Cooling Curve Analysis of A356 Alloy by Conventional Casting and the Effect of Stirring

The present investigation attempted to explore the effect of stirring during solidification of Aluminum A356 alloy, mainly focusing on the change from dendrite to globular structure. For this purpose samples of A356 alloy were melted in the electrical resistance furnace and cooling curves were recorded for each level agitation. The experimental curves were numerically processed by calculating first and second derivatives. From these were determined temperatures and times of start nucleation of alpha solid and eutectic reaction.

Complementary and normalized energies during static and dynamic uniaxial deformation of single and multi-layer foam-filled tube

This article investigates the quasi-static compressive behavior and the drop weight impact tests during the crashing of energy-absorbing structures such as aluminum foam-filled tubes. The closed-cell Al and A356 Alloy foams were cast and, after cutting, inserted into the Al thin wall tube as axial fillers of single-, double- and quad-layer structures. Then, the specific energy absorption (SEA), complementary energy (CE), normalized energy (NE), and specific normalized energy (SNE) are calculated based on static and dynamic test results under uniaxial loading. In this new method, values of NE and SNE are always between 0 and 1. Results show that the SEA-strain curves obtained from crashing the foam-filled tubes were linear and overlapping under static and dynamic loading. However, NE curves for dynamic tests were cyclic and in the static tests were asymptotic non-linear, and utterly separable. Results indicated that the SNE for Al, A356 single layer, Al-A356 double-, and Al-A356-Al-A356 quad-layer foam-filled tubes during dynamic tests were 0.25, 0.29, 0.31, and 0.31, while for the static tests, 0.14,0.15, 0.17, and 0.14 were recorded. It was found that CE and NE energies were better than the SEA energy for recognizing plastic deformation and crushing behavior.

Ultrasonically Stir Cast SiO2/A356 Metal Matrix Nanocomposites

Metal matrix nanocomposites are a newly developed materials with promising applications in a wide variety of areas, ranging from medical to aerospace structures, owing to their lightweight high-strength properties. A light metal like aluminum is usually strengthened by a reinforcing agent of carbides, nitrides, oxides, carbon-based materials, or even elementals to boost the mechanical performance without sacrificing lightweight; however, almost all reinforcing nanomaterials are commonly poorly wetted by metals leading to agglomerations, clusterings, among other problems, with diminished ductility and overall mechanical performance. To tackle the mentioned problems, a number of strategies including coatings, thermal, mechanical, or chemical treatments may be followed. In the present study, a particular focus is paid on the mechanical dispersion of nano-silica particles in a molten A356 alloy through applying high-intensity ultrasonic agitations in order to improve dispersibility, wettability, and interfacial affinity. Nano-silica being an inexpensive high-strength nanomaterial is added to an A356 aluminum alloy melt and then dispersed and distributed by a 2-kW power ultrasonic system. Experimental results including microscopic observations and those mechanical experimentations revealed that the ultrasonication of the aforesaid solid–liquid system may greatly improve the affinity between the de-agglomerated nano-silica particles and the host aluminum matrix with enhanced ductility.

Effects of Heat Treatment on the Microstructure and Hardness of A356 (AlSi7Mg0.3) Manufactured by Vertical Centrifugal Casting

The A356 alloy has been widely used in automotive components, such as wheels and brake disks, because it is an excellent lightweight material with high corrosion resistance and good mechanical properties. Recently, to reduce the weight of brake disks, the Fe-A356 hybrid brake disk has been suggested. Because brake disk quality is directly related to driving safety, the T4/T6 heat treatment of centrifugally cast A356 alloys were performed to enhance the mechanical properties and reduce micro-segregation. The solid-solution heat treatment followed by annealing caused the formation of Mg-rich intermetallic compounds on the grain boundaries of the Al matrix, decreasing the average hardness of the alloys by 13 HV. In contrast, the solid solution followed by water quenching (T4) reduced the area fractions of the intermetallic compounds and increased the average hardness by 11 HV. The T6 heat-treated A356 alloys, which were influenced by the formation of the Guinier–Preston zone exhibited a relatively higher average hardness, by 18 HV, compared to T4 heat-treated A356 alloys.

Microstructure Evolution and Solidification Behavior of a Novel Semi-Solid Alloy Slurry Prepared by Vibrating Contraction Inclined Plate

In this work, based on the A356 alloy, a novel Al–Si–Mg–Cu–Fe–Sr alloy with good mechanical property and high thermal conductivity was developed. The semi-solid slurry of the alloy was prepared via the vibrating contraction inclined plate. The microstructure evolution and solidification behavior of the alloy were investigated. The results demonstrated that, compared with the A356 alloy, the enhanced property of the Al–Si–Mg–Cu–Fe–Sr alloy was associated with the size of primary α-Al grains and morphology of eutectic Si phases. In addition, the preparation process parameters of semi-solid slurries, including the pouring temperature, inclination angle, and vibration frequency, had a crucial effect on the size and morphology of primary α-Al grains. The optimized pouring temperature, inclination angle, and vibration frequency were 670 °C, 45°, and 60 Hz, respectively. In this condition, for the primary α-Al grains, a minimum grain diameter of 64.31 µm and a maximum shape factor of 0.80 were obtained. This work provides a reference for the application of the alloy with high performance in the field of automobile and communication.

Effects of different cooling conditions on friction stir processing of A356 alloy: Numerical modeling and experiment

In the present work, the effects of in-process cooling are investigated on the material flow, temperature distribution, axial force, wear resistance, and microstructural and mechanical properties of friction stir processed (FSPed) Al-Si aluminum alloy. The finite element method (FEM) was developed for modeling the process, based on the eulerian-lagrangian technique, and then verified by the experimental force and temperature histories. Next, the material flow and temperature distribution during the friction stir process (FSP) with in-process cooling under different conditions were considered. After that, the experimental investigations, including the optical microscopy, hardness, and wear tests, were conducted. Finally, the stir zone (SZ) shape obtained by experiments and simulation model were compared for the FSPed samples without cooling and with air cooling. The material flow achievements reveal that using a coolant affects the material flow in the pin-driven zone more significantly than in the shoulder-driven zone, leading the SZ to change from the basin shape into the V shape. The SZ shapes obtained from the experiments and the simulation model show a good agreement between the shapes of the samples FSPed without cooling and with air cooling. Moreover, experimental results showed that using in-process cooling reduces Si particles' size and thus significantly increases the hardness and wear resistance. The Si particles size is reduced from 10 μm in the base metal to 2.6 μm and 2 μm in the air-cooled and water-cooled samples. Consequently, the wear mass loss reduced almost 28% and 40%, and hardness increased almost 35% and 80% for the air-cooled and water-cooled samples compared to the processed samples without coolant.

Sn-Aided Joining of Cast Aluminum and Steel Through a Compound Casting Process

Obtaining a strong bond between aluminum and steel is challenging due to poor wettability between aluminum melt and steel and brittle intermetallic phases forming in the interface. In this research, a novel coating method, namely hot dipping of Sn, has been developed to treat the steel insert surfaces. Results show that without preheating the mold or Sn-coated insert, a thin, crack-free, and continuous metallurgical bonding layer was achieved in the A356 aluminum/steel compound castings. Intermetallic structures forming in the interface have been characterized in detail. The Sn-coating layer completely melted and mixed with the liquid aluminum during the casting process. The reaction layer at the aluminum/steel interface is composed of ternary Al–Fe–Si particles and a thin layer of binary Al5Fe2 phase with thickness less than 1 µm. A small fraction of dispersed Sn-rich particles was observed distributing in the reaction layer and adjacent to eutectic Si particles in the A356 alloy. A sessile drop wetting test showed that Sn-coated steel substrates can be well wetted by aluminum melt. The improved wettability between A356 alloy melt and steel was attributed to the penetration and breaking of the aluminum oxide layer at the surface of the aluminum droplets by liquid Sn. Graphic Abstract

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

In the current investigation, additive friction stir-deposition (AFS-D) of as-cast hypoeutectic A356 Al alloy was conducted. The effect of feeding speeds of 3, 4, and 5 mm/min at a constant rotational speed of 1200 rpm on the macrostructure, microstructure, and hardness of the additive manufacturing parts (AMPs) was investigated. Various techniques (OM, SEM, and XRD) were used to evaluate grain microstructure, presence phases, and intermetallics for the as-cast material and the AMPs. The results showed that the friction stir deposition technique successfully produced sound additive manufactured parts at all the applied feeding speeds. The friction stir deposition process significantly improved the microstructure of the as-cast alloy by eliminating porosity and refining the dendritic α-Al grains, eutectic Si phase, and the primary Si plates in addition to intermetallic fragmentation. The mean values of the grain size of the produced AMPs at the feeding speeds of 3, 4, and 5 mm/min were 0.62 ± 0.1, 1.54 ± 0.2, and 2.40 ± 0.15 µm, respectively, compared to the grain size value of 30.85 ± 2 for the as-cast alloy. The AMPs exhibited higher hardness values than the as-cast A356 alloy. The as-cast A356 alloy showed highly scattered hardness values between 55 and 75.8 VHN. The AMP fabricated at a 3 mm/min feeding speed exhibited the maximum hardness values between 88 and 98.1 VHN.