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Tailoring Al-7Si-0.3Mg cast alloy properties to represent HPDC tensile and fatigue behaviour in component prototypes
Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.ORCID iD: 0000-0001-6481-5530
Scania CV AB, Södertälje.
2016 (English)In: La Metallurgia Italiana, ISSN 0026-0843, Vol. 108, no 6, 33-36 p.Article in journal (Refereed) Published
Abstract [en]

To produce prototypes with mechanical properties expectable from EN AC 46000 HPDC components, prototyping related processes such as sand and plaster gravity casting as well as proper alloying and post solidification processes need to be understood and adjusted. Therefore, the influence of process, composition and heat treatment on tensile and fatigue behaviour has been investigated for an EN AC 42100 alloy. Sand cast test samples comprised the base alloy in as-cast condition and T5 treated as well as a 2 wt. % Cu addition in as-cast condition. Plaster cast test samples consisted of the base alloy in ascast condition and T6 treated as well as a 1.7 wt. % Cu addition in as-cast condition. Tensile and fully reversed bending fatigue tests (R=-1) have been performed and the results have been compared to EN AC 46000 HPDC values. Samples in heat treated conditions and with Cu addition exhibited superior tensile properties than the base alloy in as-cast state for both casting processes. Yield strength and elongation values for the sand cast T5 treated and with Cu addition samples were similar to the HPDC ones. In terms of fatigue behaviour, T6 treated and with Cu addition samples exhibited strength improvements for plaster cast samples, while no changes were observed for sand cast samples. Only sand cast samples exhibited similar fatigue behaviour to the HPDC samples. The sand cast T5 treated samples were found to produce the most similar overall mechanical behaviour to EN AC 46000 HPDC.

Place, publisher, year, edition, pages
Milano: Associazione Italiana di Metallurgia , 2016. Vol. 108, no 6, 33-36 p.
Keyword [en]
aluminium alloys, prototyping, tensile properties, fatigue properties, sand cast, plaster cast
National Category
Metallurgy and Metallic Materials
Identifiers
URN: urn:nbn:se:hj:diva-31164Scopus ID: 2-s2.0-85008957398OAI: oai:DiVA.org:hj-31164DiVA: diva2:950914
Available from: 2016-08-03 Created: 2016-08-03 Last updated: 2017-11-28Bibliographically approved
In thesis
1. High performing cast aluminium-silicon alloys
Open this publication in new window or tab >>High performing cast aluminium-silicon alloys
2017 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The need to produce lighter components due to environmental aspects and the development of electrical vehicles represents an opportunity for cast aluminium-silicon alloys. With high specific strength, good castability, high corrosion resistance and recyclability, these alloys offer an attractive combination of properties as an alternative to steel, cast iron and titanium-based components in certain applications. To take advantage of such a combination of properties, there is a need to ensure that they can be reliably achieved. In other words, high performing components need to be produced. For that, the production cycle, from alloy selection and melt preparation, to the casting and heat treatment of the component must be understood and controlled as a whole. The different steps in the production cycle will affect the microstructure of the components and hence the resulting mechanical properties. Understanding the relation between the different steps in the production cycle, its consequences on the microstructural features and on the mechanical properties constitutes the aim of this thesis.

Experiments applying state-of-the-art knowledge regarding effect of casting process, alloying system and post-process variables were performed aimed at achieving properties similar to those of high pressure die casting (HPDC) components. Different melt quality determination tools were evaluated on three different EN AC-46000 melt qualities. The influence of modification, grain refinement and both treatments together was assessed on an Al-10Si alloy solidified under different cooling rates. The tensile behaviour and the impact of features such as secondary dendrite arm spacing (SDAS) or grain sizes was quantified.

It was corroborated that by appropriate selection and control of such alloying system, process and post-process variables it is possible to achieve HPDC EN AC-46000 tensile and fatigue properties through a T5 treated sand cast EN AC-42100 alloy. On the other hand, the available techniques for melt quality assessment are inadequate, requiring further analysis to successfully identify the melt quality. Additionally, it was observed that decreasing the melt quality by additions of 25 wt.% of machining chips did not significantly decrease the tensile properties but slightly increased the variation in them. In relation to the modification and grain refinement of Al-10Si alloys it was concluded that with the slowest cooling rate tested, additions of only grain refiner did not successfully produce equiaxed grains. For cooling rates corresponding to dendrite arm spacings of 15 μm and slower, combined additions of grain refiner and modifier can lead to higher tensile properties compared to the corresponding separate additions. SDAS was observed to describe flow stress through the Hall-Petch equation but grain size did not show a physically meaningful relationship. Furthermore, beginning of cracking was detected in the plastic deformation region at dendrite/eutectic boundaries and propagated in a trans-granular fashion.

Place, publisher, year, edition, pages
Jönköping: Jönköping University, School of Engineering, 2017. 44 p.
Series
JTH Dissertation Series, 33
Keyword
Aluminium cast alloys, melt quality, eutectic modification, grain refinement, microstructure, tensile properties
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-38005 (URN)978-91-87289-34-7 (ISBN)
Presentation
2017-12-14, E1405 (Gjuterisalen), Jönköping University, School of Engineering, Jönköping, 10:00 (English)
Opponent
Supervisors
Available from: 2017-11-28 Created: 2017-11-28 Last updated: 2017-11-28Bibliographically approved

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Riestra, MartinSeifeddine, Salem

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