Introduction to DURALCAN (TM) MMC Foundry Alloys

DURALCAN™ Aluminum Metal Matrix Composites for Shape Casting

The F3S. series of composites has been developed for use in investment, shell, sand,
semi-permanent mold and permanent mold foundries. The Aluminum Association alloy
A359.1 is the closest alloy to the aluminum used for the matrix alloy. The F3N. series of
composites is specifically for the high-pressure die-casting process and the AA pressure
die-casting alloy A360.1 has the closest composition to the matrix alloy used. Table 4
gives the composition of the two matrix alloys.

Table 4. Chemical Composition of

DURALCAN™ F3S and F3N Shape Casting Composites

Element F3S.xxS F3N.xxS

Si% 8.50 – 9.50 9.50 – 10.50
Fe% <0.20 0.80 – 1.20
Cu% <0.20 <0.20
Mn% -- 0.50 – 0.80
Mg% 0.45 – 0.65 0.50 – 0.70
Ti% <0.20 <0.20
Al% Remainder Remainder

DURALCAN™ MMCs are manufactured through a molten metal route, which ensures
that the size controlled ceramic particulate powder is prevented from agglomerating and
that each particle is thoroughly wetted by the molten aluminum matrix alloy and
uniformly distributed throughout the melt. The molten material is cast into open moulds
providing easy-to-handle remelt ingot.

Casting Processes for DURALCAN Foundry MMCs

The F3S.20S MMC has been successfully cast with investment casting, shell molding,
sand, semi-permanent mold, tilt-pouring and permanent mold processes. The F3N.20S,
developed for high-pressure die-castings, is currently in use for the production of
automotive brake drums among other items, using both vertical and horizontal die-
casting machines.

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Introduction to DURALCAN (TM) MMC Foundry Alloys 2

Melting and Stirring Procedures

The melting procedures for the composite alloys are similar to those for aluminum alloys
with some special attention given to avoid particulate settling and air entrapment. The
remelt ingot is provided with a good even distribution of the ceramic particulate. This
distribution must be held in suspension in the melt to provide a homogeneous
microstructure in the casting, as shown in Figure 5.

Figure 5. DURALCAN™ F3S.20S – typical permanent mold cast structure.

In the microstructure shown above the white material is the

aluminum rich phase, growing in dendritic form. Between the
dendrites is the light gray aluminum-silicon eutectic. The
angular dark gray-black constituents are the silicon-carbide
particles that make up the composite. The silicon-carbide
particles appear to be random in size and shape due to the
cross sectioning of the sample. The SiC is, in actuality,
regular in both size and shape.

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Introduction to DURALCAN (TM) MMC Foundry Alloys 3

During the melting process, the silicon carbide particulate, having a higher density than
the molten aluminum, will want to settle to the bottom of the melt. The rate of settling in
a stagnant molten bath is approximately 1 mm/min. The particulate settling is also
observed in very slowly solidified castings, as shown in Figure 6, and this can be
overcome through the use of chills to increase the rate of solidification

Figure 6. Denuded zone formed in a slowly solidified sand casting

To maintain the particulate as a uniform distribution in a melt, only minimal agitation is

required. Some settling of particulate is unavoidable during the melting process and
fortunately it is relatively easy to restore and maintain the particulate to a uniform
distribution in the melt.

In batch preparation* the settled particulate is best recovered with manual use of a
paddle type stirrer to lift the particulate from the bottom. Once lifted, the particulate is
then maintained in a uniform suspension with the use of a mechanical, automatic stirrer.

In continuous melting operations the judicious use of mechanical stirrers or pumps

easily maintains the uniform distribution of the particulate, as indicated in the ‘Preferred
Melting and Recycling Practices’ section.

* Advantage may be taken of this settling phenomenon by taking surface samples

of the ‘settled’ melt for spectrographic (chemical) analysis of the matrix alloy. This is
done, before the melt is stirred. A clean, preheated ladle is drawn across the skimmed
surface of the melt, with its lip 25 mm (1 in.) below the surface of the melt. The analytical
sample is poured from this ‘surface’ sample.

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Introduction to DURALCAN (TM) MMC Foundry Alloys 4

Melt Cleaning and Degassing

Prevention is better than cure and this is more important with the MMC materials than
with the ordinary aluminum alloys. The cleaning and degassing of composite melts can
be carried out to a limited degree but such practices easily lead to problems that most
often outweigh the dubious benefits.

Good housekeeping practices that ensure that furnace hearths, crucibles, charges and
tools are clean and dry will do much to reduce hydrogen gas content of the melt and will
also ensure that the melt will be as clean as possible.

The nature of the composite material enables it to tolerate the remaining hydrogen gas
porosity in castings better than the ‘regular’ alloy. The particulate ‘seeds’ the hydrogen
gas coming out of solution, ensuring fine and well distributed gas porosity that has a
negligible effect on the quality of the castings, Figure 7.

The use of filters in the runner systems of castings effectively removes or reduces the
inclusions and ceramic foam filters of 10 or 15 pores per inch (ppi) are used without
removing the particulate content.

Salt or gaseous cleaning fluxes that are commonly used for aluminum melts for the
purpose of cleaning or degassing must not be used with composite materials. Such
practices result in the removal of the particulate from the aluminum in a process called
‘dewetting’. In a similar manner the use of contaminated crucibles or contaminated
foundry tools or furnace charges, which may introduce chlorides or fluorides must also
be avoided. No amount of stirring will reverse this condition and the ‘free’ silicon carbide
particles will remain on the surface, disassociated from the melt and become part of the
dross.

Matrix only Composite Matrix only Composite

Microfocal radiographs of castings produced at low Microfocal radiographs of castings produced at high
hydrogen levels (0.07 ppm). hydrogen levels (0.27 ppm).

Figure 7. The influence of gas content on the integrity of a casting with and without
particulate content.

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Introduction to DURALCAN (TM) MMC Foundry Alloys 5

Entrapped Air

An unfortunate feature of molten composite materials is the interaction with many gases
to form particle-stabilized foam. Although the details of the physical process are not
fully understood, we do know that very high energy is required to wet and fully disperse
the finely divided ceramic particles in a liquid of high surface energy such as aluminum.
Air, moisture or materials containing hydrocarbons will partially de-wet the particulate if
introduced into the melts. The gas-liquid interface becomes ‘decorated’ with particles.
The gas bubbles, which are significantly lighter and try to rise through the molten
composite, are coated with the silicon carbide, which is heavier than the molten
composite. As a result, the bubbles are stabilized and remain suspended in the
composite eventually leading to porosity, as shown in Figure 8.

Considerable care must be taken with the cleaning and drying of crucibles, all tools
coming into contact with the composite melts and the furnace charges.

Air entrapment may be caused by turbulence in the liquid during stirring, transfer,
pouring and even as it enters the mold cavity. These sources of turbulence that could
lead to air entrapment should be recognized and such situations designed out of the
practice.

Figure 8. Air bubble in an MMC, stabilized by the SiC particles

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Introduction to DURALCAN (TM) MMC Foundry Alloys 6

Melt Temperature Control

Temperature control of Al-SiC DURALCAN™ MMC melts is essential to prevent

reaction between the SiC and the aluminum causing the creation of aluminum carbides.
This reaction is time, temperature and silicon content dependent. The DURALCAN™
series of Foundry Composites have been designed with a relatively high silicon level to
ensure good foundry fluidity and resistance to the formation of aluminum carbide. As a
result the foundryman is able to treat the composite material as he would treat any
quality aluminum alloy melt.

The presence of aluminum carbide destroys the fluidity of the composite melt and
promote subsequent corrosion in the castings. Figure 9. indicates the safe temperature
for handling SiC composites with varying silicon levels in the matrix alloy.

Figure 9. Stability of Silicon Carbide vs Silicon Content and Melt Temperature

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Introduction to DURALCAN (TM) MMC Foundry Alloys 7

Recycling Scrap Castings and Returns

Some considerations must be made in order to achieve the economical recycling of SiC
MMCs. Dirty castings will result in a dirty melt. The composite melt cleaning operation
is time consuming and results in some depletion of the particulate content.

The addition of returns to the melt or dry melting must be carefully managed. Air
entrapment, caused by poorly stacked castings, will result in stabilized air bubbles in the
melt and these can be carried over to the castings.

Temperature control is essential to avoid the formation of aluminum carbide.

The normal melting practice recommended for DURALCAN™ MMCs is adequate to

produce high levels of composite reclamation. It is recommend that no more than 1/3 of
the charge is in the form of returns; this is a standard procedure in the industry for the
production of quality aluminum castings. With composite reclamation, this can be done
with a melt loss in the order of 2%. Vented rotors cast into a semi-permanent mould in
one foundry have provided excellent quality automobile brake rotors with 50% returns
and a measured melt loss of less than 3%. The same foundry claims to have made
acceptable castings with 100% recovered composite using the recommended melting
and handling practices.

Machining chips have a relatively high surface area and are usually contaminated with
the cutting fluids used during machining, this makes the machining swarf difficult to
reclaim as a composite. High Pressure Die Casting ‘biscuits’ that are usually high in
lubricant content should also be avoided. However, the silicon carbide can be dewetted
and removed, reducing the machining chips and ‘biscuits’ to the useful matrix alloy.

Economics of the Composite Castings

The aluminum composite material is more expensive than the comparable aluminum
alloy, due in part to the cost of the specialized ceramic powder and the energy intensive
processing necessary to provide complete wetting and distribution of the particulate in
the metal. The casting process costs are the same as would be incurred with the
production of high quality aluminum cast parts. The scrap castings and gates and risers
can be recycled, whereas the machining chips can only be recycled as aluminum.
Careful gating design to minimize returns without sacrificing casting quality leads to
better economics, as they would in most aluminum foundries. There is an advantage
with the high-pressure die-casting process in providing castings with higher tolerances
and cast-in holes requiring less machining to produce the finished part.

The composite material is abrasive to machining tools and requires the use of high
quality re-usable diamond tooling that provides excellent tolerances and finishes at
acceptable costs. Rigid machining equipment and choice of suitable feeds, speeds and
depths of cut allows the machining of composite castings to be done competitively.

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