper

Cite this paper

D’Errico, F., Mattavelli, D. (2017). Secondary Aluminum Alloys Processed by Semisolid Process for Automotive Application. In: Ratvik, A. (eds) Light Metals 2017. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-319-51541-0_31

Download citation

Publish with us

Policies and ethics

Search

Navigation