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Thesis Presented to The UNIVERSITE DU QUEBEC A CHICOUTIMI THESIS PRESENTED TO THE UNIVERSITY OF QUEBEC AT CHICOUTIMI IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF DOCTOR OF PHILOSOPHY IN ENGINEERING BY ADEL MOHAMED EFFECT OF ADDITIVES ON THE MICROSTRUCTURE AND MECHANICAL PROPERTIES OF ALUMINUM-SILICON ALLOYS APRIL 2008 Library and Bibliotheque et 1*1 Archives Canada Archives Canada Published Heritage Direction du Branch Patrimoine de I'edition 395 Wellington Street 395, rue Wellington Ottawa ON K1A0N4 Ottawa ON K1A0N4 Canada Canada Your file Votre reference ISBN: 978-0-494-43180-1 Our file Notre reference ISBN: 978-0-494-43180-1 NOTICE: AVIS: The author has granted a non­ L'auteur a accorde une licence non exclusive exclusive license allowing Library permettant a la Bibliotheque et Archives and Archives Canada to reproduce, Canada de reproduire, publier, archiver, publish, archive, preserve, conserve, sauvegarder, conserver, transmettre au public communicate to the public by par telecommunication ou par Plntemet, prefer, telecommunication or on the Internet, distribuer et vendre des theses partout dans loan, distribute and sell theses le monde, a des fins commerciales ou autres, worldwide, for commercial or non­ sur support microforme, papier, electronique commercial purposes, in microform, et/ou autres formats. paper, electronic and/or any other formats. The author retains copyright L'auteur conserve la propriete du droit d'auteur ownership and moral rights in et des droits moraux qui protege cette these. this thesis. Neither the thesis Ni la these ni des extraits substantiels de nor substantial extracts from it celle-ci ne doivent etre imprimes ou autrement may be printed or otherwise reproduits sans son autorisation. reproduced without the author's permission. In compliance with the Canadian Conformement a la loi canadienne Privacy Act some supporting sur la protection de la vie privee, forms may have been removed quelques formulaires secondaires from this thesis. ont ete enleves de cette these. While these forms may be included Bien que ces formulaires in the document page count, aient inclus dans la pagination, their removal does not represent il n'y aura aucun contenu manquant. any loss of content from the thesis. Canada UNIVERSITE DU QUEBEC A CHICOUTIMI THESE PRESENTE A L'UNIVERSITE DU QUEBEC A CHICOUTIMI COMME EXIGENCE PARTIELLE DU DOCTORT EN INGENIERIE PAR ADEL MOHAMED EFFET DES ADDITIFS SUR LA MICROSTRUCTURE ET LES PROPRIETES MECANIQUES DES ALLIAGES D'ALUMINIUM-SILICIUM AVRIL 2008 Dedicated to my parents, Reham and my little Mahmoud RESUME Les alliages aluminium-silicium, particulierement a la composition eutectique, sont souvent employes dans l'industrie de 1'automobile en raison de leur de faible densite relative a des materiaux traditionnels. Les proprietes mecaniques de tels alliages sont determinees principalement par les constituants microstructuraux de leur structure apres la coulee, les morphologies et les quantites de leurs phases intermetalliques. Dans l'etat non modifie, les alliages Al-Si montrent un silicium eutectique ayant une forme aciculaire ou lamellaire, de ce fait, ces alliages ont tendance a montrer de faibles resistance et ductilite. Ainsi, les alliages avec une structure principalement eutectique doivent subir la modification afin d'assurer des proprietes mecaniques adequates. La qualite de du produit coule peut etre amelioree par affinement des grains, ceci permet de reduire la taille des grains primaires de la phase a-aluminium qui solidifie autrement dans une structure de grain grossiere. La production des alliages Al-Si avec une structure et des proprietes mecaniques ameliorees implique Implication de deux processus principaux : (i) addition de tels elements d'alliage comme Mg, Cu, Mn, et autres elements semblables, pendant l'etat liquide; et (ii) traitement thermique. Les elements de microalliage ou elements de trace utilises dans les alliages commerciaux d'aluminium sont de 0.5 a 1.0 % en poids de Pb, Bi, Sn et In, qui ont peu ou pas de solubilite en aluminium, c.-a-d. ils ont des coefficients de distribution extremement bas. L'influence du fer (0.5-1 % en poids), du manganese (0.5-1 % en poids), du cuivre (2.25- 3.25 % en poids), et du magnesium (0.3-0.5 % en poids), aussi bien que celle des elements Pb, Bi, Sn, et In, sur la microstructure et les proprietes mecaniques de l'alliage preeutectique Al-10.8%Si modifie et raffine a ete etudiee dans deux conditions, a savoir, tel que coule et application d'un traitement thermique. Les alliages en fusion ont ete verses dans (a) un moule metallique graphite-enduit rectangulaire de forme L prechauffe a 450 °C pour des mesures metallographiques et de durete ; et (b) un moule permanent de type ASTM B-108 et (c) un moule d'essai au choc d'acier doux pour produire les echantillons du test necessaire. devaluation microstructurale a ete effectuee en utilisant la microscopie optique en meme temps que l'analyse d'image pour la quantification. L'identification de phase a ete effectuee en utilisant la microsonde electronique (EPMA), couple aux equipements d'EDX et de WDS. Les barreaux d'essai ont ete divises en sept jeux : un ensemble a ete garde dans la condition de tel que coule, alors que les six autres ensembles etaient traites thermiquement, une mise en solution a 495°C pour 8 h, puis une trempe dans l'eau chaude a 65°C, suivi d'un vieillissement artificiel a 155 °C, 180 °C, 200 °C, 220 °C, et 240°C, respectivement, pendant 5 heures (c.-a-d. les traitements T6 et T7). Les proprietes mecaniques ont ete evaluees a la temperature ambiante par la durete, les proprietes de traction et d'impact pour les deux conditions, tel que coule et application du traitement thermique. Les mesures de durete ont ete effectuees en utilisant un appareil de controle brinell de durete. Des proprietes de traction ont ete determinees a l'aide d'une machine d'essai mecanique de Servohydraulic MTS. Les proprietes d'impact ont ete evaluees a l'aide d'une machine de test d'impact Charpy. ii En matiere de l'addition des elements d'alliage, les resultats prouvent que l'effet de modification du Sr diminue a mesure que la quantite de cuivre et de magnesium supplementaires est augmentee, en raison des interactions entre ces elements, ce qui cause une segregation grave des phases d'Al2Cu dans les secteurs loin du silicium eutectique modifie et change la sequence de precipitation de la phase a-Ali5(Fe,Mn)3Si2 d'une reaction post-dendritique a pre-dendritique ou l'intermetallique est observe pour se produire dans les dendrites d'a-Al. Dependant de la teneur en Fe et en Mn dans l'alliage, une grande variation dans la phase a est observee sous forme de particules formees polyhedrales connues sous le nom de « sludge ». La phase d'A^Cu est vue pour se dissoudre presque totalement pendant le traitement thermique de mise en solution, alors que les phases Al5Cu2MggSi6 et les phases intermetalliques du fer a-Ali5(Fe,Mn)3Si2 s'averent pour persister pour tous les alliages etudies, particulierement ceux qui contiennent les niveaux eleves du Mg et du Fe. La phase intermetallique de fer de 6-Al5(Fe,Mn)3Si se dissout partiellement dans les alliages modifies par le Sr, et sa dissolution devient plus prononcee apres traitement thermique de mise en solution. Pour les alliages soumis a un traitement thermique, un vieillissement maximal est realise a 180 °C, bien que l'index de la plus haute qualite corresponde a la temperature du vieillissement 155 °C, et ce est pour tous les alliages etudies. En consequence, 155 °C peut etre considere comme traitement de vieillissement optimal. A 0.5% Mn, la phase P-Fe forme quand le contenu de Fe est au-dessus de 0.75%, entrainant une diminution massive au niveau des proprietes mecaniques. Le meme resultat est obtenu quand les niveaux du Fe et du Mn sont augmentes au dela de 0.75%, en raison de la formation du residu « sludge ». D'autre part, les proprietes mecaniques des alliages contenant du cuivre sont affectees legerement aux niveaux eleves du magnesium en raison de la formation de la phase Al5Cu2MggSi6 qui diminue la quantite de magnesium libre disponible pour former la phase d'A^CuMg. Le contour courbe de la correlation entre l'UTS (limite ultime) et l'allongement observe pour tous les alliages soumis au vieillissement reflete la transition d'une forte correlation dans les conditions sous-vieillissement et vieillissement maximal liee a la faible correlation associee avec la condition de survieillissement. L'energie d'impact de Charpy de l'alliage Al-10.8%Si est influencee par sa microstructure qui depend fortement de la composition d'alliage. La morphologie du silicium fibreux en alliages modifies par le Sr augmente la durete en raison de son effet fondamental sur le declenchement des fissures et la resistance de propagation de fissure. Dans les alliages contenant -1% de fer et 1% ou 0.5% Mn, l'addition du fer mene a une plus grande precipitation du residu et des plaquettes P-Fe, respectivement; ces particules intermetalliques agissent en tant qu'emplacements de declenchement de fissures et reduisent les proprietes d'impact considerablement. Dans les alliages contenant des niveaux eleves en cuivre, le niveau de Cu accru abaisse les proprietes d'impact de maniere significative, puisque le comportement de rupture est maintenant egalement influence par la phase d'Al2Cu en plus des particules de silicium. Independamment de la composition d'alliage, le trace combine de l'energie d'impact et le Ill pourcentage d'elongation montre des relations lineaires pour tous les alliages, que ce soit dans la condition tel que coule ou traite thermiquement. Des modeles de regression multiples ont ete developpes afln de prevoir l'mfluence des variations compositionnelles sur les proprietes mecaniques (L.U, L.E, %A, et Ex) de l'alliage Al-10.8%Si soumis a un traitement T6.
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