The effects of copper (Cu) content and mold temperature on the hot tearing susceptibility (HTS) of Mg-7Zn-xCu-0.6Zr (x = 0, 1, 2) alloys were investigated experimentally using a T-type hot tearing mold. The crack volumes were measured by paraffin permeation method, and the solidification process was analyzed by thermal analysis and by using the Clyne and Davies model. The microstructure and morphology of the crack zone of Mg-7Zn-xCu-0.6Zr alloys were characterized by scanning electron microscopy, and the composition of alloys was analyzed by X-ray diffraction. The results showed the formation of a new phase of MgZnCu in the alloys with Cu addition. Moreover, addition of Cu also led to the refinement of microstructures of Mg-7Zn-xCu-0.6Zr alloys. The HTS of Mg-7Zn-xCu-0.6Zr alloys decreased with the increase in both the content of Cu and the mold temperature.

Effects of Copper Content and Mold Temperature on the Hot Tearing Susceptibility of Mg-7Zn-xCu-0.6Zr Alloys

This study investigates the effect of different solidification cooling rates (0.5, 7.5, 13.5, 57.5, and 85 °C/s) on the solidification parameters, microstructure evolution, and mechanical properties of AA5056 Al-Mg alloy. According to the results, augmenting the cooling rate lowered the solidification time, and due to high thermal undercooling, substantially refined the microstructure. For instance, increasing the cooling rate from about 0.5 to about 85 °C/s decreased the fraction of Al3Mg2, Mg2Si, and Fe-rich compounds by 58, 64, and 27%, respectively. It also substantially refined the grains, reduced the size of secondary dendrite arm spacing (SDAS), and lowered the porosity content from about 3.8% to about 0.3%. The hardness, tensile strength, and fracture strain of the alloy increased by 44%, 140%, and 395%, respectively, as the cooling rate increased from 0.5 to 85 °C/s. The fracture mechanism also changed from a brittle-dominated mode to a high-energy ductile mode comprising of extensive dimpled zones at the higher cooling rates.

Effect of Cooling Rate on Microstructure and Mechanical Properties of AA5056 Al-Mg Alloy

Secondary dendrite arm coarsening model developed by Feurer and Wunderlin was used in this study. The parameters of the model were adjusted by following a simple approach to find an equivalent eutectic composition based on the alloying additions. Results showed the simple model proposed in this study provided good fits to data from literature on the 319 alloy as well as Al-Si-Cu alloys with various compositions.

A Simple Model to Estimate Solidification Time–Dendrite Arm Spacing Relationships in Cast Aluminum Alloys with Two Major Alloying Additions: Application to the Al-Si-Cu System

The need for a more sustainable and accessible source of energy is increasing as human society advances. The use of different metallic materials and their challenges in current and future energy sectors are the primary focus of the first part of this review. Cryogenic treatment (CT), one of the possible solutions for an environmentally friendly, sustainable, and cost-effective technology for tailoring the properties of these materials, is the focus of second part of the review. CT was found to have great potential for the improvement of the properties of metallic materials and the extension of their service life. The focus of the review is on selected surface properties and corrosion resistance, which are under-researched and have great potential for future research and application of CT in the energy sector. Most research reports that CT improves corrosion resistance by up to 90%. This is based on the unique oxide formation that can provide corrosion protection and extend the life of metallic materials by up to three times. However, more research should be conducted on the surface resistance and corrosion resistance of metallic materials in future studies to provide standards for the application of CT in the energy sector.

Sustainable New Technology for the Improvement of Metallic Materials for Future Energy Applications

Effect of refractory aggregate shape on the porosity of A356 alloy castings in lost foam casting

The aim of this research was evaluation of the solidification parameters of A356 alloy, e.g., dendrite arm spacing (DAS), correlation between cooling rate (CR) and DAS, hot tearing, and microstructural analysis at different coating thicknesses and strip sizes during the lost foam casting process (LFC). To achieve this goal, the DAS was measured at six coating thicknesses and six different strip sizes. In addition, thermal characteristics, such as the CR, temperatures of start and finish points of solidification, recalescence undercooling, and hot tearing susceptibility (HCSC), at five coating thicknesses were recognized from the cooling curves and their first derivative and the solid fraction curves, which have been plotted through the thermal analysis technique. The pouring temperature and strip size were fixed at 1063 K (790 °C) and 12 mm, respectively. Besides, to derive a numerical equation to predict the CR by measuring the DAS in this alloy, a microstructural evaluation was carried out on samples cast through 12-mm strip size. The results showed that both coating thickness and strip size had similar influences on the DAS, in which, by retaining one parameter at a constant value and simultaneous enhancement in the other parameter, the DAS increased significantly. Furthermore, at thinner coating layer, the higher amount of the CR was observed, which caused reduction in the temperatures of both the start and finish points of solidification. Also, increasing the CR caused a nonlinear increase in both the recalescence undercooling and the HCSC.

Interplay among Coating Thickness, Strip Size, and Thermal and Solidification Characteristics in A356 Lost Foam Casting Alloy

In this research, effects of six different strips size (2, 4, 6, 8, 10 and 12 mm thick respectively) and six different coating thicknesses on the fluidity of A356 aluminium alloy in lost foam casting (LFC) process were investigated. It was found that, in each mould, as the strip thickness increases, fluidity length increases. By varying the coating thickness, in a constant strip thickness, the maximum fluidity lengths were obtained in a specific coating thickness. The optimum coating thicknesses to reach maximum fluidity length for 2, 4, 6, 8, 10 and 12 mm strips was measured 170, 250, 250, 280, 350 and 350 μm respectively. This seems to be the result of the simultaneous effects of heat transfer and the controlling roll of permeability of refractory coating. Also the effect of coating thickness on the molten metal velocity in LFC process was studied by using accurate thermal analysis.

Effect of strips size and coating thickness on fluidity of A356 aluminium alloy in lost foam casting process

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Interplay among Coating Thickness, Strip Size, and Thermal and Solidification Characteristics in A356 Lost Foam Casting Alloy

Effect of strips size and coating thickness on fluidity of A356 aluminium alloy in lost foam casting process