This article is made available through the Brunel Open Access Publishing Fund. Copyright @ 2012 Elsevier B.V.

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Effect of iron on the microstructure and mechanical property of Al–Mg–Si–Mn and Al–Mg–Si diecast alloys

Effect of copper and solidification conditions on the microstructure and mechanical properties of Al–Si–Mg alloys

Influence of additives on the microstructure and tensile properties of near-eutectic Al–10.8%Si cast alloy

The β-Al5FeSi platelets have long been thought to be brittle and responsible for the inferior mechanical properties of Al-Si cast alloys. Two typical cracks, transverse and longitudinal, are commonly observed in β-Al5FeSi platelets. It is thought that the cracks are probably due to the presence of doubled-over oxide films (bifilm) though some transverse cracks may be due to the brittleness. The crack is actually the gap between the two dry sides of an entrained oxide film. Its wetted sides are the favoured substrates for the nucleation and growth of β-Fe platelets. This discovery of the formation of β-Fe platelets on folded films has answered many previously intractable questions encountered in β-Fe phase. For the future, one may speculate that if oxide films could be eliminated from Al melts, it may prove possible to create alloys with unusually high toughness, despite high Fe contents.

Morphology of β-Al5FeSi phase in Al-Si cast alloys

Effect of grain refiner on the tensile and impact properties of Al–Si–Mg cast alloys

In the lost-foam casting process, liquid metal is poured directly onto a refractory-coated, foamed polymer pattern which is buried in loose sand. The polymer pattern undergoes thermal degradation and is gradually replaced by the molten metal, which solidifies and produces the casting. The inherent operating advantages of this innovative technique have generated considerable interest among casting manufacturers. Currently, the process is being utilized to manufacture a wide variety of ferrous and nonferrous components catering primarily to the automotive industry. Because the process is relatively new, there is a compelling need to quantify the influence of process parameters on microstructure and mechanical properties. Furthermore, the interaction of the thermal degradation products with the solidifying metal may produce several unique defects in the casting.

The lost-foam casting of aluminum alloy components

Premium quality aluminum alloy castings are used extensively in various applications requiring a high strength-to-weight ratio, such as aerospace, automotive and other structural components. The mechanical properties in these structure-sensitive alloys are determined primarily by the secondary dendrite arm spacing and the morphology of interdendritic phases. In addition, the amount of porosity in the casting and the inclusion concentration have a strong influence on fracture, fatigue and impact properties. During the production of the casting, various molten metal processing techniques can be implemented to control these microstructural parameters. These melt treatments include grain refinement with Ti-B, eutectic modification with strontium or sodium, degassing with purge gases and filtration of inclusions. The efficiency of these treatments determines the quality of the cast component.

Molten metal processing of advanced cast aluminum alloys

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The lost-foam casting of aluminum alloy components

Molten metal processing of advanced cast aluminum alloys