PECULIARITIES OF USING HEREDITARY PROPERTIES OF MELTING STOCK WITH HIGH IRON CONTENT TO OBTAIN HIGH QUALITY AL-SI CASTING ALLOY

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1 PECULIARITIES OF USING HEREDITARY PROPERTIES OF MELTING STOCK WITH HIGH IRON CONTENT TO OBTAIN HIGH QUALITY AL-SI CASTING ALLOY Y. Dotsenko 1, V. Selivorstov 1, K. Borodianskiy 2, M. Zinigrad 2 1 Electrometallurgical Faculty, The National Metallurgical Academy of Ukraine, Dnepropetrovsk, Ukraine 2 Laboratory for Metal and Ceramic Coatings and Nanotechnology, Materials Research Center, Ariel University Center, Ariel, Israel Abstract High iron content in Al-Si alloys results in material deterioration of mechanical properties and performance of castings. Iron-containing phases (FeAl 3, Al 2 SiFe, Al 4 Si 2 Fe, Al 5 SiFe, etc.) normally have a coarse grain structure, which negatively affects to alloy's elongation. Such negative impact of iron on alloy properties can be neutralized, in case ironcontaining phases have a compact form, as can be achieved by alloying, inoculation, and external influence to the melt (such as electric and magnetic fields, high temperature superheating, or ultrasound) [1-12]. Numerous experimental and theoretical studies of melt influence during crystallization and melting prove that these contribute to fine formation of structural components of alloys while improving their technological and mechanical properties. Introduction Iron is hardly soluble in aluminum, with a new FeAl 3 phase emerging at the thousandth of a percent level at low temperatures. Since recently, this phase has been regarded among the factors of stability and heredity of cast formation of aluminum and its alloys, so that its dendritic structure can be seen regardless of a huge plastic deformation (50-90%) and subsequent recrystallization annealing. Iron decreases conductivity and chemical stability of aluminum and its alloys. By interacting with silicon in aluminum alloys, it forms a Chinese character-shaped eutectic microstructure in the solid solution, which is based on aluminum and FeSiAl 5 crystals. To neutralize negative impact of iron, alloys are alloyed by Mn, Be, Cr, Cr, V, Ni, and other transition metals to inhibit -phase formation and facilitate the release of more complex phases (Al-Mn-Fe-Si) and (Al 7 Fe 3 Be 7 ), which are solidifying in a compact form. For example, Be 3 SiFe phase has a round shape, and phase Al 8 Si 6 Mg 3 Fe being released as fine skeletal-like veinlets [1, 4, 5]. Electric treatment of alloys ranks among most promising methods of influence on ironcontaining phases morphology during crystallization. However, the nature of physical and chemical effect of the current on crystallization is not clear enough both in terms of theory and experimental studies. Available information is inconsistent and often contradicting [4]. In industrial conditions, preventive measures are taken to rule out the contact between steel and cast-iron melting and casting tools on the one hand, and aluminum alloy melt and its saturation with iron on the other hand. The major problem here is to obtain a high-quality coating of steel and cast-iron melting crucibles, i.e., is to ensure an adequate duration and mechanical strength of coating. Special-purpose compounds and their production methods have been developed to rule out the contact with steel and cast-iron crucibles [5]

2 Iron-containing phases have covalent atomic bonds which accounts for their directivity in crystallization. To reduce anisotropy of valence electron stress fields in nucleants that emerge during crystallization, the nature of atomic interaction shall be changed [1]. One of the methods of changing the shape and the size of inclusions with covalent atomic bonds is to introduce additives to the melt. While dissolving in the growing crystal, their atoms are weakening covalent component of atomic bonding, thereby reducing directivity effect of the crystal on the adjacent liquid phase. Alloying of the melt by Mn, Cr and Mo, and its further treatment with chalcogen elements (S, Se, Tl), result in refinement of ironcontaining phases [1]. Modification of iron-containing phase by S or Tl at the ratio of Fе:Мn 2:1, helps increase the amount of hexagonal lattice phase, while somewhat changing its parameter, with the inclusions being close to regular polyhedrons, and S and Tl additives concentrating in compact inclusions of H phase. Morphology of crystallizing phases can be effectively changed by solidifying process in a highly non-equilibrium conditions [3]. This creates conditions for grain refinement, much higher solubility in a solid state, and growth inhibition of primary intermetallides coarse inclusions. This solidification method is therefore efficient in removing primary coarse ironcontaining phases. Moreover, these can serve as a strengthening phase, if formed as finely dispersed particles. The aim of the present work is the investigation of a complex treatment technology influence on the structure and mechanical properties of Al A356 cast alloy with high iron content. Results and Discussion Production tests were conducted as follows: an Al A356 was melted in electric resistance furnace and poured into a casting mold (heated up to 523 o К) at 993 o К. Three cylindrical specimens (500 mm high, 150 mm diameter) produced as follows: 1 - no treatment at all; or 2 - prior deformation of ingot (deformation degree of 25%) at 573 o К; or 3 - prior deformation of ingot (deformation degree of 25%) at 573 o К with addition of 0.2% of modifier. The chemical composition of the Al A356 alloy is shown in Table 1. Table 1. Chemical composition of A356 alloy. Si Mg Ti Fe Mn Al Bal. The obtained alloy microstructures are shwen in Figures

3 Figure 1: Microstructure of non-modified A356 alloy. Magnification 106. Figure 2: Microstructure of modified A356 alloy deformed before production. Magnification

4 Figure 3: Microstructure of modified A356 alloy deformed and modified before production. Magnification 106. Microstructure of non-treated specimen contains solid aluminum solution Al, eutectics Al +Si, and (AlFeMnSi) phase. Casting structure mostly features a great variability of grain size, which is reduced to minimum by treatment using deformation or deformation with modification. Primary crystal grain size in the solid solution decreased from 0.18 to 0.1 m after deformation treatment and from 0.18 to 0.06 m after deformation and modification. Shape and size of (AlFeMnSi) phase have also changed considerably. While treated, (AlFeMnSi) phase has acquired an almost spherical shape, which is especially pronounced after addition of the modifier. Table 2 shows test results on determining mechanical properties of A356 alloy, as produced by using the treatment technology. Table 2. Mechanical properties of A356 alloy before and after treatment. Treatment Tensile Strength [MPa] Elongation [%] Hardness [HB] Before treatment Treatment by deformation Treatment by deformation and modification Table 2 proves that complex treatment allows improving mechanical properties of castings by 10-12% after deformation, and by 20-30% after deformation and modification. CONCLUSIONS Impact of complex technology on the shape and size of structural components and on mechanical properties of Al A356 alloy with high iron content, while chilling, have been studied

5 This study allowed to change shape and size of iron-containing phase, and to improve mechanical properties by 10-30%. Complex treatment that included deformation of charging material, inoculation, and crystallization in non-equilibrium state decreased the negative effect of iron and, accordingly, improves performance of cast materials. REFERENCES 1. Nemenenok B.M.: Theory and Practice of Complex Modification of Silumins. Technoprint Publishing House Availability of Long Acting Complex Inoculator to Improve Quality of Aluminum Alloy Castings: New Machine-Building Materials and Technologies Collected Papers of IV International Scientific Conference. Bryansk: BGITA Selivorstov V.Yu., Dotsenko Yu.V.: Potential Use of Combined Cast Metal Structure Formation Control Methods. DDMA Newsletter 2009 (15) Smirnov A.N., Pilushenko V.L., Momot S.V., Amitan V.N.: Crystallization of External Effect-Exposed Metal Melt. VIK Publishing House Efimov V.A., Eldrakhanov A.S.: Physical Influence on Alloy Crystallization Process. Metallurgia Kalinichenko A.S., Bergman G.V.: Controlled Targeted Solidification and Laser Treatment: Theory and Practice. Technoprint Publishing House Dobatkin V.I., Eskin G.I., Borovikova S.I., Golder Yu.G.: Patterns of Aluminum Alloy Ingot Structure Formation at Continuous Casting with Ultrasound Treatment of Crystallizing Melt. Nauka Skvortsov A.A., Akimenko A.D., Ulyanov V.A.: Effects of External Influence on Ingot and Casting Formation Processes. Metallurgia Nikitin V.I., Nikitin K.V.: Heredity of Cast Alloys. Mashinostroenie-1, 2-nd Ed Nikitin V.I.: Perspectives of Using Gene Technologies in Alloys. Liteinoe Proizvodstvo (1) Nikitin V.I.: Heredity and Gene Engineering in Alloys. Liteinoe Proizvodstvo (10) Nikitin V.I.: On Using Gene Engineering in Non-Ferrous Alloys. Non-Ferrous Metals (9)

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