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219/1 Hiping – a Potent Post Casting Treatment for High Integrity

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219/1 Hiping – a Potent Post Casting Treatment for High Integrity HIPing – A Potent Post Casting Treatment For High Integrity Aluminium Castings R.M.PILLAI Regional Research Laboratory (CSIR) Thiruvananthapuram – 695019, India Email : [email protected] ABSTRACT The increasing use of high integrity Al castings for repeated loading applications warrants improved fatigue properties as well. The principal cause for the lower fatigue properties and reliability of aluminium castings is the presence of defects and inhomogenities, which are the preferred fatigue initiation sites. Hot Isostatic Pressing (HIPing) is a powerful post casting treatment for eliminating defects like shrinkage porosity and hydrogen pinholes leading to densification and enhanced mechanical properties of the castings meant for high performance applications. This paper brings out the current status of this potent post casting treatment for high integrity castings including basics of HIPing, its variants and their pros and cons and its effects on both microstructure and mechanical properties of aluminium alloy castings. Keywords : HIPing, LHIPing, Aluminium castings, Fatigue strength, 219/1 Introduction Applications in aerospace, automotive and general engineering, requiring high mechanical properties including resistance to fatigue failure and weight saving, look for aluminium castings. This is because of their excellent casting characteristics, corrosion resistance, near net shape capability and especially high strength to weight ratio. Performance of casting is dictated by many metallurgical features, such as, secondary dendrite arm spacing (SDAS), iron intermetallics, oxides/inclusions and porosity. Castings exhibit defects such as shrinkage and gas porosity, hot tears, inclusion and alloy segregation that generally result in lower and more variable mechanical properties than their wrought counterparts. The fatigue endurance of castings is very sensitive to the size of casting defects. On the other hand, solidification time as reflected by secondary dendrite arm spacing(SDAS) and size of silicon particles also affects it to a lesser extent.These defects can be controlled reasonably by proper mold design and good foundry practice. In many engineering applications, the response to fatigue environment is very critical. Nonetheless, the complete elimination of the shrinkage defects is not always possible without the application of external forces to close voids and porosity. Hot Isostatic Pressing (HIPing) enables this. HIPing helps to reduce porosity in thick-to- thin section transition areas as well. HIPped castings can replace forgings for some high stress applications due to the elimination of porosity and other defects. The elimination of porosity with HIPing increases fatigue life and raises tensile properties. It also significantly reduces scrap, rework and weld repair requirements. Further, mold design can be simplified to save material formerly needed in complex gating and the placement of chills becomes less critical. Despite the wide application of HIPing for titanium and Ni alloys due to the enormous cost reduction potential, it has not been readily accepted for Al castings meant for aerospace and automotive applications. The reasons include: (i). Low cost of the alloy and high cost of HIPing, (ii).Numerous casting techniques used including investment, die casting, permanent mold, green sand, dry sand, lost foam, thixoforming and squeeze casting, (iii).Very strong tendency of Al alloys to dissolve hydrogen and form oxides, eutectics and intermetallic phases, which have a strong influence on properties and (iv). Unlike Ti and Ni alloys, the predictability of improvement in properties of Al castings is not as exact due to influence of many variables. However, in recent years, the lower cost HIPing processes such as LHIPing, Densal, PIF and quick HIP have emerged with their lower cost enabling them to be considered as a post casting treatment option for aluminium castings for niche applications[1]. Considering the importance of HIPing to high integrity aluminium alloy castings, this paper brings out the current status of this potent post cast treatment tool. 219/2 Evolution of HIPing The very first patent on HIPing dates back to 1913. Table 1[1,2] lists other significant milestones in the evolution of HIPing. In view of the potential improvement realized in castings subjected to HIPing (application of a high inert gas pressure at high temperature), the foundrymen had shown interest in the utilization in the sixties for aerospace and high performance components for racing engines and other niche market. High cost due to high investments and long cycle times (up to 10 hrs) is still the main barrier for extending the use of HIPing for high volume production. In addition, the gas pressurization used in conventional HIPing process is also very dangerous. A variant and recent innovation of Metal Casting Technology Inc and GM, USA termed Liquid HIPing, wherein a molten mixture of salts is used as the fluid for applying isostatic pressure on the components, achieves results similar to those obtained by the much longer gas HIPing cycle time. Basics of HIPing Liquid aluminium is prone to both hydrogen absorption and oxidation. Aluminium castings exhibit gas porosity and oxide inclusions inevitably. Further, improper feeding can result in shrinkage porosity. Typically gas and shrinkage pores are spherical and irregular in shape respectively and can associate with aluminium oxides as well. All these significantly deteriorate the fatigue properties of Al castings by shortening both fatigue crack propagation and the initiation period. Figure 1 shows the SEM micrographs revealing the origination of fatque cracks in Sr modified A356 castings from pores and oxide films[3]. The decrease in fatigue life is directly related to the increasing defect size. Porosity is more detrimental to fatigue life than oxide films. A defective casting shows at least an order of magnitude lower fatigue life than sound casting. In HIPing, the castings placed in a chamber are slowly heated while the pressure of the surrounding inert gas is simultaneously increased. Castings/components are subjected to the simultaneous application of both heat and high pressure in an inert gas atmosphere. This pressure while acting on the casting isostatically enables collapse of any internal porosity left in the castings. Later, the castings are cooled to the room temperature. The simultaneous application of heat and pressure converts the material in to a plastic state leading to the collapse of voids and porosity. It is also to be borne in mind that the collapsed voids do not change either the shape or dimensions of the parts in general. The clean surfaces of the voids enable diffusion bonding together and making a stronger part. HIPing is invaluable in the precision casting, power metallurgical, metal bonding and ceramic industries. It improves the performance and yield of precision castings. The isostatic nature of the applied gas pressure is well suited for defects healing in castings. HIPing of complex shapes parts can be done without complex or expensive tooling. 219/3 Relationship between benefits and casting quality HIPing provides significant improvements in mechanical properties, such as higher strength, enhanced toughness, improved fatigue resistance and longer creep life. Well documented benefits of HIPing include (i) An approximately 50% improvement in ductitity (ii) 3-10 times improvement in fatigue life (iii) Definite improvement in ultimate tensile strength (UTS) (iv). No change in yield strength (YS), (v). Reduction in porosity and thus minimizing the scatter in mechanical properties and (vi). Salvaging the scrapped castings due to porosity and hence improving casting yield especially in castings subjected to radiographic inspection. However, actual benefits to be exhibited in the castings depend on its quality. For example, in test bars cast without serious porosity, HIPing does not affect the tensile properties. If porosity is fine, ductility may be controlled by silicon particles or intermetallics. If the porosity is below a critical value, HIPing will not be effective. However, HIPing results in significant improvement in fatigue properties. It has been shown[2] that a ten fold enhancement in fatigue life has been achieved in A356 alloys by HIPing for both fine and coarse structured castings (SDAS 30-90µm at 138MPa) due to the effective closure of interdendritic shrinkage porosities even in high quality castings with a very fine structure (30µm SDAS) and corresponding fine porosity. It has also been shown that fatigue properties are influenced dramatically by casting defects other than just porosity, which takes the lead followed by oxide particles. In the absence of these defects, fatigue failure was observed to initiate at slip band leading to significantly longer fatigue life. Variants of HIPing Alcoa 359 Process : A process, covered by US Patent No.3.496.624, improves the fatigue strength of aluminium sand and permanent mould castings (up to 300%) over castings without HIPing and enables the castings to meet Class A radiographic specifications[4]. Thus the process makes possible the salvaging of scrapped casting with internal porosity and enhancing he casting yield of a foundry diesel engine pistons, permanent mould cast and treated with Alcoa 359 process, constituted a prime potential market. Any casting component benefited from superior fatigue properties could justify the additional expenditure involved in the Hiping. Densal HIPing
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