Effects of Mg Enhancement and Heat Treatment on Microstructures and Tensile Properties of Al2Ca-Added ADC12 Die Casting Alloys

doi:10.1016/j.jmst.2016.07.015

Abstract

Abstract:

The effects of Mg enhancement and heat treatment on the microstructures and tensile properties of Al₂Ca-added ADC12 die casting alloys were investigated. 0.3% and 0.5% Mg in the form of a master alloy including a trace amount of Al₂Ca were added to conventional ADC12 (383 and AlSi10Cu2Fe) alloy with an initial Mg-content of 0.3% to increase the Mg content to 0.6% and 0.8%, respectively. To avoid heat treatment-induced surface blisters, shortened solution treatment for 15 min at 490 °C and artificial aging for 6 h at 150 °C was undertaken. The results show that a 10% improvement in the shape factor of eutectic Si particles was achieved for Al₂Ca-added ADC12 with 0.8% Mg compared to the conventional ADC12 in the as-aged condition. Al₂Ca-added ADC12 with 0.8% Mg exhibited a yield strength of 289 MPa, a tensile strength of 407 MPa, and an elongation of 4.22%.

Key words: Al2Ca, ADC12 alloy, Heat treatment, Die casting, Inclusion

Yeom ?Gil-Yong,Kyu Lim Hyun,K. Kim Shae,Hyun Soong-Keun,Yoon Young-Ok. Effects of Mg Enhancement and Heat Treatment on Microstructures and Tensile Properties of Al₂Ca-Added ADC12 Die Casting Alloys[J]. J. Mater. Sci. Technol., 2016, 32(10): 1043-1048.

Figures/Tables 12

Table 1 Chemical composition of the examined alloys (wt%)a

Alloy	Si	Fe	Cu	Mn	Mg	Zn	Ni	Ca
ADC12	11.8	0.93	2.04	0.23	0.24	0.99	0.07
Al₂Ca-added ADC12 with 0.6%Mg	11.49	0.90	2.13	0.24	0.60	0.94	0.09	0.0078
Al₂Ca-added ADC12 with 0.8%Mg	11.80	0.87	1.90	0.22	0.79	0.95	0.08	0.0092

Table 2 Casting and HPDC machine parameters

Classification	Condition
Casting temperature	690 °C
Fixed die temperature	232 °C
Moving die temperature	238 °C
Casting pressure	560 kgf
Plunger diameter	Φ130
Low speed injection	0.2-0.5 m/s
High speed injection	3.2 m/s
Ingate velocity	39.7 m/s
Cooling channel	Oil

Fig. 1. Schematic illustration of front shock tower similar to that used in this study (image of Audi front shock tower).

Fig. 2. Optical and IPF micrograph maps showing the as-cast microstructure of the ADC12 alloys with different amounts of Mg and added Al2Ca as well as the morphology of eutectic silicon in (a) ADC12 with 0.3% Mg, (b) Al2Ca-added ADC12 with 0.6% Mg and (c) Al2Ca-added ADC12 with 0.8% Mg.

Fig. 3. SEM micrographs of eutectic Si morphologies after artificial aging of the (a) ADC12 with 0.3% Mg, (b) Al2Ca-added ADC12 with 0.6% Mg, and (c) Al2Ca-added ADC12 with 0.8% Mg alloys.

Fig. 4. Micrographs of deeply etched specimens showing the eutectic Si morphologies of the as-cast and artificially aged (a) ADC12 with 0.3% Mg, (b) Al2Ca-added ADC12 with 0.6% Mg, and (c) Al2Ca-added ADC12 with 0.8% Mg alloys.

Fig. 5. Shape factor of the eutectic Si particles in the as-cast, solution-treated and artificially aged alloys.

Table 3 Shape factor values for the eutectic Si particles in the solution-treated and artificially aged alloys in Fig. 5

Alloy	As cast	T4	T6-1 h	T6-3 h	T6-6 h
ADC12 with 0.3% Mg	4.18	2.12	2.17	2.22	2.31
Al₂Ca-added ADC12 with 0.6% Mg	3.91	2.03	2.11	2.12	2.19
Al₂Ca-added ADC12 with 0.8% Mg	3.89	2.01	2.01	2.06	2.11

Fig. 6. Variations in the (a) yield strength, (b) tensile strength, and (c) elongation of the alloys after solution treatment and artificial aging.

Fig. 7. Dependence of quality index on aging time for the three alloys.

Fig. 8. Prefil? test results of total inclusions of ADC12 and the Al2Ca-added ADC12 with 0.8% Mg alloy.

Fig. 9. Photomicrographs of the Prefil? test samples from melt showing inclusions at the interface.

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Effects of Mg Enhancement and Heat Treatment on Microstructures and Tensile Properties of Al₂Ca-Added ADC12 Die Casting Alloys

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