Abstract
The effects of the squeeze casting process on the microstructure, mechanical properties and wear characteristics of hypereutectic Al–Si–Cu–Mg alloys have been investigated by optical, scanning and transmission electron microscopy and mechanical property test; the wear behaviour was investigated using a pin-on-disc configuration; alloy ingots were prepared by gravity casting, liquid squeeze casting and semisolid squeeze casting. The results show that the Si phase was refined and the α-Al dendrites transformed to rosette grains after semisolid squeeze casting. The peak intensity of the second phase decreased after extrusion, indicating that extrusion promotes the dissolution of solute elements into the matrix. Among the three casting processes, the alloys formed by semisolid squeeze casting had the best mechanical properties. Tensile strength, elongation and Brinell hardness reached 187.67 MPa, 2.33% and 142.5 HB, respectively. After semisolid squeeze casting, the morphology of the wear surface was flat and the number of spalling pits and furrows is less. Meanwhile, the friction coefficient and wear loss of the alloy sample are minima. Due to the uniform distribution of Si phases and equiaxed crystallization of α-Al phase in semisolid squeeze casting Al–Si–Cu–Mg alloys, the wear resistance is markedly enhanced.
Similar content being viewed by others
References
V.A. Aranda, I.A. Figueroa, G. Gonzalez et al., Study of the microstructure and mechanical properties ofAl-Si-Fe with additions of chromium by suction casting. J. Alloy. Compd. 853, 1–9 (2021). https://doi.org/10.1016/j.jallcom.2020.157155
A.K. Dahle, K. Nogita, S.D. Mcdonald et al., Eutectic modification and microstructure development in Al-Si alloys. Mater. Sci. Eng. A. 413–414, 243–248 (2005). https://doi.org/10.1016/j.msea.2005.09.055
Y. Nemri, B. Gueddouar, M.E.A. Benamar et al., Effect of Mg and Zn contents on the microstructures and mechanical properties of Al-Si-Cu-Mg alloys. Int. Met. 12, 20–27 (2018). https://doi.org/10.1007/s40962-017-0134-y
M. Qi, Y. Kang, Q. Qiu et al., Microstructures, mechanical properties, and corrosion behavior of novel high-thermal-conductivity hypoeutectic Al-Si alloys prepared by rheological high-pressure die-casting. J. Alloy. Compd. 749, 487–502 (2018). https://doi.org/10.1016/j.jallcom.2018.03.178
J. Hernandez-Sandoval, A.M. Samuel, F.H. Samuel et al., Effect of additions of SiC and Al2O3 particulates on the microstructure and tensile properties of Al-Si-Cu-Mg cast alloys. Int. Met. 10, 253–263 (2016)
S.S. Wu, G. Zhong, P. An et al., Microstructural characteristics of Al-20Si-2Cu-0.4Mg-1Ni alloy formed by rheo-squeeze casting after ultrasonic vibration treatment. Trans. Nonferrous. Met. 12, 2863–2870 (2012). https://doi.org/10.1016/S1003-6326(11)61543-4
H. Liu, L. Li, J. Niu et al., Effect of Mg and Cu additions on microstructure and mechanical properties of squeeze casting Al-Si-Cu-Mg alloy. Mater. Sci. Forum. 850, 511–518 (2016). https://doi.org/10.4028/www.scientific.net/MSF.850.511
Y.L. Liu, C.J. Wu, H. Tu et al., Microstructure and mechanical properties of Al-10Si alloy modified with Al-5Ti. China. Foundry. 15, 405–410 (2018)
M. Shafizadeh, H. Aashuri, S. Nikzad et al., Mechanical properties of Al-30Si-5Fe alloy using combination of rapid solidification and thixocasting processes. Metallogr Microstruct Anal 6, 502–511 (2017). https://doi.org/10.1007/s13632-017-0388-z
H.M. Lus, Effect of casting parameters on the microstructure and mechanical properties of squeeze cast A380 aluminum die cast alloy. Metal. Mater. 4, 270–277 (2012). https://doi.org/10.4149/km_2012_4_243
A. Maleki, A. Shafyei, B. Niroumand, Effects of squeeze casting parameters on the microstructure of LM13 alloy. J. Mater. Process. Tech. 8, 3790–3797 (2009). https://doi.org/10.1016/j.jmatprotec.2008.08.035
C. Lin, S. Wu, S. Lue et al., Effects of high pressure rheo-squeeze casting on Fe-containing intermetallic compounds and mechanical properties of Al-17Si-2Fe-(0, 0.8) V alloys. Mater. Sci. Eng. A. 713, 105–111 (2017). https://doi.org/10.1016/j.msea.2017.12.050
D. Vanluu, D.Z. Sheng, J.L. Wen, Effect of process parameters on microstructure and mechanical properties in AlSi9Mg connecting-rod fabricated by semi-solid squeeze casting. Mater. Sci. Eng. A. 558, 95–102 (2012). https://doi.org/10.1016/j.msea.2012.07.084
A. Hekmat-Ardakan, X. Liu, F. Ajersch et al., Wear behaviour of hypereutectic Al-Si-Cu-Mg casting alloys with variable Mg contents. Wear 9, 684–692 (2010). https://doi.org/10.1016/j.wear.2010.07.007
L. Lasa, J.M. Rodriguez-Ibabe, Wear behaviour of eutectic and hypereutectic Al-Si-Cu-Mg casting alloys tested against a composite brake pad. Mater. Sci. Eng. A. 1–2, 193–202 (2003). https://doi.org/10.1016/S0921-5093(03)00633-6
K. Pratheesh, A. Kanjirathinkal, M.A. Joseph et al., Study on the effects of squeeze pressure on mechanical properties and wear characteristics of near-eutecticAl-Si-Cu-Mg-Ni piston alloy with variable cu content. Int. Met. 11, 831–842 (2017). https://doi.org/10.1007/s40962-017-0132-0
B.Z. Yan, M.L. Chang, W. Kai, The structural evolutions of ZL109 alloy and 7050 alloy in the semisolid squeeze casting process. J. Wuhan. Univ. Technol. 1, 118–122 (2010). https://doi.org/10.1007/s11595-010-1118-4
K. Sukumaran, B.C. Pai, M. Chakraborty, The effect of isothermal mechanical stirring on an Al-Si alloy in the semisolid condition. Mater. Sci. Eng. A. 1–2, 275–283 (2004). https://doi.org/10.1016/j.msea.2003.11.036
W. Dai, S. Wu, S. Lue et al., Effects of rheo-squeeze casting parameters on microstructure and mechanical properties of AlCuMnTi alloy. Mater. Sci. Eng. A. 538, 320–326 (2012). https://doi.org/10.1016/j.msea.2012.01.051
L.L. Shu, S.W. Shu, W. Li et al., Microstructure and tensile properties of wrought Al alloy 5052 produced by rheo-squeeze casting. Met. Mater. Trans. A. 44, 2735–2745 (2013)
S. Li, A. Zhao, W. Mao et al., Study on forming mechanism of sphere-like α phase in microstructure of semisolid hypereutectic Al-Si alloy. Acta. Met. 5, 545–549 (2000)
Y. Zhang, X.P. Li, S.P. Sun et al., Microstructure evolution and mechanical properties of rheo-squeeze casting AZ91-Ca alloy during heat treatment. China. Foundry. 6, 485–491 (2017). https://doi.org/10.1007/s41230-017-7025-y
M.S. Salleh, M.Z. Omar, Influence of Cu content on microstructure and mechanical properties of thixoformed Al-Si-Cu-Mg alloys. Trans. Nonferrous. Metal. 11, 352–353 (2015). https://doi.org/10.1016/S1003-6326(15)63995-4
S.G. Shabestari, E. Parshizfard, Effect of semi-solid forming on the microstructure and mechanical properties of the iron containing Al–Si alloys. J. Alloys. Compd. 509, 7973–7978 (2011). https://doi.org/10.1016/j.jallcom.2011.05.052
I. Outmani, J. Isselin et al., Effect of Si, Cu and processing parameters on Al-Si-Cu HPDC castings. J. Mater. Process. Tech. 249, 559–569 (2017). https://doi.org/10.1016/j.jmatprotec.2017.06.043
Y.D. Jia, Z.J. Wei et al., Effect of high-pressure solidification on tensile properties and strengthening mechanisms of Al-20Si. J. Alloy. Compd. 688, 88–93 (2016). https://doi.org/10.1016/j.jallcom.2016.07.016
M. Akbari, M.H. Shojaeefard et al., Wear and mechanical properties of surface hybrid metal matrix composites on Al–Si aluminum alloys fabricated by friction stir processing. Proc. Inst. Mech. Eng. Part. L. J. Mater. Des. Appl 223(5), 790–799 (2017). https://doi.org/10.1177/1464420717702413
M. Qi, Y. Kang, Y. Xu et al., A novel rheological high pressure die-casting process for preparing large thin-walled Al-Si-Fe-Mg-Sr alloy with high heat conductivity, high plasticity and medium strength. Mater. Sci. Eng. A. 776, 1–18 (2020). https://doi.org/10.1016/j.msea.2020.139040
X. Dong, X. Zhu, S. Ji, Effect of super vacuum assisted high pressure die casting on the repeatability of mechanical properties of Al-Si-Mg-Mn die-cast alloys. J. Mater. Process. Tech. 266, 105–113 (2019). https://doi.org/10.1016/j.jmatprotec.2018.10.030
O. Prach, O. Trudonoshyn, P. Randelzhofer et al., Effect of Zr, Cr and Sc on the Al-Mg-Si-Mn high-pressure die casting alloys[J]. Mater. Sci. Eng. A. 759, 603–612 (2019). https://doi.org/10.1016/j.msea.2019.05.038
S. Beroual, Z. Boumerzoug, P. Paillard et al., Comparative study on the microstructures and hardness of the AlSi10.6CuMg alloy produced by sand casting and high pressure die casting. Int. Met. 32(4), 191–212 (2019). https://doi.org/10.1080/13640461.2019.1603681
J.F. Archard, Contact and rubbing of flat surfaces. J. Appl. Phys. 24(8), 981–988 (1953). https://doi.org/10.1063/1.1721448
M.I.A. El Aal, H.S. Kim, Wear properties of high-pressure torsion processed ultrafine grained Al-7%Si alloy[J]. Mater. Des. 53, 373–382 (2014). https://doi.org/10.1016/j.matdes.2013.07.045
O. Zak, B. Tonn, A. Baesgen et al., New wear resistant hypereutectic AlSi4Cu4FeCrMn alloys for high pressure die casting. Int. Met. 9, 49–57 (2015). https://doi.org/10.1007/BF03356040
Acknowledgements
The author expresses their gratitude to National Natural Science Foundation of China (No.51674168); Key-Area Research and Development Program of Guangdong Province (No.2020B010186002)
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Hao, J., Luo, H., Bian, J. et al. The effect of squeeze casting process on the microstructure, mechanical properties and wear properties of hypereutectic Al–Si–Cu–Mg alloy. Inter Metalcast 16, 153–165 (2022). https://doi.org/10.1007/s40962-021-00575-x
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40962-021-00575-x