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Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (30 June 2023) | Viewed by 20704

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Dr. Andrey Pozdniakov

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Department of Physical Metallurgy of Non-Ferrous Metals, National University of Science & Technology (MISIS), Leninskiy Ave 4, Moscow, Russia
Interests: Al alloys; microstructure; phase transformation; heat treatment; mechanical properties; corrosion resistance
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Dear Colleagues,

Aluminum and its alloys are widely used in automobiles, aircraft, shipbuilding and other industries due to a good combination of technological characteristics, such as light weight, good mechanical properties, corrosion resistance and technological properties under casting and deformation. Products from aluminum alloys are obtained by casting and thermomechanical treatment. The microstructure, phase composition that forms during casting, heat treatment, and thermomechanical treatment define the final properties and applications of the materials.

The current pace of industrial development requires materials with a higher level of mechanical and technological properties with respect to a complex combination of characteristics. The optimization of the structure and phase composition of alloys and the search for promising alloying systems and elements for the development of new materials with enhanced operational and technological properties is an urgent task, including for expanding the use of aluminum alloys and improving the level of technology.

Research articles focusing on the development of prospective Al alloys, optimization of casting and deformation technology, and investigation of the evaluation of the structure and phase composition under casting and heat and thermomechanical treatment are encouraged.

Prof. Dr. Andrey Pozdniakov
Guest Editor

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Keywords

Al alloys
casting alloys
wrought alloys
casting properties
microstructure
phase composition
phase transformation
heat treatment
strengthening
mechanical properties
corrosion resistance

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Published Papers (9 papers)

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Research

19 pages, 9117 KiB

Open AccessArticle

Phase Composition and Microstructure of Cast Al-6%Mg-2%Ca-2%Zn Alloy with Fe and Si Additions

by Vitali Doroshenko, Pavel Shurkin, Tatyana Sviridova, Anastasiya Fortuna and Ivan Shkaley

Metals 2023, 13(9), 1584; https://doi.org/10.3390/met13091584 - 12 Sep 2023

Cited by 6 | Viewed by 1573

Abstract

Investigating the effect of Fe and Si is essential for any new Al-based composition, as these impurities can be easily found both after primary production and recycling. This study is dedicated to filling the gap in revealing the phase composition of an Al-6%Mg-2%Ca-2%Zn alloy after the combined and separate addition of Fe and Si. This was addressed by permanent mold casting and solid solution heat treatment. The investigation of slowly solidified samples also contributed to understanding potential phase transitions. It was found that the alloy containing 0.5%Fe can have nearly spherical intermetallics after heat treatment, whereas a higher Fe content brought the formation of a needle-shaped Al₃Fe intermetallic. We explain this by the formation of a ternary α-Al + Al₁₀CaFe₂ + Al₄Ca eutectic, which is more compact in as-cast condition compared to divorced binary α-Al + Al₄Ca and α-Al + Al₃Fe eutectics. Similarly, 0.5%Si readily incurred the formation of a needle-shaped Al₂CaSi₂ intermetallic, probably also by a binary reaction L → α-Al + Al₂CaSi₂. In the solidified samples, no Mg₂Si phase was found, even in slowly solidified samples. This is contrary to the thermodynamic calculation, which suggests a peritectic reaction L + Al₂CaSi₂ Mg₂Si. Interestingly, the addition of 0.5%Si caused an even coarser microstructure compared to the addition of 1%Fe, which caused the appearance of a primary Al₃Fe phase. We conclude that the new alloy is more tolerable to Fe rather than Si. Specifically, the addition of 0.5%Fe can be added while maintaining a fine morphology of the eutectic network. It was suggested that the morphology of eutectic and solid solution hardening governed the mechanical properties. The strength of the alloys containing separate 0.5%Fe (UTS = 215 ± 8 MPa and YS 146 ± 4 = MPa) and the combined 0.5%Fe and 0.5%Si additions (UTS = 195 ± 14 MPa and YS ± 1 = 139 MPa) was not compromised compared to the alloy containing 0.5%Si (UTS 201 ± 24 = MPa and YS = 131 ± 1 MPa). Full article

(This article belongs to the Special Issue Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy)

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15 pages, 7574 KiB

Open AccessArticle

The Characterization of Coatings Formed on As-Cast Al, Al–Si, and Al–Ca Aluminum Substrates by Plasma Electrolytic Oxidation

by Nikolay V. Letyagin, Torgom K. Akopyan, Alexander A. Sokorev, Tatiana A. Sviridova, Stanislav O. Cherkasov and Yulbarskhon N. Mansurov

Metals 2023, 13(9), 1509; https://doi.org/10.3390/met13091509 - 23 Aug 2023

Cited by 5 | Viewed by 1403

Abstract

In this study, ceramic coatings were grown on the surface of as-cast aluminum alloys via plasma electrolytic oxidation (PEO). The effect of the Si- and Ca-alloying elements in aluminum on the growth process, morphology, composition, mechanical, and corrosion properties of the PEO coatings was investigated. Uniform coatings with a minimum number of defects were formed on the surfaces of Al–Ca alloys. Increasing the Si content in Al led to an increase in the bulk and surface porosity of the coatings. The α-Al₂O₃ phase mainly formed in the coatings synthesized on pure Al and Al–Ca alloys, while an increased amount of Si in Al alloys hindered the formation of the α-Al₂O₃ phase. The coatings had a microhardness of 660–1180 HV_, which was 20–30 times higher than that of the original as-cast alloy. Moreover, the coating on the Al–Ca alloys had the highest peak hardness, which was probably caused by the formation of a greater amount of the α-Al₂O₃ phase. Electrochemical studies in 3.5% NaCl have shown that PEO coatings reduce the corrosion current density. Of all PEO-treated alloys, Al and Al1Ca have the lowest corrosion current density and hence the highest corrosion resistance due to the composition and uniformity of the coating. Full article

(This article belongs to the Special Issue Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy)

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12 pages, 4646 KiB

Open AccessArticle

Effect of Cr on the Microstructure and Mechanical Properties of the Al-Cu-Y-Zr Alloy

by Sayed M. Amer, Maria V. Glavatskikh, Ruslan Yu. Barkov, Irina S. Loginova and Andrey V. Pozdniakov

Metals 2023, 13(2), 349; https://doi.org/10.3390/met13020349 - 9 Feb 2023

Cited by 4 | Viewed by 2003

Abstract

The present investigation aimed at the determination of Cr addition on microstructure, phase composition, and mechanical properties of the Al-Cu-Y-Zr alloy. Quasi-binary alloys of the ternary Al-Cu-Y system with atomic rotation of Cu/Y = 4/1 have a narrow solidification range with high solidus temperature. The addition of 0.3% Cr in the Al-5.1Cu-1.7Y-0.3Zr alloy provides a formation of a novel quaternary Al_81–85Cu_7–10Y_3–4Cr₅ phase. L1₂-Al₃(Zr,Y) phase spherical particles with a diameter of 50 nm were nucleated during solution treatment at 600 °C. Al₇Cr precipitates were not found in the microstructure. The main strengthening effect of 32.4 MPa and 29.1 MPa was achieved from L1₂ and θ’(Al₂Cu) precipitates, respectively, in accordance with the calculation. The calculated hardness of 61.5HV based on the calculated

σ_{y}

is consistent with the experimental value of hardness. Al₃Zr and Al₇Cr phases should be in equilibrium with (Al) in accordance with the calculated polythermal section. However, transmission electron microscopy investigation demonstrates the Al₃(Zr,Y) precipitates only. As a result, the dissolved Cr atom provides a slightly higher hardness in the rolled and annealed AlCuYZrCr alloy. A suitable combination of strength and ductility was observed both after rolling and after rolling with subsequent annealing at 150 °C for 3 h—the alloy exhibited a yield strength of 308–315 MPa, an ultimate tensile strength of 323–335 MPa, and an elongation to failure of 2.0–3.3%. Full article

(This article belongs to the Special Issue Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy)

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10 pages, 6349 KiB

Open AccessArticle

Microstructure and Mechanical Properties of Novel Heat Resistant Cast Al-Cu-Yb(Gd)-Mg-Mn-Zr Alloys

by Olga I. Mamzurina, Sayed M. Amer, Maria V. Glavatskikh, Ruslan Yu. Barkov, Irina S. Loginova and Andrey V. Pozdniakov

Metals 2022, 12(12), 2079; https://doi.org/10.3390/met12122079 - 3 Dec 2022

Cited by 6 | Viewed by 2042

Abstract

The present study focused on the development of the novel heat resistant cast Al-Cu-Yb(Gd)-Mg-Mn-Zr alloys based on the prevue investigations. Microstructures and mechanical properties were investigated by optical, scanning and transmission electron microscopy, hardness measurements, and tensile and creep tests at room and elevated temperatures. Ytterbium in combination with Zr and Ti provide greater Al grain refining than gadolinium. The L1₂-Al₃(Zr,Yb) or L1₂-Al₃(Zr,Gd) and Al₂₀Cu₂Mn₃ phase precipitates were nucleated during solution treatment. The average sizes of L1₂-Al₃(Zr,Yb) and L1₂-Al₃(Zr,Gd) are 28 ± 6 nm and 32 ± 4 nm, respectively. Al₂₀Cu₂Mn₃ phase precipitates formed with a more coarse size of 100–200 nm. The highest hardening effect was achieved after 3 h of aging at 210 °C in both alloys due to S’(Al₂CuMg) precipitates. The ultimate tensile strengths (UTS) of the AlCuYbMg and AlCuGdMg alloys at room temperature are 338 and 299 MPa, respectively. The UTS decreases to 220–272 MPa when increasing the temperature of the tensile test to 200–250 °C. The rupture stress at 250 °C for 100 h under stress is 111–113 MPa. The contribution from different structure parts in the yield strength was calculated. The main strengthening effects of 54–60 MPa and 138–153 MPa were achieved from L1₂ and S’ precipitates, respectively. The calculated values of yield strength (YS) are consistent with the experimental data. Novel AlCuYbMg and AlCuGdMg alloys are a potential option for castings for high temperature application. Full article

(This article belongs to the Special Issue Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy)

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15 pages, 6059 KiB

Open AccessArticle

Microstructure Refinement by a Combination of Heat Treatment and Thixoforming Process Followed by Severe Plastic Deformation and Their Effects on Al-Si Alloy Hardness

by Mohamed Abdelgawad Gebril, Mohd Zaidi Omar, Intan Fadhlina Mohamed, Norinsan Kamil Othman and Osama M. Irfan

Metals 2022, 12(11), 1972; https://doi.org/10.3390/met12111972 - 18 Nov 2022

Cited by 5 | Viewed by 1723

Abstract

This study fabricated a thixoformed Al-7% Si alloy using the cooling slope technique and subjected it to heat treatment before processing with severe plastic deformation to determine the effect of this combination method on the microstructure refinement and hardness of Al-Si alloys (300 Series). Each as-cast and thixoformed Al-Si alloy sample was subjected to equal-channel angular pressing (ECAP) and high-pressure torsion (HPT) individually at room temperature before and after heat treatment. ECAP was conducted in a mould with a 120° channel angle via route A, and HPT was applied with 0.75 and 5 turns. The heat-treated thixoformed Al-Si alloy subjected to the HPT process had an ultra-fine grain microstructure and showed a fine and homogeneous redistribution of the eutectic phase in the Al matrix. For the as-cast alloy, the hardness of the heat-treated thixoformed Al-7% Si alloy increased from 63 HV to 124 and 215 Hv after two ECAP passes and five turns of HPT due to the reduced and redistributed eutectic phase in the Al matrix. Subjecting the Al-7% Si alloy to a combination of semisolid and heat treatment processes before subjecting it to severe plastic deformation resulted in microstructural refinement and improved the hardness of the Al-Si alloy. The results indicate that HPT is a more effective method than ECAP for increasing the hardness of the thixoformed Al-Si alloy due to microstructure refinement. Full article

(This article belongs to the Special Issue Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy)

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12 pages, 10043 KiB

Open AccessArticle

Researches on the Macro- and Micro-Structures and Properties of the Vertical Bending Continuous Casted AA6063 Thin Slabs and Their As-Rolled Sheets

by Zhuo-Huang Wu, Qi-Jia Mao, Fu-An Hua, Guang-Lin Jia, Jian-Ping Li, Cheng-Gang Li, Guo Yuan and Guo-Dong Wang

Metals 2022, 12(11), 1937; https://doi.org/10.3390/met12111937 - 12 Nov 2022

Cited by 1 | Viewed by 1937

Abstract

A 6063 aluminum alloy thin slab with a cross-section of 260 × 40 mm² was prepared by a vertical bending continuous casting (VC) process. The effects of homogenization, hot rolling and subsequent heat treatments on the microstructure and properties of the as-cast slabs and as-rolled sheets were investigated by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), field emission electron probe (EPMA), macro- and micro-structure observation and tensile tests. The results show that the as-cast structure of AA 6063 was dominated by fine and uniform equiaxed grains. After homogenization, all Mg₂Si phases dissolved back, and the Fe-containing intermetallic phases changed from acicular β-Al₅FeSi phase to spherical α-Al₈Fe₂Si phase. Homogenizing heat treatment before hot rolling can improve the mechanical properties of the alloy. However, in the case of direct rolling without homogenization, the alloy still has good mechanical properties; the strength and plasticity are comparable to that obtained through traditional direct chill (DC) casting, homogenizing and extruding processes, indicating that the VC process has the potential to realize continuous casting and rolling. Full article

(This article belongs to the Special Issue Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy)

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20 pages, 7843 KiB

Open AccessArticle

Modelling of Strain-Controlled Thermomechanical Fatigue Testing of Cast AlSi7Cu3.5Mg0.15 (Mn, Zr, V) Alloy for Different Aging Conditions

by Pierre Heugue, Daniel Larouche, Francis Breton, Rémi Martinez, X.-Grant Chen and Denis Massinon

Metals 2022, 12(8), 1258; https://doi.org/10.3390/met12081258 - 26 Jul 2022

Cited by 3 | Viewed by 2092

Abstract

Thermomechanical fatigue loadings (TMF) applied on components in a certain temperature range with a variable state of stress (tensile and/or compression) produce a localized concentration of plastic strains that results in crack initiation and propagation. The time evolution of plastic strains must be known a priori to predict the lifetime of a part submitted to TMF loadings, which requires an extensive campaign of mechanical characterization conducted at different temperatures and aging conditions. Such a campaign was proposed for the aluminum alloy AlSi7Cu3.5Mg0.15 (Mn, Zr, V), which is recognized as being creep resistant. Combined isothermal low-cycle fatigue and isothermal creep tests were performed on this alloy to determine the constitutive parameters based on the Lemaître and Chaboche (LM&C) viscoplastic model. These laws were implemented within the finite element simulation software (Z-set) to model the response of the alloy to a thermomechanical fatigue test. The results of TMF Z-Set simulations, using the LM&C model adapted for two aging conditions, were then compared with results obtained from “Out of Phase” thermomechanical fatigue testings (OP-TMF) performed on a Gleeble 3800 machine. The modelling of the OP-TMF test revealed the complexity of the mechanical behavior of the material induced by the temperature gradient prevailing along with the cylindrical specimen. It was found that a better prediction of the evolution of plastic strains requires taking into account a larger range of plastic strain rates conditions for the determination of the constitutive law and eventually includes the role of the microstructure in the evolution of the material behavior, starting first with the yield stress. Full article

(This article belongs to the Special Issue Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy)

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15 pages, 6777 KiB

Open AccessArticle

The Effect of Ce on the Microstructure, Superplasticity, and Mechanical Properties of Al-Mg-Si-Cu Alloy

by Andrey G. Mochugovskiy, Alexey S. Prosviryakov, Nataliya Yu. Tabachkova and Anastasia V. Mikhaylovskaya

Metals 2022, 12(3), 512; https://doi.org/10.3390/met12030512 - 17 Mar 2022

Cited by 7 | Viewed by 2893

Abstract

The current study focuses on the influence of Ce on the superplastic behavior, microstructure, and mechanical properties of the Al-Mg-Si-Cu-Zr-Sc alloy. The multilevel microstructural analysis including light, scanning electron, and transmission electron microscopies was carried out. The simple thermomechanical treatment including the hot and cold rolling resulted in fragmentation of the eutectic originated particles of the Ce-bearing phases. The two-step annealing of the ingots provided the precipitation of the L1₂-structured Al₃(Sc,Zr) phase dispersoids with 10 nm mean size and a high number density. Due to the particle stimulated nucleation (PSN) effect caused by the particles of eutectic origin, and Zener pinning effect provided by nanoscale dispersoids of L1₂-structured phases, the studied alloy demonstrated good superplastic properties. Full article

(This article belongs to the Special Issue Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy)

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15 pages, 5426 KiB

Open AccessArticle

Effect of Grain Refinement on the Dynamic, Mechanical Properties, and Corrosion Behaviour of Al-Mg Alloy

by Haitham M. Ahmed, Hussin A. M. Ahmed, Mohammed Hefni and Essam B. Moustafa

Metals 2021, 11(11), 1825; https://doi.org/10.3390/met11111825 - 13 Nov 2021

Cited by 16 | Viewed by 3621

Abstract

In this investigation, aluminium Al-2.5% Mg cast alloy was modified by adding 0.5 Ti and 0.1 B wt % modifiers to investigate their impact on the dynamic behaviour, as well as the mechanical and microstructure properties. The dynamic properties were analysed experimentally using a free vibration impact test and predicted using finite element methods. This study used a high-resolution polarised optical microscope to analyse the microstructure of the studied alloys and X-ray Powder Diffraction (XRD) analysis to determine the developed phases. Microstructure and mechanical properties were mostly enhanced as a result of grain refining during solidification and through the metal segregation process. The microstructure analysis of the modified alloy showed a significant improvement in the grain refinement; hence, the grains were 10 times finer than the cast alloy. The modified Al-2.5% Mg/Ti-B alloy demonstrated reduced inter-granular corrosion (IGC) than the Al-2.5% Mg standard cast alloy. By incorporating Ti-B modifiers into the composition of the cast Al-Mg alloy, the ultimate tensile strength (UTS), strain (ε), and hardness values (HV) were increased by 30.5%, 100%, and 18.18%, respectively. The dynamic properties of the modified alloy showed an enhancement in the resonant (f_n) and damping ratio (ζ) by 7% and 68%, respectively. The predicted resonance frequencies of the investigated alloys showed results close to the experimental dynamic tests. Full article

(This article belongs to the Special Issue Advances in Casting, Thermomechanical and Heat Treatments of Aluminum Alloy)

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