Effect of Glass Tube Suction Casting on Solidification Process and Si Refinement of Hypereutectic Al-Si Alloy

doi:10.1007/s40195-024-01762-5

Abstract

Abstract:

This study unpicks the influence of the glass tube suction casting (GTSC) with different inner diameters (8, 10, 12 and 14 mm) on the solidification process of the hypereutectic Al-Si alloy (A390) and dissects the underlying mechanisms of the Al-Si divorced eutectic and refinement degree of the primary silicon particles (PSPs). The results show that a smaller inner diameter of the glass tube is more favorable for achieving Al-Si divorced eutectic in GTSC A390 alloy. Conversely, a larger inner diameter is more conducive to the formation of the lamellar eutectic Si. The GTSC A390 alloy with an inner diameter of 10 mm achieves the smallest average equivalent diameter (approximately 7.4 μm) of the PSPs. Being the prior diffusion channels for solute atoms, the grain boundaries and twin growth grooves of PSPs attract solute atoms (Cu, Mg, etc.) to enrich. The enriched solute atoms occupy the diffusion destinations of some Si atoms, which limits the overall growth of PSPs. These findings provide new insights into developing a simple and effective manufacturing process to refine the primary and eutectic Si phases in hypereutectic Al-Si alloys.

Key words: Al-Si alloy, Solidification, Primary Si particles, Divorced eutectic, Refinement

Chengcheng Han, Yuna Wu, Hao Huang, Chen Chen, Huan Liu, Jinghua Jiang, Aibin Ma, Jing Bai, Hengcheng Liao. Effect of Glass Tube Suction Casting on Solidification Process and Si Refinement of Hypereutectic Al-Si Alloy[J]. Acta Metallurgica Sinica (English Letters), 2024, 37(12): 2094-2105.

Figures/Tables 14

Table 1 Actual chemical composition of A390 alloy (wt%)

Si	Cu	Fe	Zn	Mg	Mn	Al
14.6	4.4	0.8	0.7	0.5	0.2	Bal.

Fig. 1 Schematic diagram of the glass tube suction casting and measuring of cooling curves

Fig. 2 Micro-X-ray diffraction pattern of A390 alloy

Fig. 3 SEM images and EDS mappings of GTSC A390 alloy

Table 2 EDS area mapping results of GTSC A390 alloy at different locations (at.%)

Location	Phase	Al	Si	Cu	Fe	Mg	Zn
1	α-Al	95.8	-	2.9	-	-	1.3
2	PSPs	8.4	91.2	0.4	-	-	-
3	Al₅FeSi	58.2	16.2	-	25.6	-	-
4	Al₂Mg₈Cu₂Si₆	28.2	23.5	22.2	-	26.1	-
5	Al₂Cu	68.4	0.8	30.8	-	-	-

Fig. 4 Differential scanning calorimetric (DSC) analysis of A390 Alloy

Fig. 5 Optical microstructures and equivalent diameter histograms of PSPs in GTSC A390 alloy with different inner diameters: a1, a2 8 mm; b1, b2 10 mm; c1, c2 12 mm; d1, d2 14 mm

Fig. 6 Average equivalent diameter of GTSC A390 alloy with different inner diameters

Fig. 7 SEM images of GTSC A390 alloy with different inner diameters under deep corrosion: a1, a2 8 mm; b1, b2 10 mm; c1, c2 12 mm; d1, d2 14 mm

Fig. 8 Schematic diagram presenting the divorced eutectic solidification of GTSC A390 alloy

Fig. 9 Cooling curves of the GTSC A390 alloy with different inner diameters

Fig. 10 TEM images and corresponding diffraction pattern of GTSC A390 alloy with 10 mm inner diameter: a PSPs; b Twin Si

Fig. 11 TEM image and mapping results of twin Si grooves and the schematic diagrams of PSPs growth limited by solute atoms: a TEM and mapping results; b, c PSPs growth limited by solute atoms

Fig. 12 TEM and mapping results of other phases in GTSC A390 alloy with 10 mm inner diameter: a Cu-rich phase and Mg2Si phase; b Mg2Si phase and corresponding diffraction pattern

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