On the Prediction of Hot Tearing in Al-to-Steel Welding by Friction Melt Bonding

Aluminum alloy AA6061 was welded to dual-phase steel 980 (DP980) by the friction melt bonding (FMB) process. Hot tears have been suppressed by controlling the thermomechanical cycle. In particular, the welding speed and the thermal conductivity of the backing plate have been optimized. A finite-element thermomechanical model coupled with the Rappaz–Drezet–Gremaud (RDG) criterion has been used to explain these experimental observations. The hot tear susceptibility has been reduced with large thermal gradients and with the formation of a cellular microstructure. Both effects are favored by a backing plate made of a material with high thermal conductivity, such as copper.     

A New Criterion for Prediction of Hot Tearing Susceptibility of Cast Alloys

A new criterion for prediction of hot tearing susceptibility of cast alloys is suggested which takes into account the effects of both important mechanical and metallurgical factors and is believed to be less sensitive to the presence of volume defects such as bifilms and inclusions. The criterion was validated by studying the hot tearing tendency of Al-Cu alloy. In conformity with the experimental results, the new criterion predicted reduction of hot tearing tendency with increasing the copper content.     

Effect of Melt Conditioning on Removal of Fe from Secondary Al-Si Alloys Containing Mg,Mn, and Cr

Metallurgical and Materials Transactions A - Primary intermetallic sludge formation in hypoeutectic secondary Al7.1Si(1.5-xM)FexMM alloys was investigated in view of potential Fe removal by...     

Modeling of De-cohesion and the Initiation of Hot Tearing in Coherent Mushy Zones of Metallic Alloys

The initiation of a hot tear in the coherent mushy zone of metallic alloys is associated commonly with the opening up of the solid skeleton caused by thermally induced deformation. A previously established constitutive model for the continuum modeling of coherent mushy zones has been further developed in the current study to address the opening up, or decohesion, of the solid skeleton associated with volumetric tensile deformation. Whereas the original model accounts for the cohesion of the solid skeleton caused by the deformation by means of an internal variable, an additional internal variable accommodating the decohesion has been introduced in the new model. The modeled decohesion is interpreted as the initiation of a hot tear.     

Experimental and Theoretical Studies of the Hot Tearing Behavior of Al-xZn-2Mg-2Cu Alloys

The effect of Zn addition on the hot tearing susceptibilities of non-refined Al-xZn-2Mg-2Cu (x = 2-12 wt pct) alloys was investigated via direct crack observations and load response measurements. The obtained experimental results were compared with the predictions made using a modified Rappaz–Drezet–Gremaud (RDG) hot tearing model. Both the minimum crack width and load at the non-equilibrium solidus (NES) temperature (which served as a good indicator of hot tearing response) were observed at a Zn concentration of approximately 4 wt pct, and the formation of cracks was highly correlated with the predictions made via the modified RDG hot tearing model (although the obtained relationship critically depended on the magnitude of fraction solid at which solid coalescence was expected to occur). Furthermore, it was confirmed from the load development pattern that the addition of Zn into the matrix of Al-xZn-2Mg-2Cu alloys promoted the formation of coalesced networks, which decreased their corresponding coalescence fraction solids.

     

热镀锌合金锭的生产工艺和质量控制

生产过程的工艺控制是热镀锌合金锭质量控制的一个重要环节。针对用户提出的合金质量问题，分析了生产过程中影响合金质量的原因，提出了控制和改进合金质量的措施，并取得了满意的效果。     

Effects of Copper Content and Mold Temperature on the Hot Tearing Susceptibility of Mg-7Zn-xCu-0.6Zr Alloys

Metallurgical and Materials Transactions B - The effects of copper (Cu) content and mold temperature on the hot tearing susceptibility (HTS) of Mg-7Zn-xCu-0.6Zr (x = 0, 1, 2)...     

Low-Cost Process for Silicon Purification with Bubble Adsorption in Al-Si Melt

The primary silicon and Al-Si alloy have been separated in hypereutectic Al-Si melt by the electromagnetic stirring and directional solidification processes. During the electromagnetic separation process, the behavior of a hydrogen bubble in Al-Si melt has been discussed. Furthermore, the bubble adsorption effect for the Si purification has been revealed. The results show that the bubble cavity formed in the lower part of the sample by pulling it up. The scanning electron microscope along with energy dispersive spectrometer (SEM-EDS) analysis indicated that a lot of impurities were adsorbed onto the surface of the bubble cavity that may be beneficial for the Si purification. By decreasing the pulling-up rates, the size of the bubble cavity in Al-Si alloy increased, which results in the decreasing of the impurity contents in primary silicon. In this work, the impurity content in primary silicon is 10.8 ppmw, which is obviously improved compared with the 777.57 ppmw in metallurgical silicon. It is a low-cost technology that will be a potential route for the Si purification.     

Effects of Melt Thermal-Rate Treatment on Fe-Containing Phases in Hypereutectic Al-Si Alloy

In this paper, effects of melt thermal-rate treatment (MTRT) on Fe-containing phases in hypereutectic Al-Si alloy were investigated. Results show that MTRT can refine microstructures and improve castability, mechanical properties, wear characteristics, and corrosion resistance of Fe-containing Al-Si alloy. When Al-15Si-2.7Fe alloy is treated with MTRT by 1203 K (930 °C) melt: coarse primary Si and plate-like Fe-containing phase both can be refined to small blocky morphology, and the long needle-like Fe-containing phase disappears almost entirely; ultimate tensile strength and elongation are 195 MPa and 1.8 pct, and increase by 12.7 and 50 pct, respectively; and the wear loss and coefficient of friction decrease 7 to 17 and 24 to 30 pct, respectively, compared with that obtained with conventional casting technique. Corrosion resistance of the alloy treated with MTRT by 1203 K (930 °C) melt is the best, that is it has the lowest i _corr value and the highest E _corr value. Besides, effects of MTRT on Al-15Si-xFe (x = 0.2, 0.7, 1.7, 3.7, 4.7) alloys were also studied, MTRT can only refine microstructure and improve mechanical properties of Al-15Si alloy with 0.7 to 3.7 pct Fe content greatly in the present work.     

Role of Grain Refinement in the Hot Tearing of Cast Al-Cu Alloy

The effects of grain refinement on hot tear formation and contraction behavior in a modified Al-Cu alloy 206 (M206) have been studied. The experiments were conducted using a newly developed mold which could simultaneously measure the contraction force/temperature during solidification for a restrained casting, and thereby could be used to investigate hot tear formation. Quantitative information on crack initiation and propagation was obtained by analyzing load measurement data. Al-Ti and Al-Ti-B master alloys were added to the melt to refine the grains to obtain grains ranging from columnar dendritic to equiaxed dendritic and globular structures. Effects of grain structure and grain size on hot tearing susceptibility were investigated. The correlations between microstructure evolution in grain-refined castings at various levels and hot tear formation were determined and discussed. Grain refinement was found to have a complex effect on load onset. Hot tearing tendency was significantly affected by both grain size and grain morphology as reflected by the measured data.     

Density,Viscosity, and Diffusion Coefficients in Hypoeutectic Al-Si Liquid Alloys: An Assessment of Available Data

This article is a review of empirical and calculated data on density, viscosity, and diffusion coefficients in hypereutectic Al-Si liquid alloys. Many regressions of the data were effected in order to consolidate the data as functions, which can be used to calculate each property as a function of temperature and concentration of Si. The chemical diffusion coefficient in the alloys was derived based on the Sutherland model, which relates the diffusion coefficient to viscosity.     

Dissolution of iron intermetallics in Al-Si Alloys through nonequilibrium heat treatment

Conventional heat treatment techniques in Al-Si alloys to achieve optimum mechanical properties are limited to precipitation strengthening processes due to the presence of second-phase particles and spheroidization of silicon particles. The iron intermetallic compounds present in the microstructure of these alloys are reported to be stable, and they do not dissolve during conventional (equilibrium) heat treatments. The dissolution behavior of iron intermetallics on nonequilibrium heat treatment has been investigated by means of microstructure and mechanical property studies. The dissolution of iron intermetallics improves with increasing solution temperature. The addition of manganese to the alloy hinders the dissolution of iron intermetallics. Nonequilibrium heat treatment increases the strength properties of high iron alloys until a critical solution temperature is exceeded. Above this temperature, a large amount of liquid phase is formed as a result of interdendritic and grain boundary melting. The optimum solution treatment temperature for Al-6Si-3.5Cu-0.3Mg-lFe alloys is found to be between 515 °C and 520 °C.     

Physical Properties and Solidification Structure of Al－SiEutectic Alloy Melt with Cerium Modification

ＰｈｙｓｉｃａｌＰｒｏｐｅｒｔｉｅｓａｎｄＳｏｌｉｄｉｆｉｃａｔｉｏｎＳｔｒｕｃｔｕｒｅｏｆＡｌ－ＳｉＥｕｔｅｃｔｉｃＡｌｌｏｙＭｅｌｔｗｉｔｈＣｅｒｉｕｍＭｏｄｉｆｉｃａｔｉｏｎＬｉＰｅｉｊｉｅ（李培杰）；ＧｕｏＪｉｎｇｊｉｅ（郭景杰）；ＪｉａＪｕ...     

稀土在Al-Si合金中的分布及其对变质过程的影响

通过俄歇微探针定点成分分析和Ｘ射线粉末照像方法,分别对稀土在初生Ｓｉ颗粒和共晶组织两相中的存在和分布特点进行了研究。结果表明：稀土变质剂使初生Ｓｉ颗粒由开花状板片变成多面体颗粒状。产生这种变化的原因是与稀土吸附并阻碍Ｓｉ相沿挛晶凹坑的生长有关;在ＡＩ－Ｓｉ合金中,微量稀土主要存在于Ｓｉ相,在Ｓｉ相中分布较均匀,未发现选择性吸附和明显的浓度偏聚;微量稀土变质剂没有明显的形成化合物,不形成Ｓｉ相的异质核心。