845 to 852
Special Issue on Solidication Science and Processing for Advanced Materials
#2003 The Japan Institute of Metals
1.
Introduction
Phase
Temperature (K)
Aluminum FCC
885883
0.2
867844
Al5 FeSi
842841
Mg2 Si
826812
Aluminum FCC
886881
0.6
5.0
865843
Al5 FeSi
836834
Mg2 Si
825815
Aluminum FCC
887884
863847
Al5 FeSi
838835
Mg2 Si
821814
814778
846
1.5
xi xj
j>i
vij xi xj v ;
Graphite Cover
5
24
Sample
30
Graphite Crucible
3.
45
Sample
30
Table 2
Alloy
vij
TC
Fig. 1
XX
Condition
Cu
Mg
Fe
Mn
Zn
Ni
Ti
Cr
number
380
356
Reference
8.21
2.37
0.03
1.01
0.13
0.08
0.05
0.05
0.03
Cu-added
7.87
4.62
0.29
1.01
0.13
0.86
0.05
0.04
0.03
Fe-added
7.96
2.41
0.29
1.32
0.11
0.88
0.05
0.05
0.03
Reference
7.23
0.02
0.48
0.16
0.002
<0:001
0.003
0.14
0.003
Cu-added
6.29
0.17
0.40
0.07
0.004
<0:001
0.001
0.13
0.002
Fe-added
6.43
0.01
0.47
0.99
0.006
0.017
<0:001
0.13
0.002
Inuence of Copper and Iron on Solidication Characteristics of 356 and 380-Type Aluminum Alloys
847
1000
880
aluminum FCC
950
Temperature, T/K
Temperature, T/K
860
840
silicon
820
800
Solidification
completes (equilibrium)
780
Al15(Fe,Mn)3Si2 starts
Aluminum FCC starts
Al FeSi starts
5
Silicon starts
900
850
800
750
0.0
0.4
0.6
0.8
700
10000
1.0
Fraction Solid
Temperature, T/K
900
Al (Fe,Mn) Si
15
3 2
aluminum FCC
Al FeSi
5
silicon
800
Al Cu
2
Al5Cu2Mg8Si6
Solidification
completes
750
700
2000
2500
3000
3500
4000
20000
25000
30000
850
15000
4500
5000
Fig. 4
Table 3 Solidication sequence of sample 2 (Cu-added 380-type alloy) and weight percentage of each phase at complete solidication
temperature.
Phase
Calculated
Observed
Crystallization
temperature (K)
Amount
(mass%)
881.6
1.12
Aluminum FCC
863.1
82.83
Al5 FeSi
857.7
2.90
Silicon
835.0
6.06
Al7 Cu2 Fe
792.6
negligible
Al7 Cu4 Ni
786.9
negligible
Al2 Cu
784.7
4.94
778.2
0.54
Solidication completed
764.7
Crystallization
temperature (K)
Microstructure
Y
849.0
Y
Y
833.7
848
900
890
880
y=x
fcc aluminum
870
860
850
840
silicon
830
820
820
830
840
850
860
870
880
890
900
Fig. 5 Comparison between the calculated temperatures from the GulliverScheil model and the observed temperatures of aluminum FCC and silicon
in 380-type from various literatures.
aluminum FCC phases. However, binary interaction parameters are practical while the higher order ones derive from
laborious work and consumed time.
The observed crystallization temperatures of aluminum
FCC and silicon from other literatures316,2022) were
collected and compared with the calculated thermodynamic
results of which chemical compositions were input. Compared in Fig. 5, almost all the calculated temperatures for
aluminum FCC are higher than the observed ones not more
than 15 degree. However, the calculated temperatures for
silicon deviate from the observed temperatures 5 degree,
corresponding to this study.
The microstructure of solidied 380-type alloys (sample 1,
2, and 3) contains aluminum FCC, silicon, Al15 (Fe,Mn)3 Si2 ,
Al5 FeSi, Al2 Cu, and Al5 Cu2 Mg8 Si6 . The quantity of phases
in sample 2 was also calculated and is compared with the
detection by SEM with EDX analysis in Table 3. Al7 Cu2 Fe
and Al7 Cu4 Ni, which were predicted to have negligible
amount, could not be detected in the solidied microstructure. The electron micrographs of sample 2 are shown in
Fig. 6. The Al15 (Fe,Mn)3 Si2 phase (usually called the alpha
phase) crystallizes in two dierent morphologies: dense
idiomorphic and Chinese script as in Figs. 6(a) and (b)
respectively. The former is the primary phase that crystallizes
and normally termed sludge. Certain sedimentation of the
sludge Al15 (Fe,Mn)3 Si2 phase was found in all samples in
380 series due to the slow cooling rate used in this study. The
Al5 FeSi phase (usually called the beta phase) appears as
platelets or needles which are very distinct (Fig. 6(c)). The
eutectic phase Al2 Cu seems agglomerated pink bubbles (Fig.
6(c)).
For sample 3, the variations of the predicted amount of
intermetallics and calculated crystallization temperature of
major phases with copper are revealed in Figs. 7(a) and (b)
respectively. The quantity of Al2 Cu increases greatly with
copper content while others varies slightly. The crystallization temperatures of aluminum FCC (liquidus temperature) and silicon decline moderately with copper content
while those of Al15 (Fe,Mn)3 Si2 and Al5 FeSi remain almost
constant. The crystallization temperature of Al5 Cu2 Mg8 Si6
goes down signicantly at copper content 1.03.0 mass% and
decreases slightly at 3.06.5 mass%. In the range of 0.0 to
1.0 mass% of copper, the nal solidication temperature
decreases signicantly and then rises up to some degree and
decreases slightly.
In the same sample, the relationships between the
predicted amount of intermetallics and calculated crystallization temperatures of major phases with iron are shown in
Figs. 8(a) and (b). With increasing iron content, the amount
of Al5 FeSi rises up remarkably but saturates at about
2 mass% Fe and then decreases moderately. Al8 Fe2 Si does
not crystallize until the iron content is added up to 2.1 mass%
and then increases abruptly. The crystallization temperatures
of aluminum FCC, silicon, Al5 Cu2 Mg8 Si6 , Al2 Cu and the
complete solidication temperature remain unchanged while
those of Al15 (Fe,Mn)3 Si2 and Al5 FeSi increase substantially
and saturated at 2.2 mass% Fe.
Inuence of Copper and Iron on Solidication Characteristics of 356 and 380-Type Aluminum Alloys
Al (Fe,Mn) Si
15
Al Cu
Al Fe Si
Al Cu Mg Si
Al (Fe,Mn) Si
Al FeSi
5
Al Cu
15
849
Al Cu Mg Si
Al FeSi
8.0
(a)
7
5.0
4.0
3.0
2.0
1.0
0.0
0.0
2.0
3.0
Al (Fe,Mn) Si
15
4.0
5.0
6.0
7.0
0
0
0.5
Al Cu
1.5
2.5
3.5
Fe Content, (mass%)
Al5 FeSi
aluminum FCC
silicon
Solidification completed
(b)
Al8 Fe2 Si
Al5 FeSi
aluminum FCC
Al Cu Mg Si
silicon
Al2 Cu
Solidification completes
880
950 (b)
860
840
820
800
780
760
0
Cu Content, (mass%)
Fig. 7 Eects of copper content on the solidication characteristics of 380type alloy predicted from the Gulliver-Scheil model. (Fe 1.32%, Si 7.96%,
Mg 0.29%, Mn 0.11%, Zn 0.88%, Ni 0.05%, Ti 0.05%, Cr 0.03%); (a) The
relationship between the amount of intermetallics and copper content., (b)
The relationship between the crystallization temperatures of major phases
and copper content.
1
1.0
Cu Content, (mass%)
900
(a)
6.0
7.0
900
850
800
750
0
0.5
1.5
2.5
3.5
Fe Content, (mass%)
Fig. 8 Eects of iron content on the solidication characteristics of 380type alloy calculated from the Gulliver-Scheil model. (Cu 2.41%,
Si 7.96%, Mg 0.29%, Mn 0.11%, Zn 0.88%, Ni 0.05%, Ti 0.05%, Cr
0.03%); (a) The relationship between the amount of intermetallics and iron
content., (b) The relationship between the crystallization temperatures of
major phases and iron content.
850
950
aluminum FCC
Temperature, T/K
Temperature, T/K
880
860
silicon
840
Solidification
completes (equilibrium)
900
aluminum FCC
silicon
850
800
820
Solidification
completes (Scheil)
800
0.0
0.2
0.4
0.6
0.8
750
2000
1.0
Fraction Solid
Al8FeMg3Si6
Al FeSi
2500
Mg Si
2
Solidification
completes (Scheil)
3000
3500
4000
4500
Table 4 Solidication sequence of sample 5 (Cu-added 356-type alloy) and mass percentage of each phase at complete solidication
temperature.
Phase
Calculated
Observed
Crystallization
Amount
Crystallization
temperature (K)
(mass%)
temperature (K)
894.4
93.67
885.2
836.4
Aluminum FCC
Microstructure
Y
Silicon
845.9
4.83
Al5 FeSi
836.3
0.12
831.4
0.35
Mg2 Si
826.2
0.20
816.8
0.0003
Solidication completed
815.2
900
fcc aluminum
890
880
y=x
870
860
silicon
850
840
830
820
820
830
840
850
860
870
880
890
900
Inuence of Copper and Iron on Solidication Characteristics of 356 and 380-Type Aluminum Alloys
Al5 FeSi
Mg Si
Al Cu
Al FeMg Si
8
Mg2Si
Al5FeSi
Al8FeMg3Si6
Al8Fe2Si
851
(a)
(a)
0.8
0.6
0.4
1
0.2
0
0
0
0
0.2
0.4
0.6
0.8
0.2
0.4
Mg Si
Al FeMg Si
Al Cu
Solidification completes
Al Cu Mg Si
900
880
(b)
860
840
820
800
780
0
0.4
0.6
0.8
1.2
1.4
1.6
Mg2Si
Solidification completed
Al8Fe2Si
(b)
880
860
840
820
800
0
0.2
900
Aluminum FCC
Silicon
Al5FeSi
Al8FeMg3Si6
0.8
Fe Content, (mass%)
Cu Content, (mass%)
aluminum FCC
silicon
Al FeSi
0.6
1.2
1.2
0.5
1.5
Fe Content, (mass%)
Cu Content, (mass%)
Fig. 13 Eects of copper content on the solidication characteristics of
356-type alloy predicted from the Gulliver-Scheil model. (Fe 0.07%, Si
6.286%, Mg 0.403%, Mn 0.004%, Zn < 0:001%, Ti 0.130%, Cr 0.002%);
(a) The relationship between the amount of intermetallics and copper
content., (b) The relationship between the crystallization temperatures of
major phases and copper content.
Fig. 14 Eects of iron content on the solidication characteristics of 356type alloy predicted from the Gulliver-Scheil model. (Cu 0.17%, Si
6.286%, Mg 0.403%, Mn 0.004%, Zn < 0:001%, Ti 0.130%, Cr 0.002%);
(a) The relationship between the amount of intermetallics and iron
content., (b) The relationship between the crystallization temperatures of
major phases and iron content.
852
Al FeSi at Si 7.0%
Al FeMg Si at Si 7.0%
Al FeSi at Si 7.5%
Al FeMg Si at Si 7.5%
5
5
(a) 0.6
0.5
0.4
Acknowledgements
0.3
0.2
0.1
0
0
0.05
0.1
0.15
0.2
Fe Content, (mass%)
Al FeSi at Si 6.5%
Al FeSi at Si 7.0%
Al FeMg Si at Si 7.0%
5
5
0.6
REFERENCES
(b)
0.5
0.4
0.3
0.2
0.1
0
0
0.05
0.1
0.15
0.2
Fe Content, (mass%)
Fig. 15 The variation in amount of Al5 FeSi and Al8 FeMg3 Si6 phases with
iron and silicon content within A356 specication; (a) at magnesium
0.25 mass%, (b) at magnesium 0.45%.
4.
Conclusions