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Casting of Aluminium Dr.

Victor Risonarta

Casting of Aluminium
Casting of Aluminium Dr. Victor Risonarta

More than 100 compositions are registered with the Aluminum Association, and more
than 300 alloys are in international use.
Casting of Aluminium Dr. Victor Risonarta

Introduction The Ellingham Diagram


Casting of Aluminium Dr. Victor Risonarta

How to use The Ellingham Diagram


1. Element having more negative change of Gibbs energy, has higher possibility to be
oxidized with oxygen.
E.g. When Al, Fe, and Cu present together and oxygen is uniformly distributed, Al will
be oxidized first than Fe and Cu.

2. Element having more negative Gibbs energy can de-oxidize oxides having less
negative Gibbs energy.
E.g. Al can de-oxidize Cr2O3

Reduction: Endothermic reaction


Need heat
Oxidation: Exothermic reaction
Release heat

According the Ellingham Diagram, Aluminium casting should be carefully done since
it is difficult to remove unwanted elements from liquid Aluminium
Casting of Aluminium - Advantages of Al casting Dr. Victor Risonarta

Advantages:
An ability to produce near-net-shape parts with dimensional
accuracy, controlled surface finish, complex geometries including
internal passages, and properties consistent with specified
engineering requirements
Aluminum products are typically lighter and free of corrosion
In many cases, multi components welded or joined assemblies can
be replaced with a single cast part
Machining requirements are reduced.
Aluminum castings display controlled variations in as-cast finish.
Contrasts between as-cast and machined finishes can be highlighted
to create pleasing cosmetic effects.
Capital requirements are typically less than for wrought products.
Many aluminum casting alloys display excellent fluidity for casting
thin sections and fine detail.
Aluminum casting alloys melt at relatively low temperatures.
Casting of Aluminium - Primary and secondary material Dr. Victor Risonarta

While the production of aluminum is energy-intensive, it can be efficiently recovered


from scrap at 5% of the energy required for reduction. The cost of ingot produced from
scrap is typically less than that of primary metal. Therefore, most aluminum alloy castings
are produced from recycled metal.

Virtually all aluminum forms classified as old scrap (end of cycle) and new scrap (turnings,
borings, gates and risers, rejections) are recyclable.With appropriate recycling processes,
recoveries typically exceed 90%.
Casting of Aluminium - Castability Dr. Victor Risonarta
Hardening and desired properties are achieved through the addition of alloying
elements and through heat treatment. Since work hardening plays no significant role
in the development of casting properties, the use and purposes of some alloying
elements differ in casting and wrought alloys.

3 types of alloying elements in Al casting:


Major alloying elements define the ranges of elements that control castability and
property development.
Minor alloying elements control solidification behavior, modify eutectic structure,
refine primary phases, refine grain size and form, promote or suppress phase
formation, and reduce oxidation.
Impurity elements influence castability and the form of insoluble phases that at
times limit or promote desired properties.
For maximum strength is due to:
the concentration of elements that form hardening phases can be maximized.

Improved ductility is due to:


from finer structures
restricting insoluble-element concentrations, and
by controlling the concentrations of impurities in ratios that favor the formation of
the least detrimental intermetallic constituents.
Casting of Aluminium - Alloys elements Dr. Victor Risonarta

Eutectic microstructure:
Higher solidification rates promote a finer unmodified eutectic microstructure.
Calcium is a weak eutectic modifier
a more lamellar eutectic can be achieved with antimony.
Casting of Aluminium - Alloys elements Dr. Victor Risonarta

Role of alloys element


Copper:
Improves strength and hardness in the as cast and heat treated conditions.
Aluminum-silicon-copper alloys with less than 5.6% Cu are heat treatable
Copper reduces hot tear resistance and increases the potential for interdendritic
shrinkage.

Silicon:
improves castability
reduces hot shortness.
Alloys containing higher hypoeutectic concentrations of silicon are normally better
suited for more complex castings and for permanent mold and die casting processes.
Aluminum-silicon alloys exhibit low specific gravity and coefficients of thermal
expansion.
The strength, ductility, and castability of hypoeutectic aluminum-silicon alloys can
be further improved by modification of the aluminum-silicon eutectic.
Casting of Aluminium - Alloys elements Dr. Victor Risonarta
Magnesium:
Increase the corrosion resistance
Retain low level of thermal expansion

Tin:
Tin is the major alloying element in compositions developed for bearing applications.
It has also been employed with bismuth, lead, and cadmium at lower concentrations
to provide free-machining properties.

Antimony:
At concentration levels equal to or greater than 0.10%, antimony refines the
aluminum-silicon eutectic.
The effectiveness of antimony in altering the eutectic structure depends on an
absence of phosphorus and on an adequately rapid rate of solidification.
Antimony also reacts with either sodium or strontium to form coarse intermetallics
with adverse effects on castability and metallurgical structure.

Beryllium:
Improve strength and ductility by affecting the morphology and chemistry of the
iron-containing intermetallic.
Additions of a few ppm beryllium reduces oxidation losses and associated inclusions
in magnesium-containing compositions.
Casting of Aluminium - Alloys elements Dr. Victor Risonarta

Bismuth:
improve the machinability of cast aluminum alloys at concentrations greater than
0.1%.

Boron
Titanium boride forms stable nucleation sites that interact with active grain-
refining phases such as TiAl3 for grain refinement.
Rotor alloys may specify boron to exceed titanium and vanadium contents to
ensure either the complexing or precipitation of these elements for improved
electrical performance.
Borides also contribute to sludging, the precipitation of intermetallics from liquid
solution in furnaces and troughing.

Cadmium
In concentrations exceeding 0.1%, cadmium improves machinability.

Chromium
Improve strength and ductility by affecting the morphology and chemistry of the iron-
containing intermetallic.
Casting of Aluminium - Al-Alloy cast product Dr. Victor Risonarta
Iron:
Substantially decreases ductility.

Lead
At concentrations greater than 0.1% to improve machinability.

Tin
Improving antifriction characteristics and is therefore useful in bearing applications

Nickel
Used with copper to enhance elevated temperature properties.
Reduces coefficient of thermal expansion.
Casting of Aluminium - Al-Alloy cast product Dr. Victor Risonarta
Characteristic of Al-Si casting:
Binary aluminum-silicon alloys exhibit excellent fluidity, castability, and corrosion
resistance.
Display low strength and poor machinability.
The strength, ductility, and castability of hypoeutectic aluminum-silicon alloys can be
further improved by modification of the aluminum-silicon eutectic which can be
achieved through the controlled addition of sodium and/or strontium.

Characteristic of Al-Mg casting:


Aluminum-magnesium alloys offer excellent weldability
often used in architectural and other decorative applications.
Have good machinability, weldability, and an attractive appearance
Aluminum magnesium alloys require more care in gating, larger risers, and greater
control of temperature gradients.

Characteristic of Al-Sn casting:


Aluminum and tin are essentially immiscible. Before and after solidification, tin is
present in dispersed form.
Mechanical agitation is required initially to achieve suspension of tin, and, because
of density differences, gravity segregation may occur over time in the molten state.
Aluminum-tin alloys containing copper are conventionally precipitation hardened
and may be fully heat treated.
Dr. Victor Risonarta

Microstructure
and
Mechanical Properties
Casting of Aluminium - Microstructure Dr. Victor Risonarta
The microstructural features, that most strongly affect mechanical properties are:
Size, form, and distribution of intermetallic phases
Dendrites
Grain size and shape
Eutectic modification and primary phase refinement
Defect
Casting of Aluminium - Microstructure Dr. Victor Risonarta
Intermetallic Phases
How intermetallic phase influence mechanical properties?
Solidification rate and the rate of post solidification cooling promote uniform size and
distribution of intermetallics and influence their morphology.
Slower rates of solidification result in coarse intermetallics and second-phase
concentrations at grain boundaries.
Phase formation is diffusion controlled so that more rapid solidification and more
rapid cooling to room temperature from solidification temperature results in greater
degrees of retained solid solution and finer dispersions of smaller constituent
particles.

The size, volume and morphology of intermetallic phases are functions of


chemistry,
solidification conditions and
heat treatment
Casting of Aluminium - Intermetallic Phase Dr. Victor Risonarta

Case study: Al5FeSi intermetallic phase

The first phase (Al5FeSi) precipitates in the interdendritic and intergranular regions as
platelets (appearing as needles in the metallographic microscope Right Figure).
Long and brittle Al5FeSi platelets (more than 500 m) can adversely affect mechanical
properties, especially ductility, and also lead to the formation of excessive shrinkage
porosity defects in castings
Casting of Aluminium - Intermetallic Phase Dr. Victor Risonarta

Case study: Al5FeSi intermetallic phase


The deleterious effect of Al5FeSi can be reduced by:
increasing the cooling rate,
superheating the molten metal, or
the addition of a suitable neutralizer like Mn, Co, Cr, Ni, V, Mo and Be. The
most common addition has been manganese.
Excess Mn may reduce Al5FeSi phase and promote formation Fe-rich phases
Al15(FeMn)3Si2 in form skeleton like

Advantage of this compact morphology Chinese


script (or skeleton - like):
does not initiate cracks in the cast material
to the same extent as Al5FeSi does and
phase Al15(FeMn)3Si2 is considered less
harmful to the mechanical properties than
phase
Casting of Aluminium - Alloys elements Dr. Victor Risonarta
Grain refinement of aluminum provides a number of technical and economic
advantages:
reduced ingot cracking

better ingot homogeneity

better mechanical deformation characteristics and

improved mechanical properties

Grain refining elements, titanium and boron, were originally introduced into molten
metal as refractory titanium alloy and a corrosive complex potassium metal fluoride
salts.

99.9% aluminum grain refined with 0.008%


99.9% aluminum ungrainrefined. The Titanium added as 5%Ti-1%B-Al The nominal
nominal grain size is 4500. grain size is 120.
Casting of Aluminium - Microstructure Dr. Victor Risonarta
Grain Refinement

Several characteristics:
Increased solidification rate reduces grain size
To be effective, grain refiners must introduce controlled, predictable, and operative
quantities of aluminides and borides or carbides in the correct form, size, and
distribution for grain nucleation.
Refiners in rod formare available in sheared lengths for foundry use.

99.9% aluminum grain refined with 0.008%


99.9% aluminum ungrainrefined. The Titanium added as 5%Ti-1%B-Al The nominal
nominal grain size is 4500. grain size is 120.
Casting of Aluminium - Eutectic Modification Dr. Victor Risonarta

The silicon content in most aluminum castings is in the range of 5 to 12%. When
melts of these alloys are not modified, coarse platelet crystals of the aluminum
silicon eutectic phase form in the casting during solidification . These particles are
brittle and tend to reduce the strength and ductility of the casting (Left Picture).

Modification of the silicon phase produces a silicon phase that is fibrous and finely
dispersed. Ductility of castings improves markedly and tendency for cracking / brittle
fracture is less (Right Picture).

Si in 0.018 %
Sr modified
eutectic
Si in
unmodified
eutectic
Casting of Aluminium - Eutectic Modification Dr. Victor Risonarta
Agent for eutectic modification:
1. Sodium
Sodium is a very reactive metal. It can react when exposed to air and can burn
violently during addition to molten aluminum silicon alloy. Therefore, close control of
the addition level is difficult.
2. Antimony
Antimony is toxic and not recommended.
3. Strontium
could be used in place of sodium.
Casting of Aluminium - Microstructure Dr. Victor Risonarta

Aluminum-Silicon Eutectic Modification


Characteristics:
A finer, more fibrous eutectic structure can be obtained by increased solidification rate
and by the addition of chemical modifiers.
Calcium, sodium, strontium, and antimony are known to influence the degree of
eutectic modification that can be achieved during solidification.
Improved casting results include improved feeding and superior resistance to elevated-
temperature cracking.
Casting of Aluminium - Microstructure Dr. Victor Risonarta
Dendrite
There are at least three measurements used to describe dendrite refinement see
picture below :
Dendrite arm spacing (d): The distance between developed secondary dendrite arms
Dendrite cell interval: The distance between centerlines of adjacent dendrite cells
Dendrite cell size: The width of individual dendrite cells

Influence of dendrites on microstucture and mechanical properties


The larger the dendrite arm spacing, the coarser the micro-constituents and the
more pronounced their effects on properties.
Finer dendrite arm spacing is desirable for improved mechanical property
performance
Casting of Aluminium - Microstructure Dr. Victor Risonarta
Dendrite Arm Spacing
Characteristics:
The larger the dendrite arm spacing, the coarser the microconstituents and the more
pronounced their effects on properties.
Finer dendrite arm spacing is desirable for improved mechanical property
performance
Casting of Aluminium - Microstructure Dr. Victor Risonarta
Dr. Victor Risonarta

Build Up of Inclusion in
Aluminium Casting
Casting of Aluminium - Alloy selements Dr. Victor Risonarta

3 types of alloying elements in Al casting:


Major alloying elements define the ranges of elements that control castability and
property development.
Minor alloying elements control solidification behavior, modify eutectic structure,
refine primary phases, refine grain size and form, promote or suppress phase
formation, and reduce oxidation.
Impurity elements influence castability and the form of insoluble phases that at
times limit or promote desired properties.
Casting of Aluminium - Gas solubility in Al alloys Dr. Victor Risonarta
Casting of Aluminium - Gas solubility in Al alloys Dr. Victor Risonarta
Casting of Aluminium - Oxides formation in Al alloys Dr. Victor Risonarta
Dr. Victor Risonarta

Heat Treatment
of
Aluminium Alloys
Heat treatment of aluminium alloys

Heat treatment of aluminium alloys can be done to decrease the grain size so that the
mechanical properties of casted aluminium can increase.

The general types of heat treatments applied to aluminum and its alloys are:
Preheating or homogenizing, to reduce chemical segregation of cast structures and to

improve their workability


Annealing, to soften strain-hardened (work-hardened) and heat treated alloy structures, to

relieve stresses, and to stabilize properties and dimensions


Solution heat treatments, to effect solid solution of alloying constituents and improve

mechanical properties
Precipitation heat treatments, to provide hardening by precipitation of constituents from

solid solution.
Basic Aluminum Heat Treatment Designations

F As Fabricated - No special control has been performed to the heat treatment or strain
hardening after the shaping process such as casting, hot working, or cold working.
O Annealed - This is the lowest strength, highest ductility temper
H Strain Hardened - (applied to wrought products only) Used for products that have been
strengthened by strain hardening, with or without subsequent heat treatment. The
designation is followed by two or more numbers as discussed below.
W Solution Heat Treated - This is seldom encountered because it is an unstable temper that
applies only to alloys that spontaneously age at ambient temperature after heat treatment.
T Solution Heat Treated - Used for products that have been strengthened by heat treatment,
with or without subsequent strain hardening.
The designation is followed by one or more numbers as discussed below.
Heat Treating T Temper Codes

T1 - Cooled from an elevated temperature shaping process and naturally aged to a substantially
stable condition.
T2 - Cooled from an elevated temperature shaping process, cold worked, and naturally aged to a
substantially stable condition.
T3 - Solution heat treated, cold worked, and naturally aged to a substantially stable condition.
T4 - Solution heat treated, and naturally aged to a substantially stable condition.
T5 - Cooled from an elevated temperature shaping process then artificially aged.
T6 - Solution heat treated then artificially aged.
T7 - Solution heat treated then overaged/stabilized.
T8 - Solution heat treated, cold worked, then artificially aged.
T9 - Solution heat treated, artificially aged, then cold worked.
T10 - Cooled from an elevated temperature shaping process, cold worked, then artificially aged.
H Temper Strain Hardening Codes

H1 - Strain hardened only


H2 - Strain hardened and partially annealed
H3 - Strain hardened and stabilized
H4 - Strain hardened and lacquered or painted. This assumes that thermal affects from the
coating process affect the strain hardening; seldom encountered.

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