Investigation of rheo-diecasting mold filling of semi-solid A380 aluminum alloy slurry

Abstract

The rheo-diecasting mold filling capacity and the microstructure of the semi-solid A380 aluminum alloy slurry were investigated. The results show that the mold filling capacity was strengthened with increasing pouring temperature or increasing injection pressure. Under certain process parameters, the mold cavity was fully filled. However, the mold filling capacity decreased with increasing holding time. The mold filling capacity was improved with increasing shape factor of primary α(Al) grains; however, the solid fraction and the grain size significantly increased at the same time. In addition, the microstructures along the route of the spiral samples obviously differed. The grain size decreased gradually from the near-end to the far-end, whereas the shape factor increased gradually.

Keywords

aluminum alloys / semi-solid slurry / rheo-diecasting / mold filling / microstructure

References

[1] Flemings M.C. Behavior of metal alloys in the semisolid state. Metall. Trans. B, 1991, 22(3): 272.

[2] Mao W.M. Semisolid Metal Forming Technology, 2004, Beijing, China Machine Press 62.

[3] Sistaninia M., Terzi S., Phillion A.B., Drezet J.M., Rappaz M. 3-D granular modeling and in situ X-ray tomographic imaging: A comparative study of hot tearing formation and semi-solid deformation in Al–Cu alloys. Acta Mater, 2013, 61(10): 3831.

[4] Phillion A.B., Hamilton R.W., Fuloria D., Leung A.C.L., Rockett P., Connolley T., Lee P.D. In situ X-ray observation of semi-solid deformation and failure in Al–Cu alloys. Acta Mater., 2011, 59(4): 1436.

[5] Zhao H.D., Ohnaka I., Zhu J.D. Modeling of mold filling of Al gravity casting and validation with X-ray in-situ observation. Appl. Math. Modell., 2008, 32(2): 185.

[6] Zabler S., Ershov A., Rack A., Garcia-Moreno F., Baumbach T., Banhart J. Particle and liquid motion in semi-solid aluminum alloys: A quantitative in situ microradioscopy study. Acta Mater., 2013, 61(4): 1244.

[7] Neag A., Favier V., Bigot R., Atkinson H.V. Analysis by micromechanical modeling on material flow under rapid compression in the semi-solid state. Solid State Phenom., 2014, 217-218, 182.

[8] Hufschmidt M., Modigell M., Petera J. Modelling and simulation of forming processes of metallic suspensions under non-isothermal conditions. J. Non-Newtonian Fluid Mech., 2006, 134(1-3): 16.

[9] Bai Y.L., Mao W.M., Gao S.F., Li Q. Effect of technological parameters on filling behavior of semi-solid A356 alloy by rheocasting. J. Univ. Sci. Technol. Beijing, 2006, 28(7): 645.

[10] Gao S.F., Mao W.M., Bai Y.L., Li Q. Filling ability of semi-solid A356 alloy in rheo-casting and microstructure distribution. Spec. Cast. Nonferrous Alloys, 2005, 25(10): 598.

[11] Bai Y.L., Mao W.M., Xu H., Hou H., Xu J. Numerical simulation on rheo-diecasting mould filling of semi-solid key-shaped component. Trans. Nonferrous Met. Soc. China, 2008, 18(3): 682.

[12] Haga T., Fuse H. Semi-solid die casting of Al-25%Si. Solid State Phenom., 2014, 217-218, 312.

[13] Zhong G., Wu S.S., Wan L., Qin B. Study on filling capacity of semi-solid Al-20%Si alloy prepared by rheo-casting. Foundry, 2010, 59(10): 1044.

[14] Timelli G., Capuzzi S., Bonollo F. Optimization of a permanent step mold design for Mg alloy castings. Metall. Mater. Trans. B, 2015, 46(1): 473.

[15] Yang X.J. Study on the Rheological Behavior and Gates of the Thixoforming of Semi-Solid Aluminum (A356) Alloy, 1999 66.

[16] Feng P.F., Tang J.L., Li S.S., Zeng D.B. Experimental studies on rheocasting processing of A356 alloy. Foundry, 2007, 56(1): 31.

[17] Janudom S., Wannasin J., Basem J., Wisutmethangoon S. Characterization of flow behavior of semi-solid slurries containing low solid fractions in high-pressure die casting. Acta Mater., 2013, 61(16): 6267.

[18] Pathak N., Kumar A., Yadav A., Dutta P. Effects of mould filling on evolution of the solid–liquid interface during solidification. Appl. Therm. Eng., 2009, 29(17-18): 3669.

[19] Kang C.G., Bae J.W. Numerical simulation of mold filling and deformation behavior in rheology forming process. Int. J. Mech. Sci., 2008, 50(5): 944.

[20] Ren J.L., Ouyang J., Jiang T. An improved particle method for simulation of the non-isothermal viscoelastic fluid mold filling process. Int. J. Heat Mass Transfer, 2015, 85, 543.

[21] Modigell M., Hufschmidt M., Petera J. Two phase simulation and visualisation of isothermal die filling processes. The 7th International Conference on Semi-Solid Processing of Alloys and Composites, 2002 509.

[22] Alexandrou A.N., Florides G.C., Georgiou G.C. Squeeze flow of semi-solid slurries. J. Non-Newtonian Fluid Mech., 2013, 193, 103.

[23] Liu Z.Y., Mao M.W., Wang W.P., Zheng Z.K. Preparation of semi-solid A380 aluminum alloy slurry by serpentine channel. Trans. Nonferrous Met. Soc. China, 2015, 25(5): 1426.

[24] Luo S.J., Chen B.G., Qi P.X. Hydraulic Die Forging and Squeeze Casting Technology, 2007, Beijing, Chemical Industry Press 34.

[25] Chen Z.Z. Preparation of Semi-Solid Slurry Through The Serpentine Channel and Rheo-diecasting Process of A356 Aluminum Alloy, 2011 45.

[26] Sun X.P., Shi L., Guan R.G., Wang S.C., Qi W.J. Study progress and new trends of grain refinement in aluminum alloys. Non-Ferrous Min. Metall., 2010, 26(5): 32.

[27] Song W.X. Metallography, 2008, Beijing, Metallurgical Industry Press 231.

[28] Masuku E.P., Möller H., Curle U.A., Pistorius P.C., Li W. Influence of surface liquid segregation on corrosion behavior of semi-solid metal high pressure die cast aluminum alloys. Trans. Nonferrous Met. Soc. China, 2010, 20(3): s837.

[29] Wang Y.F. Solution Treatment of Vacuum High Pressure Die Cast Aluminum Alloy A380, 2004, Windsor, University of Windsor 34.