Investigation on solidification conditions in functionally Si-gradient Al alloys using simulation and cooling curve analysis methods

During recent years, functionally graded alloys have been widely produced by melt processing routes to achieve advanced material properties. In this paper, the new cast-decant-cast (CDC) method has been used to produce the gradient in concentration of Si particles in cross section of final Al–Si castings. For this purpose, the hypereutectic LM28 and hypoeutectic LM25 alloys were selected for each step casting into the steel mold. Cooling curve thermal analysis and simulation methods were applied to investigate the cooling behavior of first poured LM28 alloy and improve the accuracy of CDC process by determining the curves of solid fraction and temperature profiles. The final products were studied through optical microscopy, image analysis, and Brinell hardness measurement. The results showed that the silicon concentration decreased along transition zone between two alloys by increasing the decanting time in the order of 25, 40, and 50 s. This can be due to the lower temperature of exterior LM28 alloy in semi-solid state and shorter solidification time of interior LM25 alloy. This can lead a to reduction of the diffusion rate of elemental silicon along the transition zone. The microscopic scale of transition zone between two alloys developed the maximum thickness of 438 μm and hardness value of 83 HB comparing with the hardness of 88 and 62 HB for external and internal alloys, respectively. The microscopic observations and hardness evaluations confirmed the creation of functionally Si-gradient products.