Effects of T6 Heat Treatment On Mechanical Properties of A356 Alloy Castings Prepared Under Oscillatory Conditions

IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441
A Publisher for Research Motivation........
Volume 4, Issue 2, February 2016
Effects of T6 Heat Treatment on Mechanical

Properties of A356 Alloy Castings Prepared
Under Oscillatory Conditions
Sakendra Kumar1, Dr. S.P.Tewari2
1
Research Scholar, 2Professor

IIT (BHU), Varanasi-221005
Abstract
Experiments have been conducted at 10 m amplitude in frequency of oscillation range of 0-400Hz. Experiments have been
carried out at two solutionising temperature 515 C and 540C for four hour and quenched in warm water of temperature 60C
and aging temperatures 160C for four hour. The effect of mold oscillation during solidification and T6 heat treatment on
microstructure, tensile properties and hardness were. The results show that percentage increase due to mold oscillation
intensile strength, yield strength, elongation and hardness are 32% ,18%, 41.6% and 36.5% respectivelyand decrement in grain
size is up to49%as compared to as cast without oscillation.Tensile strength,percentage elongation and hardness were improved
further as compared to that of as cast due to heat treatment. Combined effect of moldoscillation and heat treatment on tensile
strength, yield strength elongation and hardness are observed and it was found that these increased by 37% ,88%, 170% and
75% respectively and decrement in grain size was up to58%.Improvements in the properties are attributed to grain refinement
of oscillatory prepared casting with heat treatment at 400Hz frequency, 540C temperature.
Keywords:-Moldoscillation, Heat treatment, Microstructure, SEM, Grain Refinement
1. INTRODUCTION
Solidification rate of any metallic casting depend upon two factors, cooling rate and melt temperature. These factors are
responsible for formation of structure and the quality of any casting. Mechanical properties of the casting alloys depend
mainly on their chemical composition and parameters of casting process. A lot of research has been done regarding
grain refinement and mechanical properties improvement under oscillations during solidification of a metallic alloy.
This is also being done to increase the solidification rate and cooling rate of casting. Evidence found shows that
solution treatment time can be reduced if the microstructure is finer in as cast conditions. For the Al-Si alloys
containing additives of the Mg and Cu, it is possible to improve these properties by the heat treatment.
J. Pezda[1]observed the improvement in mechanical properties of aluminum casting alloys. Further improvement
through the heat treatment in case of machinery elements from these alloys concerns the 3xx.x series of the alloy (AlSi-Cu/Mg and Al-Si-Cu-Mg).
N. Abu-Dheir et al. [2] studied about the silicon morphology modification in the eutectic AlSi
alloy under mechanical mold vibration. The microstructure responsible is 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 by exceeding a critical value of vibration amplitude, the
silicon tends to coarsen.
W. Jiang et al. [3] found the refinement of microstructure mainly through chemical elements modification,
electromagnetic vibration, ultrasonic vibration, and mechanical vibration.
F. Taghavi et al.[4] state that mechanical vibration is possible to be a simple, economic and effective method to refine
the microstructure and improve mechanical properties ,which was first applied on the steel by Chernov..
InASTM[5],it is given that the major phase in as cast microstructure of Al-Si alloys are large size grains and primary
-Al, acicular eutectic Si, and other harmful intermetallic phases such as needle like -Al5FeSi,with uncontrolled and
unevenly distributed porosities etc.
According to Mishra S.S. et. al.[6],mechanical and metallurgical properties of Al-Cu alloy casting improved by mold
vibration andtheyshowed that significant grain refinement and remarkable improvement in hardness of casting occurs
with mechanical mold vibration as compared to without vibration.
Kumar P. Sujith et al.[7] observed the effect of vibration during solidification and cooling conditions (air and furnace
cooling atmosphere) on gravity die cast A356 aluminum alloy and found the significant change in SDAS and
reduction in porosity in casting solidified under mold vibration and air cooling as compared to furnace cooling.
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2. EXPERIMENTAL PROCEDURE
The A356 aluminum alloy was melted in a graphite crucible ina pit furnace. It is taken out and degassed using the
required quantity of degassing powder of HexaChloro Ethane in order to remove the dissolved hydrogen gas.
Aluminum alloys will absorb or dissolve harmful quantities of hydrogen from atmosphere during melting and pouring.
If the molten metal reaches the approximate pouring temperature (700C), subsequent cooling and solidification will
result in gas evolution, pinholes, and microscopic gas porosity. So degassing is performed to minimize these defects.
The presence of oxides and coal ash in the surface of the molten metal are skimmed. Then the molten metal is poured
into the mold cavity at a temperature approximately of 700 C.During the solidification of casting mold were oscillated
at different frequencies (0 Hz,100 Hz,200Hz 300Hz and 400Hz) at amplitude of 10m of vibration with the help of an
oscillator/ power amplifier and vibration exciter. Test specimens for tensile test, impact test, hardness test and
microstructure examinations were made from castings prepared under oscillatory ,non- oscillatory conditions and with
heat treatment also .Test specimens were T6 heat treatedand had a sequence of four hour of solutionising (540 C and
515 C), quenching in water (temperature of 60 C) and artificial aging at 160 C for four hours. Test specimens were
tested for tensile test, hardness test, impact test and microstructure examination was carried out
3. RESULT AND DISCUSSIONS

3.1 Microstructure
Photograph of Optical microstructure of stationary and stationary heat treated,oscillatory and oscillatory heat-treated
alloys are shown in Figs.2(a,b,c).In the as cast microstructure of castingunder stationary condition acicular silicon
particle and dendrite was found.When mold oscillation increases during the solidification, eutectic silicon phase
become coarser, morphology of silicon particle change from faceted to more roundsand broken of dendrites as shown in
[Fig. 2 a (ii-v)]. Two treatment temperature 515C and 540 C was used .When solutioning temperature is 515 C [fig.
2 b (i-v)], no obvious change in the morphology of silicon particle and eutectic silicon phase because of eutectic
silicon can be found at or close to eutectic temperatureof Al-Si alloy.But when solutioning temperature 540 C i.e. just
near to the eutectic temperature of A356 aluminum alloy, dendrite structure is gradually broken along with coarsening
of aluminum grains as shown in fig. 2 c (i-v).In general we conclude that melt treatment(oscillated) of alloy, the
coarsening of silicon particles is clearly visible and further, heat treatment of the alloy leads to spheroidisation of
eutectic silicon. Solutionizing temperature near eutectictemperature enhances the distribution and refinement of
eutectic silicon particles.
Figure 1: Photograph of Optical Microstructure samples A356 alloy under (a) as-cast and vibrated modified, (b) T6
Heat Treatment at solutioning Temperature 515 C, (c) T6 Heat Treatment at solutioning Temperature 540 C
3.2 SEM Study of Tensile Fracture Surfaces:
Tensile fracture surfaces were observed by Scanning Electron Microscope (SEM) to identify the type of fracture of
A356 aluminum alloy in different casting conditions. Photograph of tensile fracture surface under different frequencies
of vibration of mold (melt treatment) during solidification of casting and post heat treatment are shown in Figure 2.
The SEM images of the tensile fracture surface of as cast under stationary condition (fig 2-a) exposes faceted, brittle
appearance of silicon particle and black area form where hard second phase particle seem to have been pulled out
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ISSN 2321-6441
during tensile loading.Fine dimples and intergranular decohesion fracture surfaces are also visible.This shows the
mixed mode of fracture. Cleavage formation may be attributed to the presence of acicular silicon needles and hard and
brittle Mg2Si phase. The SEM images (fig 2 -b) of the tensile- fractured surface of oscillated and heat treated alloy
reveals cleavage fracture along with fine dimples. The smooth, shiny area and dimples patterns indicate a tendency
near to ductile rupture. In the heat treated SEM images (fig 2-c) of tensile- fracture surface of stationary as cast as well
as oscillated mostlyrevels fine dimples than as cast and melt treated (oscillated) with few cleaves facets. This indicates
that good plastic deformation has taken place prior to fracture i.e. ability of matrix to deform plastically has increased.
Solidification
Conditions
Heat
treatment
Under
Stationary Condition
At
frequency=100 Hz
At
frequency=200 Hz
At
frequency=300 Hz
At
frequency=400 Hz
As Cast
(a)
T-6
515C
(b)
at
T-6
540C
(c)
at
Figure 2: SEM photograph of tensile fracture surfaces of A356 alloy under (a) as-cast and vibrated modified, (b) T6
Heat Treatment at solutioning Temperature 515 C, (c) T6 Heat Treatment at solutioning Temperature 540 C.
3.3Mechanical Properties
The variation of combined frequency and heat treatment is show in fig 3(a-d). It is observed that the ultimate tensile
strength, yield strength , hardness and ductility of A356 alloys increases with increase in mold vibration up to 400 Hz.
Beyond 400Hz the improvement properties are insignificant for the range of values used.On heat treatment at
twodifferent solutioning temperature thetensile strength and hardness increases more due to change in silicon
morphology and existence of hard silicon particles. The increase in ductility of the oscillated alloy after heat treatment
may be endorsed to the spheroidisation of silicon crystals because stress required for nucleating avoid or crack at a
particle matrix interface would increase with this morphology. The results indicate that percentage increment in tensile
strength, yield strength, elongation and hardness are 32% ,18%, 41.6% and 36.5% respectively with oscillated than
without oscillated of as cast. These mechanical properties also increased by heat treatment, the results combined with
heat treatment effect, the percentage increments in tensile strength, yield strength, elongation and hardness are 37%,
88%, 170.8% and 75% respectively and decrement in grain size up to 58%.
40
30
% in c r e m e n t A s C a s t
0
% in c r e m e n t T 6 -5 1 5 C
0
% in c r e m e n t T 6 -5 4 0 C
Y S (A s C as t)
Y S (T 6 -5 1 5 C )
Y S (T 6 -5 4 0 C )
% Increment(YS)
% Increment (UTS)
30
20
20
10
10
0
-5 0
50
100
150
200
250
300
350
400
Freq ue ncy(H z)
(a) Frequency Vs. Percentage increment in UTS
450
0
-5 0
50
100
15 0
200
25 0
3 00
350
40 0
4 50
F re q u e n c y (H z )
(b) Frequency Vs. Percentage increment in YS
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ISSN 2321-6441

60
80
Hadrdness(As Cast)
0
Hadrdness(T 6- 515 C)
0
Hadrdness(T 6- 540 C)
50
60
% Decrement in Grain Size
% Increment in Hardness
70
% D ecremen t in G rain S ize(As C ast)

0
% D ecremen t in G rain S ize (T 6-515 C )
0
% D ecremen t in G rain S ize (T 6-540 C )
50
40
30
20
40
30
20
10
10
0
-50
50
100
150
200
250
300
350
400
-50
450
50
100
150
200
250
3 00
350
400
450
Freq uen cy(H z)
Frequency(Hz)
(c) Frequency Vs. Percentage increment in Hardness

180
% Increm ent in E longartio n(As C ast)

0
% Increm ent in Elon gartion (T6-515 C )
0
% Increm ent in Elon gartion (T6-540 C )
160
% Increment in Elongartion
(d) Frequency Vs. Percentage increment in G.S.
140
120
100
80
60
40
20
0
-50
50
1 00
150
200
250
3 00
350
400
4 50
Freq uen cy(Hz)
(e) Frequency Vs. Percentage increment in Elongation
Figure 3:Combined effect of frequency of vibration and T6 heat treatment on Mechanical Properties(a) Percentage
increment in UTS, (b) Percentage increment in Yield Strength (c) Percentage increment in Hardness (d) Percentage
increment in Yield Strength,(e) Percentage increment in elongation
4. CONCLUSION
Experimental Results obtained during the course of investigations and testing. The results pertain to the casting of
A356 aluminum alloy at different frequency of vibratory mold during the solidification and followed by T6 heat
treatment. The frequency varied from 0 Hz to 400 Hz and amplitude of oscillation 10 m .Two solutionizing
temperature 515 C and 540 C for four hour ,quench in water of temperature 60C and lastly 160 C artificial ageing
for four hour use.
1. It is observed that the ultimate tensile strength, yield strength, hardness and ductility of A356 alloys increases
with increase in mold vibration.
2. Appling the T6 heat treatment to testing sample of casting was effective in grain refinement and further
increasing the mechanical properties than vibrating casting and without vibration.
3. I found eutectic silicon phase become coarser, morphology of silicon particle change from faceted to more round
and broken of dendrites with increase of vibration.
4. Heat treatment of the alloy leads to spheroidisation of eutectic silicon.
5. The SEM of tensile fractography consists of faceted as well as dimples which indicate the tensile specimen
failed in a quasi-cleavage.
6. The SEM tensile- fracture surface of melt treated (vibrated) fraction of fine dimples more than as cast with few
cleaves facets. This indicates that ability of matrix to deform plastically has been increased.
7. In the heat treated SEM images of tensile- fracture surfacemostly revels fine dimples than as cast and melt
treated (vibrated) with few cleaves facets. This indicates that good plastic deformation has taken place prior to
fracture i.e. ability of matrix to deform plastically has increased than before heat treated.
8. T6 heat treatment (ST: 540 C) out of two solutioninsing temperature (515 C and 540 C) is found to be
much significant among all combination the vibratory casting as well as stationary casting.
9. Apart from the heat treatment, the process mythology used for casting has significant influence on mechanical
as well as metallurgical properties.
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ISSN 2321-6441
REFERENCE:
[1.] J. Pezda, Effect of Shortened Heat Treatment on Change of the Rm Tensile Strength of the 320.0 Aluminum Alloy,
Arhives Of F o u n d r y E n g i n e e r i n g, ISSN (1897-3310) Volume 15 Issue 1,2015
[2.] Numan Abu-Dheir and Marwan Khraisheh, Kozo Saito, Alan Male Silicon morphology modification in the
eutectic AlSi alloy using mechanical mold vibration, Materials Science and Engineering, vol. 393 pp.109
117,2005.
[3.] W. Jiang et al, Combined effects of mechanical vibration and wall thickness on microstructure and mechanical
properties of A356 aluminum alloy produced by expendable pattern shell casting, Materials Science &
Engineering A 619,pp. 228237,2014..
[4.] Taghavi, F., Saghafian, H., & Kharrazi, Y. H.,Study on the effect of prolonged mechanical vibration on the grain
refinement and density of A356 aluminum alloy. Materials & Design, 30(5),pp.1604-1611,2009.
[5.] ASTM Aluminum and Magnesium Alloys Annual (Volume 02.02), ASTM standards, 2006.
[6.] Mishra S.S. et. al.,Effect of mold vibration on mechanical and metallurgical properties of al-cu alloy,
International Journal For Technological Research In Engineering, Volume 3, Issue 1, ISSN(online):23474718,September-2015,
[7.] Kumar P. Sujith et al., Solidification under Mechanical Vibration: Variation in Metallurgical Structure of
Gravity Die Cast A356 Aluminium Alloy,International Conference on Frontiers in Mechanical Engineering,2022nd May,2010, NITK India.
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Effects of T6 Heat Treatment On Mechanical Properties of A356 Alloy Castings Prepared Under Oscillatory Conditions

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Effects of T6 Heat Treatment On Mechanical Properties of A356 Alloy Castings Prepared Under Oscillatory Conditions

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IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

A Publisher for Research Motivation........

Volume 4, Issue 2, February 2016