Synchrotron radiography studies of shear-induced dilation in semi-solid Al alloys and steels

An improved understanding of the response of solidifying microstructures to load is required to further minimize casting defects and optimize casting processes. This article overviews synchrotron radiography studies that directly measure the micromechanics of semisolid alloy deformation in a thin sample direct-shear cell. It is shown that shear-induced dilation (also known as Reynolds’ dilatancy) occurs in semisolid alloys with morphologies ranging from equiaxed-dendritic to globular, at solid fractions from the dendrite coherency point to ~90% solid, and it occurs in both Al alloys and carbon steels. Discrete-element method simulations that treat solidifying microstructures as granular materials are then used to explore the origins of dilatancy in semisolid alloys

Strength-ductility behaviour of Al-Si-Cu-Mg casting alloys in T6 temper

A comparative study of the mechanical properties of 20 experimental alloys has been carried out. The effect of different contents of Si, Cu, Mg, Fe and Mn, as well as solidification rate, has been assessed using a strength-ductility chart and a quality index-strength chart developed for the alloys. The charts show that the strength generally increases and the ductility decreases with an increasing content of Cu and Mg. Increased Fe (at Fe/Mn ratio 0.5) dramatically lowers the ductility and strength of low Si alloys. Increased Si content generally increases the strength and the ductility. The increase in ductility with increased Si is particularly significant when the Fe content is high. The charts are used to show that the cracking of second phase particles imposes a limit to the maximum achievable strength by limiting the ductility of strong alloys. The (Cu + Mg) content (at.%), which determines the precipitation strengthening and the volume fraction of Cu-rich and Mg-rich intermetallics, can be used to select the alloys for given strength and ductility, provided the Fe content stays below the Si-dependent critical level for the formation of pre-eutectic alpha-phase particles or beta-phase plates

Microsegregation In Cellular Solidification

Microsegregation in a binary alloy solidified in the form of deep cells is predicted using a simplified finite difference model. The model accounts for solid state diffusion and for flow of liquid between cells driven by solidification shrinkage. Cell tip undercooling is predicted using the expression originally derived by Bower et al. Cells are assumed to be cylindrical, and solid state diffusion along the cell axis is ignored, simplifying considerably prediction of solid state diffusion and cell shape behind the tip, which are treated as a one-dimensional moving boundary problem. Experiments were conducted on binary Al-4.5 wt pct Cu, solidified in the cellular growth regime using a Bridgman furnace. Microsegregation in the samples was measured and is compared to predictions; good agreement is found, both for cell heights and microsegregation in the fully solidified material. It is found that intercellular fluid flow exerts a small, but discernable, influence on microsegregation and cell shape