Formation of hot tear under controlled solidification conditions

Aluminum alloy 7050 is known for its superior mechanical properties, and thus finds its application in aerospace industry. Vertical direct-chill (DC) casting process is typically employed for producing such an alloy. Despite its advantages, AA7050 is considered as a "hard-to-cast" alloy because of its propensity to cold cracking. This type of cracks occurs catastrophically and is difficult to predict. Previous research suggested that such a crack could be initiated by undeveloped hot tears (microscopic hot tear) formed during the DC casting process if they reach a certain critical size. However, validation of such a hypothesis has not been done yet. Therefore, a method to produce a hot tear with a controlled size is needed as part of the verification studies. In the current study, we demonstrate a method that has a potential to control the size of the created hot tear in a small-scale solidification process. We found that by changing two variables, cooling rate and displacement compensation rate, the size of the hot tear during solidification can be modified in a controlled way. An X-ray microtomography characterization technique is utilized to quantify the created hot tear. We suggest that feeding and strain rate during DC casting are more important compared with the exerted force on the sample for the formation of a hot tear. In addition, we show that there are four different domains of hot-tear development in the explored experimental window-compression, microscopic hot tear, macroscopic hot tear, and failure. The samples produced in the current study will be used for subsequent experiments that simulate cold-cracking conditions to confirm the earlier proposed model.This research was carried out within the Materials innovation institute (www.m2i.nl) research framework, project no. M42.5.09340

Influence of melt feeding scheme and casting parameters during direct-chill casting on microstructure of an AA7050 billet

© The Minerals, Metals & Materials Society and ASM International 2012Direct-chill (DC) casting billets of an AA7050 alloy produced with different melt feeding schemes and casting speeds were examined in order to reveal the effect of these factors on the evolution of microstructure. Experimental results show that grain size is strongly influenced by the casting speed. In addition, the distribution of grain sizes across the billet diameter is mostly determined by melt feeding scheme. Grains tend to coarsen towards the center of a billet cast with the semi-horizontal melt feeding, while upon vertical melt feeding the minimum grain size was observed in the center of the billet. Computer simulations were preformed to reveal sump profiles and flow patterns during casting under different melt feeding schemes and casting speeds. The results show that solidification front and velocity distribution of the melt in the liquid and slurry zones are very different under different melt feeding scheme. The final grain structure and the grain size distribution in a DC casting billet is a result of a combination of fragmentation effects in the slurry zone and the cooling rate in the solidification range

Linear Contraction Behavior of Low-Carbon, Low-Alloy Steels During and After Solidification Using Real-Time Measurements

A technique for measuring the linear contraction during and after solidification of low-alloy steel was developed and used for examination of two commercial low-carbon and low-alloy steel grades. The effects of several experimental parameters on the contraction were studied. The solidification contraction behavior was described using the concept of rigidity in a solidifying alloy, evolution of the solid fraction, and the microstructure development during solidification. A correlation between the linear contraction properties in the solidification range and the hot crack susceptibility was proposed and used for the estimation of hot cracking susceptibility for two studied alloys and verified with the real casting practice. The technique allows estimation of the contraction coefficient of commercial steels in a wide range of temperatures and could be helpful for computer simulation and process optimization during continuous casting. © 2013 The Minerals, Metals & Materials Society and ASM International

Study of Cold Cracking during DC-casting of High Strength Aluminum Alloys

Materials Science & EngineeringMechanical, Maritime and Materials Engineerin

Cold cracking in DC-cast high strength aluminum alloy ingots: An intrinsic problem intensified by casting process parameters

For almost half a century the catastrophic failure of direct chill (DC) cast high strength aluminum alloys has been challenging the production of sound ingots. To overcome this problem, a criterion is required that can assist the researchers in predicting the critical conditions which facilitate the catastrophic failure of the ingots. This could be achieved at first glance by application of computer simulations to assess the level and distribution of residual thermal stresses. However, the simulation results are only able to show the critical locations and conditions where and when high stresses may appear in the ingots. The prediction of critical void/crack size requires simultaneous application of fracture mechanics. In this paper, we present the thermo-mechanical simulation results that indicate the critical crack size distribution in several DC-cast billets cast at various casting conditions. The simulation results were validated upon experimental DC-casting trials and revealed that the existence of voids/cracks with a considerable size is required for cold cracking to occur.Materials Science & EngineeringMechanical, Maritime and Materials Engineerin

Numerical simulation of residual thermal stresses in AA7050 alloy during DC-casting using ALSIM5

Non-homogenous cooling rates and solidification conditions during DC-casting of high strength aluminum alloys result in the formation and accumulation of residual thermal stresses with different signs and magnitudes in different locations of the billet. Rapid propagation of microcracks in the presence of thermal stresses can lead to catastrophic failure in the solid state, which is called cold cracking. Numerical models can simulate the thermomechanical behavior of an ingot during casting and after solidification and reveal the critical cooling conditions that result in catastrophic failure, provided that the constitutive parameters of the material represent genuine ascast properties. Simulation of residual thermal stresses of an AA7050 alloy during DC-casting by means of ALSIM5 showed that in the steady-state conditions large compressive stresses formed near the surface of the billet in the circumferential direction. Stresses changed sign on moving towards the centre of the billet and became tensile with high magnitudes in radial and transverse directions, which made the alloy prone to hot and cold cracking.Materials Science & EngineeringMechanical, Maritime and Materials Engineerin

On the development of a cold cracking criterion for DC-casting of high strength aluminum alloys

Materials Science & EngineeringMechanical, Maritime and Materials Engineerin

Investigation of fracture behavior of high strength aluminum alloys in the as-cast condition

Materials Science & EngineeringMechanical, Maritime and Materials Engineerin

Constitutive parameters, mechanical properties and failure mechanism in DC-cast AA7050 billets

Materials Science & EngineeringMechanical, Maritime and Materials Engineerin

Microstructural features of intergranular brittle fracture and cold cracking in high strength aluminum alloys

Intergranular brittle fracture has been mainly observed and reported in steel alloys and precipitation hardened At-alloys where intergranular precipitates cover a major fraction of the grain boundary area. 7xxx series aluminum alloys suffer from this problem in the as-cast condition when brittle intermetallics cover almost all the interdendritic spaces and grain boundaries. Brittle intermetallics formed during the non-equilibrium solidification upon direct chill (DC) casting provide favorable sites forcrack initiation and propagation at different stages of solidification and cooling. Such micro-cracks may propagate rapidly in the presence of residual thermal stresses and lead to catastrophic failure of DC-cast billets that is called "cold cracking". In this research work fractographic investigations were performed on as-cast AA7050 specimens failed during tensile tests. In-situ tensile tests were also performed using an Environmental Scanning Electron Microscope (ESEM) to follow the propagation path of cracks at critical temperatures. They revealed that the alloy loses its ductility below 300 degrees C and becomes extremely vulnerable to cracking and failure. Comparison of the fracture surfaces of tensile samples with real cracked billets helps to understand the mechanisms of crack formation and catastrophic failure. (C) 2009 Elsevier B.V. All rights reserved