Understanding Segregation to Predict Solidification Solidification paths may be calculated from segregation equations, and may be used to pinpoint optimum alloy compositions for your castings. Seo ee aC Tis article isthe last in a serie on Al-Cu phase diagram. A number the outside of the arms, which ideation in aluminum castings of intermetallic compounds form corresponds to metal freezing later, Sn this system, Aluminum casting the copper content increases. An Wile the series focuses on solidifeat principles in alaminum all ned with the example of this type of measurement be applied to other metals ar wel aluminum-rich postion of the figure is shown in Fig. 3 and the formation of the @ (Al,Cu) Solidification scientists have whase. The relevant portion of the studied this phen s, many can ities are conc fhen a metal is lig uid, iis homoge- ure is showa in Fig.2 years and have offered models to neous. That is, fan alloy containing 4.5% explain inicrosegeegation. One can metal properties copper is poured and held near the now calculate the amount of non (especially com- eutectic temperature the casting will equilibrium eutectic according to a position) aze the same everywheze. be in the single phase field coree rode! proposed by Brody and Flem However, during freezing thece is sponding to solid aluniaum.This ings (B+F). The B-F equations may redistribution of alloying elements is indicated by the red box in Fig, __be used to calculate the composition and impurities called segregation. 2. According to the phate diagram, of liquid during solidification, and Segregation has a significant influ- hig allay should be a single phase the fraction of solid at which the ence on casting quality, Understand- sluminum with copper in solid eutectic forms. The B-F works well ng the pracess is useful for the solution the elements commonly found casting engineer or metallusgist. Looking at a sample from « n aluminum castings and for ll but 10 types of segregation casting of this alloy, it is found to extremely fast freezing cates. (The gregation Microsegegation isthe eutectic AL,Cu phase. This eutectic systems for most clements, Howevet, Small scale: between dendrites and the phase diagram. Soyit is called 2 lements that diffuse rapidly—for fe AI-Cu alloy system wil be ‘lvoit the distribution of copper ste! casings) used to illustrate ow segregation’ in a sample ofthe casting i studied occurs. Researchers ave examined by microprobe analysis ina SEM, Macrosegregation this alloy system in great detail by one inds thatthe copper content in Macrosegregation isthe redistei- retearchere. Tt forms the basis forthe aluminum phate varies. In the bation of elute elements ona larger the high strength family of dex cast- center of dendtite arms, which cor-—_scale-In net-shaped castings this galleys, responds tothe firs sold, the cop- caused by the motoa of uid inside Figure 1 shows the complete per content slow. Moving toward the caring and ually i elated to June 2014 MODERN CAST NG | 35[Atomic Percent Copper 0 n 0 8 9 on mm oy r Pop 100 +022 00 a0 Be ees zs 8 s ‘x 0 0 @ em mm Vieight Percent Copper feeding, Macrosegregation is most aleulating Solidification Paths easily seen in copper-containing Equations for microsegzegation loy systems. The alloys. As example is shown in Fig. during solidification ean be used starting point for our calculations 4.This X-ray shows a section of ato caleulate solidification paths for _is che aluminum rich corner of the cylinder head cast in 319 slloy.Two casting alloys AL-Si-Fe ternary. Eleven different ners are visible at the top. Both The easiest way to proceed is to intermetallic compounds have been show shrinkage cavities. Underneath assume the distribution coefficients identified in this system. Four of rich liquid has been “sucked eo presented in Pig. 5. They are: to” the casting, Risers are placed in the mold to fet + FeAI3, which is found in the ALFe binary and in alloys iquid to the low ia silicon, solidifying metal, whose 7% during solidification, When the risers are not sufficiently +a-FeSiAl, which has a com- position close to Fe2SiAls. *+B-FeSiAl, which is usually tion FeSiAIS. +8-FeSiAl, which has the composition FeSi2A13. "The compound which is of most concern here is the B phase. This is the in compound normally observed n AL-Si casting alloys, but in commercial castings is more difficult to see fais in casting X-rays. (The density difference between volume shrinks by arge, they will feed the east ng late in the solidific when the remaining liquid Composition vt % Cu) s enriched in copper (and other solute elements). Macrosegregation of etallic this sort also can develop ‘The calculated solidifies tion paths for an A309 alloy having 5% silicon and vari~ ous iron contents have been caleulated. (This alloy also hhas 1.2% copper and 0.596 aluminum and silicon is much smaller than between aluminum and cappes.) 36 | moDERN cat "ING June 2014eutectic according to this reaction Liquid > Al(solid) + Sitsolid) + 8 At lower solidification rates, owever, primary B should form. At higher iron contents (0.6%) pr & § : £ & z sy B forms before any AI-Si eurec~ tic, regardless of the freezing rate. This alloy was studied by the Center for Advanced Solidification Technologies (CAST) zesearchers in Australia. They found that casting defects were associated with iron contents that produced primary B Sie systomis shown. ules However, when they switched 0 a higher silicon version of the same alloy, the defects went awa} sagnesium, but this is ignored in is for a solidification time of 10 reason for this behavior may be ewlation,) To simplify pre~ seconds. The upper (biue curve) is seen by considering Fig. 7. Similar sentation of the results, only the for a longer freezing time of 1,000 calculations are made for the same phase houndaries are shown. Also a seconds. two iron contents. In this alloy the detailed section from Fig. 5 is taken From this result, it cam be seen gher iron content (0.6%) becomes ‘The result is shown in Fig. 6 for that 0.3% iron is a borderline case __ the borderline case. Therefore, 9% alloy iron contents of 0.3 and 0.6%. for this alloy. In rapidly solidified silicon alloy can tolerate twice the ‘Two segregation curves are given parts of a casting there should be iron content of the 5% silicon alloy. for each case. The lower (red) curve no primary B phase, only a ternary In exactly this manner, the CAST Synchro ERP foe ee tere eae Lotest Addinignal Gevelogment arta oe a Career -#f OS a Ae kg 3) Synchro ERP eS eetca) Te an Shop Floor APP E & Phase 1 complate = 4 Phase 2in development al synchroerp.com June 2014 MODERN CASTING | 37we Porcont ion searchers calculated solidifica- on paths for numerous silicon contents. Tn this way they derived a map of safe iron con: casting (Fig. 8). nts for The results of related research, conducted by Caceres and co- workers, should also be consid. ered. They produced castings in a number of alloy compositions and measured mechanical properties shown in Fig, 9, which illustrates the impor segregation, and how higher silicon contents may be used to advantage n AI-Si based alloy castings The tensile strengths for cast- ngs heat treated to the T6 tem per are shown on a (Ultimate Tensile plot [UTS] wt Percent on versus he log of elongation) The red lines shaw constani ues of quality index (in MPa). blue arrows indicate the change in alloy composition, For example, iron was added to alloy 1 to obtain alloy 2. The result was a significant loss in casting quality—shout 120 MPa according to the quality index. Silicon was added to alloy 2 t0 obtain alloy 3. Nearly all of the lost quality was regained by increasing the silicon content from 4.5 to 9% A similar result was found going om alloys 19 6 > 7, except in + case copper was added along swith the iron, The loss in quality with the combined addition of iron and copper was larger—about 200, ‘Mpa—but that loss was regained by 7 8 9 0 nN m4 Weight Percent Silicon By contrast, when copper was added by itself, in the alloys 1 > 4.9 5,only a small loss of quality was found in alloy 4. This article was based om Paper 15-1224, whicd was presented at the 117th Metalcasting Congres. @ ONLINE RESOURCE The B-F equations and data used to caleu late soliifcation paths have been paced into Excl programs. You may download afew ofthese calculations by going to www.moderncasting.com. The Excal programs maka it 2a3y to do your ‘own caleuations 11 Content (we) ne 38 | MODERN cat Sn "ING June 2014 urs (mPa) BB se es eee = cect Sree ee ena) eee ne cer Ur aCe eer) Poe ae ey LEE Pear roe ee