Accepted Manuscript

Influence of vibration on the solidification behaviour and tensile properties of

an Al-18wt%Si alloy
G. Chirita,, I. Stefanescu, D. Soares, F.S. Silva

PII: S0261-3069(08)00384-1
DOI: 10.1016/j.matdes.2008.07.045
Reference: JMAD 2061

To appear in: Materials and Design

Received Date: 22 May 2008

Revised Date: 18 July 2008
Accepted Date: 22 July 2008

Please cite this article as: Chirita,, G., Stefanescu, I., Soares, D., Silva, F.S., Influence of vibration on the
solidification behaviour and tensile properties of an Al-18wt%Si alloy, Materials and Design(2008), doi: 10.1016/
j.matdes.2008.07.045

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INFLUENCE OF VIBRATION ON THE SOLIDIFICATION BEHAVIOUR AND TENSILE

PROPERTIES OF AN Al-18wt%Si ALLOY
Chirita, G.1, Stefanescu, I2, Soares, D. 1, Silva, F.S. 1
1
Mechanical Engineering Department; School of Engineering, Minho University, PORTUGAL
2
Faculty of Mechanical Engineering, Dunarea de Jos University Galati, ROMANIA

________________________________________________________________________________
Abstract. This paper is concerned with the influence of vibration on mechanical properties of
castings. The main vibration effects include: promotion of nucleation and thus reducing as-cast grain
size; reduction of shrinkage porosities due to improved metal feeding; and production of a more
homogenous metal structure. In the present study, mechanical mold vibration was applied to an Al–
Si hypereutectic alloy at fixed amplitude and different frequencies. Tensile tests were done on
specimens obtained with the different vibrating frequency levels. Experimental results show that
mechanical properties were influenced by the level of applied frequency. The tensile strength was
improved for low vibration frequencies but decreased for high frequencies, as compared with gravity
castings without vibration. A microstructure analysis along with a solidification behavior study was
performed in order to understand the mechanism responsible for the previous behavior. A heat-
transfer mechanism, that is acceleration dependent, seems to be the responsible for the shift in
mechanical properties response to the vibration effect.

Keywords: vibration; acceleration; mechanisms.

________________________________________________________________________________

1. INTRODUCTION

Due to many advantages such as good thermal conductivity, excellent castability, high strength-to-
weight ratio, wear and corrosion resistance, pressure tightness and good weldability, aluminium-
silicon alloys are considered one of the most commonly used foundry alloys. Controlling the
microstructure that results from the casting process is considered one of the main challenges faced
by today’s foundry industry. Fine equiaxed microstructures generally exhibit favourable mechanical
properties of strength and ductility with low susceptibility to microporosity and cracks.
The use of mechanical, sonic or ultrasonic vibration may have the advantage of promoting grain
refinement, increased density, degassing, low shrinkage porosities, and changes of the shape, size
and distribution of the second phase [1-9].
Regarding the vibration effect in microstructure it is documented [1] that applying mechanical
vibration to a mould during solidification may have an effect on mechanical properties of the
casting. The responsible is the microstructure where the lamellar spacing tends to reduce and silicon
morphology becomes fibrous with the increasing of the vibration amplitude as compared to gravity
casting. However, it is also reported that exceeding a critical value of vibration amplitude, the
silicon tends to coarsen [1]. Fragmented primary dendrites with thicker dendrite arm thickness and
reduced solidification time were obtained on Al–8% Si with rectilinear vibration by transforming
rotary motion of a DC motor, 100 cycles/min ( 2 Hz). The same level of vibration was applied to
Al–12% Si and it was reported a reduction of the eutectic cell size from 5 to 1.6 mm and a tendency
of coarsening of eutectic Si [2]. Significant reduction in gas content was obtained with low
frequency melt agitation in Al–20Si [3]. With an applied vibration at a constant frequency of 100
Hz and different amplitudes from 18 to 199 m an increase between 19 and 68 %, in percent
elongation was reported while ultimate stress had a slight change, about 3% [1]. The increase in
elongation was correlated with the increase in the amount of eutectic volume fraction compared to
the non-vibrated case [1]. In another study [9] the amount and size of pores were increased in LM25
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[Al–Si 7,15%] and LM6 [Al–Si 12,30%] alloys with increasing frequencies between 15 and 41.7 Hz
and amplitudes between 0,125 and 0,5 mm.
Thus, it is clear that vibration may promote changes in microstructure and consequently in
mechanical properties, either increasing or decreasing it. However the mechanisms under which
those changes occur are still unclear. This work proposes a mechanism that is able to explain the
reason for the shift on metallurgical and mechanical properties with vibration acceleration.

2. EXPERIMENTAL METHODS AND MATERIALS

Materials
The material used for castings is a commercial AlSi18 alloy with the following chemical
composition (wt%): 18 Si 22; Fe 0,75; 1,5 Cu 3,0; Zn 0,2; Mg 0,1; Mn 0,3; Ni 0,5; Pb 0,1;
Sn 0,05; Ti 0,2.

Methods
The material was melt at 800 0C and poured into a permanent mould which was preheated at 130
0
C. A high frequency induction furnace (Titancast 700 mP Vac, from Linn High Term, Germany),
equipped with a vacuum chamber, was used for melting. A charge of approx. 240g of material was
used in each melting, always performed under vacuum. After melting in the induction furnace the
material was poured into the mould which was attached on the system that provides the mechanical
vibration due to the eccentric of the shafts (Fig.1). The vibration was linearly applied with 0,5 mm
amplitude for all castings and different frequencies, namely 0 Hz, 8 Hz and 24 Hz.
The obtained castings were heat treated with a temper during 8h at 200ºC.
For the analysis of the solidification behavior two thermocouples type K were attached to the mould
in order to acquire the temperature during the pouring and solidification of the material. Two holes
were done in the wall of the mould in which thermocouples were inserted at a distance of 2 mm
from the inside wall surfaces. The positions of the inserting points of the thermocouples are shown
in figures 2 and 3.
Specimens for mechanical tests were cut from each casting in three slices (each slice indicates the
position in the mould) in order to compare the properties of the aluminum alloy not only between
different frequencies but also in different places of the ingot. (Fig.4).
Tensile tests were done in a Dartec tensile testing machine at room temperature. After doing the
tensile tests the specimens were cut close to the fracture area and polished. An optical measurement
method was used to do the phase quantification and microstructure analysis. The microstructure
examination was made on the middle part of specimen slice 1 of each casting.

3. RESULTS

Rupture strength and rupture strain results are shown on Figs. 5 and 6 respectively. It is clear on Fig.
5 that rupture strength increases in about 31% for the casting with 8Hz in any position, when
compared to simple gravity castings, and that rupture strength decreases in about 13% for castings
with 24Hz of vibration, as compared to simple gravity castings, again in all three positions. It is also
observed that there is a tendency of properties to increase from position 3 to position 1 in the case of
vibrated gravity with 8 Hz and 0 Hz but with no tendency on vibrated gravity with 24Hz.
Regarding rupture strain results, Fig. 6 shows that rupture strain is much higher ( 95%) for the
vibrated gravity process with 8Hz in any position then vibrated gravity with 8Hz and 0Hz. It is also
clear a tendency of increasing properties from position 3 to position 1 in all the casting processes.
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Thus mechanical properties increase with vibration till a certain level frequency (acceleration) but
decrease for higher levels of vibration frequencies.
Figs 7 and 8 show the temperature readings during solidification for the three frequencies used. It is
clear that the maximum temperatures reached in the mould, in both positions (down and front) are
obtained on the vibration level of 8 Hz. For 0Hz and 24 Hz results are closer and different in the
two different positions (down and front).
On table 1 (also represented on fig. 7) are quantified both the solidification starting point and the
solidification intervals (difference between starting and ending solidification points) for the three
vibration levels in position down (results were quantified in this position because the starting and
ending solidification points are more clearly identified. It is shown on fig. 7 the starting and end
solidification points. The starting solidification point is the point when there is an increase in
temperature resulting from latent heat of fusion of the first phase to solidify. The ending
solidification point corresponds to the last inflection temperature point indicating the end of the
latent heat of fusion release of the eutectic constituent.
It is observed that for 8Hz the solidification starts first and last less. 0Hz and 24 Hz have closer
results for both the solidification starting point and interval.

Table 1 – Solidification characteristics for the three vibration frequencies:

solidification starting time and solidification interval.
Reading position: Down
Solidification frequency (Hz) 0 8 24
Starting Solidification Point (s) 9,6 5,0 8.5
Solidification Interval (s) 9,5 9,3 10.5

In Fig 9 is observed that, considering the 0 Hz frequencies as a comparison value, the amount of
eutectic increases for the 8Hz test in about 11% and decreases in about 8% for the 24 Hz test. This
happens for the three tested positions. The volume fraction of -Al phase shows the opposite effect
since the alloy has essentially these two phases (Fig. 9).
The presence of isolated alpha phase in the microstructure can be attributed to a high undercooling
level associated with the alloy and casting process characteristics [10].
Fig 10 provides the silicon lamellae thickness. It is observed that the thinner values are observed for
the 8Hz test and the thicker ones are for the 24Hz, in all three positions.
Fig. 11 provides the microstructure pictures for the different vibration levels (0Hz, 8Hz and 24Hz
frequency). Basically, a thinner structure is found for 8Hz and courser structure for 24 Hz. It can
also be observed that the morphology of eutectic silicon was modified from a dispersed coral like
form (0Hz) to a more finely and nested coral like form (8Hz) and to a coarse acicular plate-like form
with less coral like eutectic form for 24Hz.

4. DISCUSSION

Mechanical results depend on metallurgical features which itself depend on solidification behavior.
Starting from the obtained solidification curves it is clear that the 8Hz test is the one that starts and
completely solidify first (and also has the smaller solidification interval)(table 1). Thus it is
expected a thinner microstructure in these castings (Figs. 10 and 11), a higher amount of eutectic
(fig. 10)[8] and, as a consequence, better mechanical properties (both rupture strength and rupture
strain)(Figs. 5 and 6). Regarding the comparison between 0Hz and 24 Hz, the results provide the
same reasoning: 24 Hz is the one that takes longer to solidify (table 1); has the coarsest
microstructure (Figs 10 and 11); has the lowest amount of eutectic (Fig. 10); and consequently has
the poorer mechanical results, in particular tensile strength (figs 5 and 6). Thus, there is a perfect
correlation between solidification behavior, microstructure, and mechanical properties.
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These results are basically in accordance with refs [1-2], and [8]. Furthermore it is also observed a
peak shift in mechanical properties, after a certain frequency (acceleration), as reported in [1].
The differences between position 1 and 3 are explained by the distance to the mould wall and
consequent solidification behavior. The material in position 1 solidifies first and then has the
thinner microstructure (Fig. 10), the higher amount of eutectic phase (Fig. 9), and consequently the
better mechanical properties (Figs. 5 and 6), among all positions. Position 3 obviously has the lower
properties.
The main aspect is therefore to find an explanation that may provide a physical explanation for the
phenomena of the mechanical properties shifting point with vibration level.

5. PROPOSED MECHANISM

These results may be explained based on heat transfer mechanisms both in the liquid phase and in
the mould wall interface. The proposed mechanism is schematically provided in Fig. 12, and is the
following:

• In the case of 0Hz casting, there is a ‘normal’ contact between liquid metal and mould. The heat
transfer is ‘normal’ and the solidification rate has a certain value giving rise to a determined
microstructure;
• In the case of 8 Hz the vibration induces a higher heat transfer to the mould (higher cooling rate)
due to the alternated movement of the liquid (see Figs. 7 and 8 with higher initial solidification
temperatures in the mould). Furthermore this movement may also provide displacement of the
germen solidification sites providing a higher solidification rate. The contact between liquid
metal and mould is about the same as for the 0Hz case. However as the heat convection in the
liquid phase is improved by the vibration movements the liquid temperature near the interface is
higher what explains the higher temperatures in the mould obtained in the cooling curves for
these experiments (fig. 7 and 8). The lower cooling times (table 1) resulted from the faster liquid
cooling rate and the improved nucleation characteristics by germen distribution in the liquid.
The consequence is that the microstructure is thinner (see Figs. 10 and 11) and the amount of
eutectic is higher (see Fig. 9). Consequently rupture strength and rupture strain increase (see
Figs. 5 and 6);
• In the case of 24 Hz the vibration should induce even a higher heat transfer inside the liquid to
the mould interface due to the quicker alternated movement of the liquid. However, the relative
acceleration between liquid metal and mould seems to be high enough in order to create a loss
of contact (low pressure zones in the interface liquid metal-mould)(in front position) and even
eventually low pressure bubbles as those originated in cavitation. This situation occurs when the
surface tension (liquid – mould wall) is not low enough in order to keep the surface contact
when high acceleration rates (frequency*amplitude) exist. A loss of contact means to switch the
heat transfer mode from totally conductive to a conductive + convective transfer in the interface.
Because the convective heat transfer is much lower than the conductive heat transfer the heat
transfer and consequent solidification rate substantially decreases (see mainly Fig. 8 with lower
initial solidification temperature in the mould). The consequence is a courser microstructure (see
Figs. 10 and 11) and a lower eutectic content (see Fig. 9). Mechanical properties should then
decrease (this is particularly evident for rupture strength)(Fig. 5 and 6).
Although with the same consequence, in the down position a different mechanism may occur.
There is a loss of contact due to the tangential movement of the liquid (in front position there is
a normal contact – see figs. 1 and 3 with vibration direction and temperature readings/walls
positions and detail on Fig. 12). This loss of contact is due to the liquid movement and
roughness effect (see detail on Fig. 12).
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This means that vibration can be beneficial as well as detrimental depending on the acceleration
level between liquid metal and microstructure and surface tension of the liquid metal and mould
material. This may be the reason why some papers attribute to vibration beneficial effects and others
detrimental effects on properties.

5. CONCLUSIONS

Solidification behavior as obtained by solidification curves, microstructure analysis and mechanical

results seem to point out that:

• Vibration affects the solidification rates and its characteristics;

• Vibration has an influence on mechanical properties;
• Its influence seem to be due to heat transfer related aspects;
• Vibration increases heat transfer in the liquid;
• Vibration may substantially reduce heat transfer in the interface metal-wall due to the loss of
contact under mainly two hypothetic mechanisms: high surface tension and wall roughness
effect.

6. ACKNOWLEDGEMENT

The research presented here was carried out in Materials Testing Laboratory of the Mechanical
Engineering Department of University of Minho, and was supported by “Fundação para a Ciência e
Tecnologia” (Portugal) through the PhD grant with the reference SFRH / BD / 19618 / 2004.

7. REFERENCES
[1] Abu-Dheir Numan, Marwan Khraisheh, Kozo Saito, Alan Male, ”Silicon morphology
modification in the eutectic Al-Si alloy using mechanical mold vibration”, Materials Science and
Engineering A393 pp. 109-117, (2004).
[2] T.P. Fisher, “Effects of vibrational energy on the solidification of aluminium alloys”, Br.
Foundryman 66 (3), 71–83, (1973).
[3] A.A. Ivanov, G.G. Krushenka, “Preparation of Al–Si alloying composition by means of
vibration”, Liteinoe Proizvod (3) (1993) 7–8 (Russian); Met. Abs. 46-0019,(1992).
[4] X. Jian, T.T. Meek, Q. Han, “Refinement of eutectic silicon phase of aluminum A356 alloy
using high-intensity ultrasonic vibration”, Scripta Materialia 54, 893–896, (2006).
[5] F.C. Robles Hernandez, J.H. Sokolowski, “Comparison among chemical and electromagnetic
stirring and vibration melt treatments for Al–Si hypereutectic alloys”, Journal of Alloys and
Compounds 426, 205–212, (2006).
[6] M.T.Alonso Rasgado, K. Davey, “The effect of vibration on surface finish for semisolid and cast
components”, Journal of Materials Processing Technology, Vol. 125-126, 543-548, (2002).
[7] M.T. Alonso Rasgado, K. Davey, “Vibration and casting surface finish”, Journal of Materials
Processing Technology 153–154, 875–880, (2004).
[8] Chirita, G.; Stefanescu, I; Barbosa, J.; Puga, N.; Soares, D., Silva, F.S.,” On the Assessment Of
Precessing Variables In a Vertical Centrifugal Casting Technique”, submitted to International
Journal of Cast Metals Research
[9] Kadir Kocatepe, “Effect of low frequency vibration on porosity of LM25 and LM6 alloys”,
Materials and Design, Vol. 28 Issue 6, 1767-1775, (2006)
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[10] H.S. Kanga, W.Y. Yoon, K.H. Kimb, M.H. Kimc, Y.P. Yoon, “Microstructure selections in the
undercooled hypereutectic Al–Si alloys”, Materials Science and Engineering A 404, 117–123,
(2005)
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Vibration direction

Fig. 1 - Mechanical vibrating device. e - excentricity

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Fig. 2 – Thermocouples positions on the mould

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Fig. 3 – Temperature reading positions in walls of the mould: 1 – Down; 2 - Front

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pouring
direction
3

30 mm

90 mm

30 mm

Fig. 4 - Position of the specimen slices in castings. Positions 1, 2, and 3.

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Rupture strength Vibration 8Hz

200 Vibration 24Hz
Vibration 0Hz
180
160

140
120

100
Stress [MPa]

80

60
40
20

0
1 2 Position 3

Fig. 5 - Rupture strength for 0Hz, 8Hz and 24Hz frequencies for the three sample positions.
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Rupture strain Vibration 8Hz

0.6 Vibration 24Hz
Vibration 0Hz

0.5

Strain [%]
0.4

0.3

0.2

0.1

0.0
1 2 Position 3

Fig. 6 - Rupture strain for 0Hz, 8Hz and 24Hz frequencies for the three sample positions.
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400
DOWN
350

Temperature [°C]
300

250

200 Gravity

8Hz
150 Temperature
24 Hz
acquisition point
on the mould
100
0 5 10 15 20 25 30 35 40 45 50
Time [s]

Fig. 7 - Solidification curves for the different vibration levels on the down position of the mould
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340
FRONT
Gravity
320
8Hz
Temperature [°C] 300 24 Hz

280

260

240
Temperature
acquisition point
220
on the mould

200
0 5 10 15 20 25 30 35 40 45 50
Time [s]

Fig. 8 - Solidification curves for the different vibration levels on the front position of the mould
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100
Al18Si
90

80

70

Volume fraction [%]

60
(Al) phase-Vibration 24Hz
Eutectic-Vibration 24Hz
50 (Al) phase-Vibration 8Hz
Eutectic-Vibration 8Hz
(Al) phase-Vibration 0Hz
40 Eutectic-Vibration 0Hz

30

20

10

0
0 1 2 3 4
Position

Fig. 9 – Phases volume fraction for the three different vibration levels and tested positions.
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2.5

Thickness [mm]
2

1.5 Gravity

1 Vibrated gravity 8Hz

Vibrated gravity 24Hz

0.5

0
0 1 2 Position 3 4

Fig. 10 – Eutectic silicon lamellas thickness for the three different vibration levels and tested positions.
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0Hz 8Hz

24Hz
Fig. 11 Microstructure of castings with vibration at different frequencies (500x)
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Liquid movement
direction - tangential

Down position

Liquid movement
direction - normal

Front position

Fig. 12 – Heat transfer variation with acceleration and mechanism representation.