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AFS Transactions 2010 American Foundry Society, Schaumburg, IL USA
F.H. Samuel
Universit du Qubec Chicoutimi, Chicoutimi (QC), Canada
Center of Excellence for Research in Engineering Materials, King Saud University, Riyadh, Saudi Arabia
H.W. Doty
General Motors Powertrain Group, Metal Casting Technology, Inc., Milford, New Hampshire
Copyright 2010 American Foundry Society
ABSTRACT
INTRODUCTION
Aluminum-copper based alloys containing Si and Mg are
used for the manufacturing of vehicle and airplane parts
because of their superior mechanical properties,
castability, weldability and machinability. As in most
aluminum alloys, the mechanical properties of Al-Cu-MgSi alloys can be improved through the use of various
metallurgical parameters including melt treatment,
alloying element additions and heat treatment. The
machinability of such alloys can be metallurgically
improved so that the chips would flow freely from their
cast specimens during machining operations. The present
work was undertaken to study the effects of additives on
the microstructures and tensile properties of a new Al-Cu
based alloy intended for free-machining automotive
castings. The additives in question include Sr, TiB2, Zr,
39
40
Table 1. Nominal Composition and Codes for the Alloys Prepared in the Present Study
Group I
Alloy
Code
A
A1
A2
A3
A4
Group II
Composition
Base alloy
A + Sr
A + 0.10%Ti
A + Sr + 0.10%Ti
A + 0.10%Ti + 0.20%Zr
Alloy
Code
A3
A31
A32
A33
Group III
Alloy
Code
A4
A41
A42
A43
Composition
A + Sr + 0.10%Ti
A3 + 0.20%Fe
A3 + 0.20%Fe + 0.2%Mn
A3 + 0.50%Ag
Composition
A + 0.10%Ti + 0.20%Zr
A4 + 0.15%Sn
A4 + 0.50%Bi
A4 + 0.15%Sn + 0.50%Bi
Si
1.32
1.28
1.23
1.23
1.28
1.22
1.17
1.21
1.33
1.26
1.24
Mg
0.42
0.42
0.40
0.40
0.41
0.40
0.39
0.39
0.43
0.45
0.47
Fe
0.58
0.58
0.61
0.52
0.61
0.84
0.82
0.57
0.63
0.52
0.45
Mn
0.59
0.60
0.61
0.60
0.58
0.59
0.79
0.60
0.59
0.61
0.61
Sr
0.000
0.013
0.000
0.011
0.000
0.014
0.010
0.010
0.000
0.000
0.000
Ti
0.07
0.08
0.15
0.16
0.15
0.16
0.18
0.16
0.16
0.18
0.17
Zr
0.00
0.00
0.00
0.00
0.20
0.00
0.00
0.00
0.20
0.20
0.20
Ag
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.50
0.00
0.00
0.00
Sn
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.22
0.00
0.24
Bi
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.51
0.55
Al
bal.
bal.
bal.
bal.
bal.
bal.
bal.
bal.
bal.
bal.
bal.
41
METALLOGRAPHY
For metallographic observations, 25 x 25 mm samples
were cut from the castings prepared for this purpose and
mounted in bakelite. The samples were ground and
polished to the desired fine finish on 9, 6, 3 and 1 m
diamond lap wheels. The microstructures were examined
by means of an electron probe micro-analyzer (EPMA)
and an optical microscope. The grain-size measurements
were carried out using a Clemex image analyzer in
conjunction with the optical microscope. The grain size
was obtained from the average of 200 measurements
taken over 20 fields (10 measurements per field) at 100x
magnification for each alloy sample. Volume fraction of
the intermetallic phases was quantified using the electron
probe micro-analyzer with built-in software for such
measurements, based on phase brightness. The
quantification process is based on the elimination
technique which calculates the volume fraction of each
phase by subtracting the volume fraction of the brighter
phases from the total volume fraction of the other phases
that are present within the matrix. For each case, 15 fields
were measured at 100X magnification.
TENSILE TESTING
The tensile test bars were pulled to fracture at room
temperature at a strain rate of 4 x 10-4/s, using a
Servohydraulic MTS Mechanical Testing machine. An
extensometer with a 50.8 mm (2 in) gage length was
attached to the test bar to measure percentage elongation
as the load was applied. The tensile properties, namely
yield stress (YS) at a 0.2% offset strain, ultimate tensile
Al2Cu
AlCuMgSi
-Fe
42
Al2Cu
Al2Cu
-Fe
-Fe
AlCuMgSi
Al2Cu
(a)
(b)
Fig. 2. Micrographs obtained from: (a) the unmodified base A alloy; and (b) the Sr-modified A1 alloy
in as cast condition.
(a)
(b)
Fig. 3. Micrographs obtained from: (a) A alloy; and (b) A4 alloy in as cast condition.
43
-Fe
-Fe
Al2Cu
-Fe
Al2Cu
Al2Cu
Al2Cu
(b)
-Fe
(a)
(b)
Fig. 4. Micrographs obtained from: (a) A31alloy; and (b) A32 alloy in as cast condition.
(a)
(b)
Bi
TiB2
ZrTi
Bi
Al2Cu
Bi
-Sn
Fig. 5. High magnification backscattered images obtained from: (a) Sn-containing A41 alloy;
and (b) Bi-containing A42 alloy in as cast condition.
(a)
(b)
Fig. 6. Higher magnification backscattered images obtained from T6-treated A41 alloy showing:
(a) morphology of Mg2Sn; and (b) resolidified -Sn particle which had undergone incipient melting.
-Fe
44
TENSILE PROPERTIES
Effects of Melt Treatment (Alloying Group I)
The effects of melt treatment on the tensile properties of
Alloying Group I are shown in Fig. 9a for the as cast
condition, and in Figs. 10 and 11 for the 180C (356F) and
220C (428F) aged conditions, respectively. These aging
temperatures refer to the T6 and T7 tempers. (Here, it ought
to be noted that, with respect to Figs. 10 and 11 (as well as
Figs. 12-15), the Y-axis scales have been plotted according
to the maximum/minimum values noted in each case to
facilitate separation of the curves). It can be observed that
the Sr-containing A1 alloy did not exhibit any noticeable
change in the strength properties in the as cast and heat
treated conditions, compared to the base A alloy. The
improvement in the ductility of A1 alloy, especially in the
as cast condition, can probably be ascribed to the role of Sr
in refining the morphology of the -Fe script phase
appearing in the alloy microstructure.
Volum e Fraction %
5
4
3
2
1
0
A
A1
A2
A3
A4
A31
A32
A33
A41
A42
A43
Alloy
As-Cast
SHT
Fig. 8. Effect of solution heat treatment on the volume fraction (%) of copper and iron intermetallic phases.
45
250
4.50
225
4.00
200
3.50
%El
175
150
3.00
125
100
2.50
75
50
2.00
A
A1
A2
A3
Alloy
(a)
YS
UTS
%El
A4
A = base alloy
A1 = A + Sr
A2 = A + 0.10%Ti
A3 = A + Sr + 0.10%Ti
A4 = A + 0.10%Ti + 0.20%Zr
250
4.50
225
4.00
175
3.50
%El
200
150
3.00
125
100
2.50
75
50
2.00
A3
A31
A32
Alloy
(b)
YS
UTS
%EL
A33
A3 = A + Sr + 0.10%Ti
A31 = A3 + 0.20%Fe
A32 = A3 + 0.20%Fe + 0.20%Mn
A33 = A3 + 0.50%Ag
250
4.50
225
4.00
175
3.50
%El
200
150
3.00
125
100
2.50
75
50
2.00
A4
(c)
A41
A42
Alloy
YS
UTS
%El
A43
A4 = A + 0.10%Ti + 0.20%Zr
A41 = A4 + 0.15%Sn
A42 = A4 + 0.50%Bi
A43 = A4 + 0.15%Sn + 0.50%Bi
Fig. 9. Tensile properties in as cast condition: (a) Alloying Group I, (b) Alloying Group II and (c) Alloying Group III
46
340
320
300
280
YS (MPa)
260
240
220
200
A = base alloy
180
A1 = A + Sr
160
A2 = A + 0.10%Ti
A3 = A + Sr + 0.10%Ti
140
A4 = A + 0.10%Ti + 0.20%Zr
120
0
(a)
8
12
Aging Time (hrs)
16
20
24
48
380
360
UTS (MPa)
340
320
300
A = base alloy
280
A1= A + Sr
A2 = A + 0.10%Ti
260
A3 = A + Sr + 0.10%Ti
A4 = A + 0.10%Ti + 0.20%Zr
240
0
(b)
8
12
Aging Time (hrs)
16
20
24
48
A = base alloy
6.5
A1 = A + Sr
A2 = A + 0.10%Ti
5.5
A3 = A + Sr + 0.10%Ti
A4 = A + 0.10%Ti + 0.20%Zr
% El
4.5
3.5
2.5
1.5
0.5
(c)
8
12
Aging Time (hrs)
16
20
24
48
Fig. 10. Variations in tensile properties of Alloying Group I after aging at 180C (356F): (a) YS, (b) UTS and (c) %El
47
320
300
A = base alloy
280
A1 = A + Sr
260
A2 = A + 0.10%Ti
A3 = A + Sr + 0.10%Ti
YS (MPa)
240
A4 = A + 0.10%Ti + 0.20%Zr
220
200
180
160
140
120
100
0
(a)
8
12
Aging Time (hrs)
16
20
24
48
340
A = base alloy
320
A1 = A + Sr
A2 = A + 0.10%Ti
A3 = A + Sr + 0.10%Ti
300
UTS (MPa)
A4 = A + 0.10%Ti + 0.20%Zr
280
260
240
220
200
(b)
8
12
Aging Time (hrs)
6.5
16
20
24
48
A = base alloy
A1 = A + Sr
A2 = A + 0.10%Ti
5.5
A3 = A + Sr + 0.10%Ti
A4 = A + 0.10%Ti + 0.20%Zr
% El
4.5
3.5
2.5
1.5
0.5
(c)
8
12
Aging Time (hrs)
16
20
24
48
Fig. 11 Variations in tensile properties of Alloying Group I after aging at 220C (428F): (a) YS, (b) UTS and (c) %El
48
49
340
320
300
280
260
YS (MPa)
240
220
200
180
A3 = A + Sr + 0.10%Ti
160
A31 = A3 + 0.20%Fe
140
120
A33 = A3 + 0.50%Ag
100
0
(a)
8
12
Aging Time (hrs)
16
20
24
48
360
340
UTS (MPa)
320
300
280
260
A3 = A + Sr + 0.10%Ti
A31 = A3 + 0.20%Fe
240
220
0
(b)
8
12
Aging Time (hrs)
16
20
24
48
7.5
A3 = A + Sr + 0.10%Ti
6.5
A31 = A3 + 0.20%Fe
A32 = A3 + 0.20%Fe + 0.20%Mn
A33 = A3 + 0.50%Ag
5.5
% El
4.5
3.5
2.5
1.5
0.5
(c)
8
12
Aging Time (hrs)
16
20
24
48
Fig. 12. Variations in tensile properties of Alloying Group II after aging at 180C (356F): (a) YS, (b) UTS, and (c) %El
50
300
280
A3 = A + Sr + 0.10%Ti
A31 = A3 + 0.20%Fe
260
YS (MPa)
240
220
200
180
160
140
120
100
0
(a)
8
12
Aging Time (hrs)
16
20
24
48
340
A3 = A + Sr + 0.10%Ti
320
A31 = A3 + 0.20%Fe
A32 = A3 + 0.2%Fe + 0.20%Mn
UTS (MPa)
300
A33 = A3 + 0.50%Ag
280
260
240
220
200
0
(b)
12
16
20
24
48
7.5
A3 = A + Sr + 0.10%Ti
6.5
A31 = A3 + 0.20%Fe
A32 = A3 + 0.20%Fe + 0.20%Mn
A33 = A3 + 0.50%Ag
5.5
% El
4.5
3.5
2.5
1.5
0.5
(c)
12
16
20
24
48
Fig. 13. Variations in tensile properties of Alloying Group II after aging at 220C (428F): (a) YS, (b) UTS, and (c) %El
51
340
320
300
280
YS (MPa)
260
240
220
200
180
A4 = A + 0.10%Ti + 0.20%Zr
160
A41 = A4 + 0.15%Sn
140
A42 = A4 + 0.50%Bi
120
100
0
(a)
8
12
Aging Time (hrs)
16
20
24
48
380
360
340
UTS (MPa)
320
300
280
260
A4 = A + 0.10%Ti + 0.20%Zr
240
A41 = A4 + 0.15%Sn
A42 = A4 + 0.50%Bi
220
200
0
(b)
8
12
Aging Time (hrs)
16
6.5
20
24
48
A4 = A + 0.10%Ti + 0.20%Zr
A41 = A4 + 0.15%Sn
A42 = A4 + 0.50%Bi
5.5
% El
4.5
3.5
2.5
1.5
0.5
(c)
8
12
Aging Time (hrs)
16
20
24
48
Fig. 14. Variations in tensile properties of Alloying Group III after aging at 180C (356F: (a) YS, (b) UTS, and (c) %El
52
320
300
A4 = A + 0.10%Ti + 0.20%Zr
A41 = A4 + 0.15%Sn
280
A42 = A4 + 0.50%Bi
260
YS (MPa)
240
220
200
180
160
140
120
100
80
0
(a)
8
12
Aging Time (hrs)
16
20
24
48
340
A4 = A + 0.10%Ti + 0.20%Zr
320
A41 = A4 + 0.15%Sn
A42 = A4 + 0.50%Bi
UTS (MPa)
300
280
260
240
220
200
0
(b)
8
12
Aging Time (hrs)
6.5
16
20
24
48
A4 = A + 0.10%Ti + 0.20%Zr
A41 = A4 + 0.15%Sn
A42 = A4 + 0.50%Bi
5.5
% El
4.5
3.5
2.5
1.5
0.5
(c)
8
12
Aging Time (hrs)
16
20
24
48
Fig. 15. Variations in tensile properties of Alloying Group III after aging at 220C (428F): (a) YS, (b) UTS, and (c) %El.
53
7.
ACKNOWLEDGMENTS
Financial assistance received from the Natural Sciences
and Engineering Research Council of Canada (NSERC)
and General Motors Powertrain Group (U.S.A.) is
gratefully acknowledged.
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CONCLUSIONS
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