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High Performing Aluminium Cast Components- Literature Study

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High Performing Aluminium Cast Components- Literature Study Report No. 2013-030 High performing aluminium cast components- Literature study Salem Seifeddine and Maria Nylander Swerea SWECAST AB P O Box 2033, SE-550 02 Jönköping, Sweden Telephone +46 (0)36 - 30 12 00 Fax +46 (0)36 - 16 68 66 [email protected] http://www.swereaswecast.se © 2014, Swerea SWECAST AB Swerea SWECAST AB Status Confidential Project No. Project name G891P1 High performing aluminium cast components Corresponding Author Report No. Date Salem Seifeddine 2013-030_ 2013-12-30 Sammanfattning Denna litteraturstudie är en etapp av projektet ”High performing aluminium cast components”. Studien syftar dels till belysa inverkan av smälthantering, process, stelning och defektbildning på de mekaniska egenskaperna hos Al-Si legeringar, dels att kartlägga tillgängliga legeringar som används i högtemperaturbeständiga komponenter. Studien kartlägger och rekommenderar ett antal olika sätt att arbeta förebyggande i syfte att uppnå högre duktilitet och belyser tillgängliga kommersiella legeringar med en uttalad hög duktilitet samt legeringar som anses vara varmhållfasta. Summary This literature review is one of the stages in the project ”High performing aluminium cast components”. The study aims at highlighting the impact of melting handling, processing, solidification, post solidification and defect formations on the mechanical properties of Al-Si alloys, and to map available alloys used in components for elevated temperature usage. The study identifies and recommends a number of routes to work proactively to achieve higher ductility and highlights available commercial alloys with a pronounced high ductility and alloys that are considered to be able to serve and are stable at elevated temperatures. In case of questions regarding sections 1-4.4 and 4.7-5, please contact Salem Seifeddine In case of questions regarding sections 4.5-4.6, please contact Maria Nylander Report No. Swerea SWECAST AB 2013-030_ Table of content 1 BACKGROUND.................................................................................................................... 1 2 INTRODUCTION ................................................................................................................. 1 3 OBJECTIVES AND TARGET ............................................................................................ 2 4 PARAMETERS INFLUENCING THE DUCTILITY AND THE PERFORMANCE AT ROOM AND ELEVATED TEMPERATURE OF CAST AL-SI ALLOYS .............................. 2 4.1 INTRODUCTION AND OVERVIEW – AL-SI BASED ALLOYS ..................................................... 2 4.1.1 The Relationship between Process, Microstructure and Mechanical Properties ..... 4 4.1.1.1 Melt treatment and processing variables ....................................................................... 4 4.1.1.2 System and metallurgy variables .................................................................................... 5 4.1.1.3 Post-solidification/-process variables ............................................................................ 10 4.2 HOW TO REACH IMPROVED DUCTILITY – MATERIALS RELATED PARAMETERS ................... 12 4.2.1 Oxide films .............................................................................................................. 12 4.2.1.1 Characteristics of oxide films ........................................................................................ 14 4.2.1.2 Bifilm formation ............................................................................................................. 14 4.2.1.3 Furling and unfurling of oxide bifilms ......................................................................... 15 4.2.1.4 Identification and measurement of oxide bifilms ......................................................... 15 4.2.1.5 Introduction of oxide bifilms through casting processes ............................................. 16 4.2.1.6 Detrimental Nature of oxide bifilms and related microstructural features ............... 17 4.2.1.7 Influence of oxides and inclusions on the mechanical properties ............................... 19 4.2.2 Porosity formation .................................................................................................. 23 4.2.2.1 Shrinkage porosity ......................................................................................................... 24 4.2.2.2 Hydrogen Porosity.......................................................................................................... 26 4.2.2.3 Influence of porosity on the mechanical properties ..................................................... 28 4.2.3 Fe-rich intermetallics .............................................................................................. 33 4.2.3.1 Introduction of Fe intermetallics due to die soldering ................................................ 34 4.2.3.2 Formation of Fe intermetallics ...................................................................................... 35 4.2.3.3 Influence of Fe and Mn on the mechanical properties ................................................ 39 4.3 HOW TO REACH IMPROVED DUCTILITY – PROCESS RELATED PARAMETERS ....................... 44 4.3.1 Gravity casting ........................................................................................................ 45 4.3.2 High pressure die casting ....................................................................................... 46 4.4 SUMMARY OF THE RELATIONSHIP BETWEEN PROCESS, MICROSTRUCTURE AND MECHANICAL PROPERTIES .......................................................................................................... 48 4.5 DUCTILE ALLOYS – COMMERCIALLY AVAILABLE .............................................................. 49 4.5.1 Producers ................................................................................................................ 49 4.5.1.1 RHEINFELDEN ............................................................................................................ 49 Alufont .............................................................................................................................................. 49 Anticorodal®-04 .............................................................................................................................. 50 Castasil®-37TM ................................................................................................................................ 51 4.5.1.2 TRIMEt aluminium SE ................................................................................................. 52 4.5.1.3 RIO TINTO ALCAN ..................................................................................................... 53 4.6 TECHNIQUES FOR SOUNDNESS AND MELT QUALITY MEASUREMENTS ................................ 54 Report No. Swerea SWECAST AB 2013-030_ 4.6.1 Reduced pressure test.............................................................................................. 55 4.6.2 Qualiflash ................................................................................................................ 56 4.6.3 PoDFA .................................................................................................................... 56 4.6.4 LiMCA ..................................................................................................................... 57 4.6.5 K-Mold .................................................................................................................... 57 4.6.6 Linkage between analytical results and mechanical properties .............................. 58 4.7 SIMULATION TOOLS FOR DEFECT PREDICTIONS ................................................................. 61 4.7.1 Sand inclusions ....................................................................................................... 61 4.7.2 Oxides ..................................................................................................................... 61 4.7.3 Discontinuities ........................................................................................................ 61 4.7.4 Air entrapment ........................................................................................................ 62 4.7.5 Proposed procedure for set-up of defect elimination simulation ............................ 62 4.8 AL-ALLOYS FOR ELEVATED TEMPERATURE USAGE ............................................................ 64 4.8.1 2-Series: Al-Cu alloys ............................................................................................. 64 4.8.2 3- /4-Series: Al-Si alloys ......................................................................................... 71 4.8.2.1 Hypoeutectic Al-Si alloys ................................................................................................ 71 4.8.2.2 Eutectic and hypereutectic Al-Si alloys ............................................................................ 83 4.8.3 5-series: Al-Mg alloys ............................................................................................. 91 4.8.4 7-series: Al-Zn ........................................................................................................ 97 4.8.5 Other alloys ........................................................................................................... 103 4.8.5.1 Al-Sc .............................................................................................................................. 103 4.8.5.2 Al-Ni .............................................................................................................................
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