Porous media reinforced with carbon soots

This paper illustrates the effects of stirring and graphene nanosheet (GNS) addition on the microstructure and mechanical behaviour of 393 hypereutectic Al-Si alloys used in the diesel engine pistons. Two processing routes were applied to fabricate hypereutectic Al-Si alloys: The first route mainly depends on stirring Al-Si alloys for 12 minutes at 400 rpm. The second one involves stirring Al-Si alloys for 2 minutes and then adding graphene nanosheets into the vortex, and consequently continue stirring for 10 minutes at 400 rpm. Results show that the distribution of the primary silicon was improved significantly in stir casting at both the edge and the center of the samples with relative reduction of 34% and 37% in the average particle size respectively. This average primary silicon size was further reduced by 17% with the addition of 1 wt% GNSs. GNS embedding into Al-Si alloy matrix resulted in remarkable increase in hardness values of the nanocomposites compared to the cast alloy.

/pdf/microscopical-characterization-of-cast-hypereutectic-al-si-k5sj7v8uyu.pdf

Microscopical Characterization of Cast Hypereutectic Al-Si Alloys Reinforced with Graphene Nanosheets

The aim of this research is to develop a novel analytical approach to determine the level of modification of silicon in Al-Si hypoeutectic and hypereutectic alloys. Two standards to determine the level of modification of silicon particles were investigated: the AFS Si Modification Standard and the Primary Si Grade.1,2 The first method can only be used for Al-Si hypoeutectic alloys and the second one for Al-Si hypereutectic alloys. In both methods, the determination of the level of modification of silicon is carried out by comparing micrographs of the test sample with the respective standards by simple observation. This results in a method with a bias error and does not take advantage of the analytical accuracy made possible by modern image analysis techniques. This paper presents a method known as image-analysis-based silicon modification level, which provides highly reliable results to determine the level of silicon modification for Al-Si hypoeutectic and hypereutectic alloys.

Novel image analysis to determine the si modification for hypoeutectic and hypereutectic Al-Si alloys

This chapter gives an introductory description of Al-Si alloys. The intention of this chapter is to provide a brief review and understanding of these alloys including their designation, standards, and the effects of alloying additions to the alloy. The additions to the Al-Si alloy are classified as minor, major, and impurity elements or additions. Minor and major additions are defined based on the fraction or percentage added to the alloy. The impurity element (usually Fe) is present as a byproduct of recycling.

Al-Si Alloys, Minor, Major, and Impurity Elements

Purpose: Aluminum-Silicon (Al-Si) alloys are commonly used in the automotive industry. At high Si levels they offer good wear resistance. Abrasive wear however, has been identified as the main insert cutter damage mechanism during High-Speed-Milling (HSM). This study investigates the effect of the tool cutter immersion on Al-Si bi-metallic materials in HSM operation. Design/methodology/approach: This study considers the effects of the tool cutter immersion on the resultant cutting forces, associated machined surface roughness, and machined subsurface microstructural damage caused by the tool cutter during the Minimum Quantity Lubricant – High Speed Milling (MQL-HSM) operation of AlSi bi-metallic materials with varying amounts and morphologies of the silicon phase. Findings: Experimental results indicate that a combination of gray cast iron with the W319 microstructure yields the greatest resistance to the tool cutter rake face during the face milling operation for all investigated tool cutter radial immersions. Machined surface roughness measurements reveal that surface roughness is a function of both the silicon content and morphology, as well as the percentage of tool cutter immersion. Matrix hardness measurements indicate that machining at all immersions has the same effect on compressing the matrix structure. Research limitations/implications: This study considers the effects of the radial tooling immersion and material selection while the speed, feed, and axial depth-of-cut are kept constant. Future work should address variability in the machining parameters in an attempt to maximize tool life, while optimizing the machined surface quality. Practical implications: Material selection affects the machining conditions in HSM of Al-Si bi-metallic materials. As a result careful consideration should be given when tailoring the machining conditions to the cast microstructures. Originality/value: North American automakers rely heavily on Al-Si precision sand cast components. As a result bi-metallic machining has to be often addressed during the face milling of engine blocks and cylinder heads. The research conducted here broadens the understanding of the impact of radial immersion on the machining behavior of Al-Si bi-metallic materials.

Effect of tool cutter immersion on Al-Si bi-metallic materials in High-Speed-Milling

Improvement in functional characteristics of aluminum-silicon cast components through the utilization of a novel electromagnetic treatment of liquid melts

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Improvement in functional characteristics of aluminum-silicon cast components through the utilization of a novel electromagnetic treatment of liquid melts