Research on semi-solid slurry of a hypoeutectic Al-Si alloy prepared by low superheat pouring and weak electromagnetic stirring

The semi-solid slurry of a hypoeutectic Al-Si alloy was manufactured by low superheat pouring and weak electromagnetic stirring. The effects of pouting temperature and stirring power on the semi-solid slurry were investigated. The results indicated that the semi-solid slurry to satisfy rheocasting can be manufactured by low superheat pouring and weak electromagnetic stirring. The pouring temperature （or superheat） and the stirring power remarkably affected the morphology of primary α-Al and the size of primary α-Al, and there is no obvious effect of stirring time on primary α-Al. Compared with the samples made by low superheat pouring with no stirring, the nucleation rate, particle morphology and grain size of primary α-Al in A356 were markedly improved by low superheat pouring and weak electromagnetic stirring. On the condition of weak electromagnetic stirring, the pouring temperature with low superheat can be suitably raised to reach the effectiveness obtained from the lower pouring temperature without stirring.     

新工艺制备半固态A356铝合金浆料

提出了在电磁搅拌制备半固态A356铝合金浆料时插拔Cu棒的一个新工艺.由于在半固态铸锭轴向区域引入低温,可进一步提高电磁搅拌效果,铸锭各部位均由细小α-Al晶粒组成.该工艺还可适当提高低过热度浇注的温度而有利于实际生产.     

Effect of melt pulse electric current and thermal treatment on A356 alloy

Effects of the melt pulse electric current and thermal treatment on solidification structures of A356 alloy were investigated.In the experiments.the low temperature melt(953K and 903K)treated by pulse electric current was mixed with high temperature metl(1223K).By the control experiments,the results show that the solidification structure of A356 alloy is refined apparently by the pulse electric current together with melt thermal treatment process,and the mechanical properties.especially the elongation ratio of the specimen treated is improved greatly.The structure change of the melt by pulse electric current and melt thermal treatment is the main reason for the refinement of the solidification structure of A356 alloy.     

Effect of high density pulse electric current on solidification structure of low temperature melt of A356 alloy

The effect of high density pulse electric current(HDPEC)on the solidification structure of the low temperature melt(LTM)of commercial A356 alloy was investigated.In th experiments.the HDPEC was discharged in the LTM(953K,903K and 873K),By the control experiments,the results showed that the solidification structure of the LTM of A356 alloy is refined apparently when the HDPEC is discharged in low temperature melt.However,the holding time of melt treated has an adverse effect on the soliification structure.The longer the holding time of the melt treated with HDPEC,the coarser the microstructure.With the same discharge voltage.the lower the temperature of LTM,the more obscure the refinement of solidification structure.Finally,the mechanism of microstructure refining by HDPEC was analyzed.     

含铒A356合金半固态浆料的制备

采用添加稀土元素铒(Er)变质处理和弱电磁搅拌制备了A356合金的半固态成形浆料。利用微观组织观察、扫描电镜、透射电镜与能谱分析等手段,对制得试样的微观组织进行了研究,并对其形貌演变机理做了分析讨论。结果表明,微量(0.05%)Er元素添加到合金中,可使合金的初生α-Al晶粒从蔷薇花状变成细小的球状。在625℃时对含Er的合金液进行适当的弱电磁搅拌,可以进一步细化合金晶粒,制得半固态成形所需的浆料。     

Effect of local chilling on morphology of primary α（Al） in semi-solid A356 alloy

The semi-solid slurry ofA356 alloy was prepared by low superheat pouring and slightly electromagnetic stirring, in which a pure copper rod was used to produce local chilling. The effect of chilling by the rod on morphology and size of primary a（Al） in A356 was researched. The results indicate that the chilling by the rod remarkably affects the morphology and the size of primary a（Al）. Primary a（Al） with particle-like shape is distributed uniformly in A356, and there is no transient area in structure morphology. Compared with the samples prepared without the local chilling, the nucleation rate, morphology and grain size of primary a（Al） in A356 prepared by low superheat pouring and slightly electromagnetic stirring with the rod are markedly improved. Under the condition of chilling, the pouring temperature can be suitably raised to obtain primary a（Al） with particle-like shape.     

Effect of pouring temperature on semi-solid slurry of A356 Al alloy prepared by weak electromagnetic stirring

The semi-solid slurry of A356 Al alloy was manufactured by low superheat pouring and weak electromagnetic stirring. The effects of pouring temperature on the slurry manufactured by weak electromagnetic stirring were researched. The results indicate that it is feasible to manufacture the slurry with particle-like primary phases by low superheat pouring and weak electromagnetic stirring, and there is an important effect of the pouring temperature （superheat temperature） on the morphology and the size of primary α -Al in A356 Al alloy. By the action of suitable weak electromagnetic stirring, increasing pouring temperature to put low superheat pouring in practice is capable of obtaining semi-solid slurry of A356 Al alloy with particle-like primary phase. Compared with the samples made only by low superheat pouring without stirring, raising pouting temperature by 15-35℃ above the liquidus temperature under condition of weak electromagnetic stirring can ensure the same grain size and morphology of the primary phase.     

电磁搅拌时间对半固态A356合金凝固组织的影响

应用变频控制的电磁搅拌装置对低过热度浇注的A356合金熔体进行短时弱电磁搅拌,探讨了不同的搅拌时间对合金凝固组织中的初生α-Al相和共晶相形貌与分布规律的影响,从而得到最佳的电磁搅拌工艺参数.研究表明,A356合金熔体在620℃浇注,并经频率为30 Hz的电磁搅拌15 s,在615℃保温10 min后,初生α-Al的平均等积圆直径为55.70μm,平均形状因子达到了0.86,共晶组织颗粒细小、致密且分布均匀,此条件下得到的半固态A356合金浆料的室温凝固组织形貌最好.     

Influence of process parameters on microstructure of semisolid A356 alloy slug cast through vertical pipe

Suitable microstructures required for semisolid casting were formed by using a vertical pipe. Different lengths of vertical pipe, slug dimensions and pouring time were used to investigate their influence on the microstructure of A356 alloy. The results indicate that at the same length of the vertical pipe, the morphology of the primary a（Al） gradually deteriorates by the enlargement in the slug size, but the deteriorating speed slows down with increasing pipe length. They also reveal that the increase in the pipe length improves the microstructure, whereas no further improvement appears when the pipe length reaches a certain value. The optimum length of the pipe obtained in the present work is 430 mm. The microstructure of larger slug poured at higher pouring temperature gets worse and it can be improved by moderately elongating pouring time. The relative mechanisms were also discussed.     

Grain and dendrite refinement of A356 alloy with Al–Ti–C–RE master alloy

Commercial A356 alloy was refined with a homemade Al-5Ti-0.25C-2RE master alloy, and the microstructure and macrostructure of the refined alloy were investigated. The results show that the grain refining effect of A356 is poor by the addition level of 0.5 wt% master alloy, but when the level reaches 3.0 wt% the grain can get a satisfactory refining effect. Dendrite of A356 can be effectively refined by addition of 0.5 wt% master alloy; however, the refining effect is not significantly improved by further increasing the addition of master alloy. Grain and dendrite refining effects are compared in this article, and the results show that the grain and dendrite exhibit different refining effects with the same addition level of master alloy. Dendrite is easier to reach the optimal refining effect than grain.     

Effect of Temperature on Segregation and Deformation Mechanism of α+Ti2Cu Alloy during Semi-Solid Forging

以新型阻燃钛合金Ti14 (α＋Ti2Cu)为对象,研究了合金在不同温度半固态锻造过程中的偏析和偏聚现象及由此导致的变形机制的变化。结果表明,半固态温度影响液相含量和分布,随着温度的升高液相在晶界由不连续分布转变为连续分布析出,并最终形成了网状结构分布。锻造过程中由于液相和应力的共同作用出现了宏观偏析现象,液相在压力作用下的流动在晶界处产生了宏观液相/固相分离现象,靠近试样中心固相离子集中;这种现象导致了锻造过程中变形机制的变化,中心区仍旧是固相粒子的塑性变形为主变形机制,靠近试样外边缘主变形机制转变为固相粒子的相对滑移,通过唯象模型对其过程进行讨论     

半固态A356铝合金浆料的行波搅拌制备工艺

采用行波电磁搅拌和低过热度浇注复合制备工艺,成功制备出初生α-Al为球状的较大尺寸A356铝合金半固态浆料.研究了浇注温度、搅拌频率和搅拌功率对A356铝合金半固态浆料组织的影响.结果表明,随着浇注温度的降低,半固态A356铝合金组织中的初生α-Al更圆整.当搅拌频率达到或高于10Hz时,半固态A356铝合金浆料中的组织比较理想.当电磁搅拌功率增大时,半固态A356铝合金熔体中的蔷薇状初生α-Al受到更剧烈的附加温度起伏而使枝晶根部熔断,形成更多更圆整的球状初生相.因此,在630℃浇注、搅拌频率为10Hz和搅拌功率为1.72kW下,能制备出更圆整、细小的初生α-Al.