Grain Refinement of Aluminum Alloys

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1 Grain Refinement of Aluminum Alloys Presented By SUBRATA SAHA

2 Objectives Whats and Whys? Grain Refinement is a process used for grain boundary strengthening of casting material. Aluminum alloys with ultra fine grain structure has received tremendous increase in research interest in various disciplines specially in automotive and aerospace industries for properties like low density and good castability. Grain refinement of Al and its alloys improve the mechanical properties of casting along with surface finish, soundness etc.

3 Grain Refining Effect a. Grain refiner added: fine, equiaxed structure; b. no grain refiner: coarse, columnar structure; c. no grain refiner: predominantly twinned columnar grains (feather grains) Source: Quested, 2004

4 Methods of Grain Refinement Methods of grain refinements used in casting process are mainly classified into following three groups Thermal method i.e. Cooling rate control Chemical method i.e. Grain size refiners addition Mechanical method i.e. agitation of melt during solidification

5 Grain Refinement Technology TiAl 3 nucleates aluminum grain Source: Backerud, 1983

6 Cooling Curve Cooling curve during solidification Source: Sigworth and Kuhn, 2008

7 Comparison of Effect of Grain Refinement Grain refining of A356 alloy by three master alloys Source: Lu, Wang and Kung, 1981

8 What s the Figure Says? TiAl 3 crystals are poor nuclei. TiB 2 particles are excellent nuclei. Mostly used AlB 2 is the best nucleus. Not Suitable for Industry.

9 Best Grain Refinement Practices Al-Si Alloys : like A356 and A357 best result by adding ppm of boron in the form of Al-5Ti-1B or Al-3Ti-1B rod. Al-Cu Alloys: for Al-4.5%Cu-0.5%Mn alloys best result by titanium less than 0.05% and adding ppm of boron as Al-5Ti-1B or Al-3Ti-B rod. Al-Si-Cu Alloys : like A319 alloys (Al-3%Cu-5.5%Si) best ppm of boron in the form of Al-5Ti-1B or Al-3Ti- 1B rod.

10 Best Grain Refinement Practices (Continued) Al-Zn-Mg Alloy: For these alloys best result found with 0.02 to 0.05% of titanium and addition of ppm of boron as Al-5Ti- 1B or Al-3Ti-1B rod. Al-Mg Alloys: like 535 alloys (Al-7%Mg) best result found with addition of 30 ppm B in the form of Al-3%Ti-1%B master alloy.

11 Benefit of Grain Refinement Process Major benefits: better distribution of Porosity. improved Feeding. improved Fluidity. improved Surface finish & Machinability. better mechanical properties

12 Future Work Development of a model to predict grain size in the presence of significant thermal gradient. Development of an economical viable method allowing tight control of the size distribution of inoculants particles present in the melt. This might be achievable via filtering of the molten maser alloys or by direct inoculation of ceramic Application of grain refinement theories to non-aluminum based system

13 References Arnberg, L., Backerud, L. and Klang, H. (1982). Grain refinement of aluminium-3. Evidence of metastable phase in Al-Ti (B) system. Metals technology, 9,1, Askeland, D. R., Fulay, P. P. and Wright, W. J. (2010). The science and engineering of materials, 6 th edition. Backerud, L. (1983). How does a good grain refiner work? Light metal age, 41, Chai, G. (1994). Dendrite coherency during equiaxed solidification in aluminum alloys. Chemical communications. Stockholm university, 1. Chai, G., Backerud, L. and Arnberg, L. (1995). Study of dendrite coherency in Al-Si alloys during equiaxed dendritic solidification. Materials research and advanced techniques, 86, 1, Cibula, A. (1949) Mechanism of grain refinement of sand castings in aluminum alloys. Institute of metals-journal, 76, 4, Cibula, A. and Ruddle, R.W. (1949) Effect of grain-size on tensile properties of high-strength cast aluminum alloys. Institute of metals-journal, 76, 4, Cibula, A. (1951) Grain refinement of aluminum alloy casting by additions of titanium and boron. Institute of metalsjournal, 80, 1, 1-16 Crossley, F. A. and Mondolfo, L. F. (1951) Mechanism of grain refinement in aluminum alloys. Journal of metals, 3, 12, Dahle, A.K., Tondel, P.A., Paradise, C.J. and Arnberg, L. (1996). Effect of grain refinement on the fluidity of two commercial Al-Si foundry alloys. Metallurgical and materials transactions A, 27A, 8, Easton, M. and StJohn, D. (1999). Grain refinement of aluminum alloys: Part-I. The nucleant and solute paradigms-a review of literature. Metalurgical and materials transactions, 30A Easton, M. and StJohn, D. (1999). Grain refinement of aluminum alloys: Part-II. Confirmation of, and a mechanism for, the solute paradigm. Metalurgical and materials transactions, 30A Johnsson, M., and Backerud, L. (1992). Nucleants in grain refined aluminum after addition of Ti- and B- containing master alloys. Zeitschrift fur metallkunde, 83, 11,

14 References Johnsson, M., Backerud, L. and Sigworth, G. K. (1993). Study of the mechanism of grain refinement of aluminum after additions of Ti- and B- containing master alloys. Metallurgical transactions A(physical metallurgy and material science), 24A, 2, Jones, G. P. (1985). Mechanism of nucleation of liquid aluminium by Al-Ti-B master alloys. Aluminium-verlag GMbH, Kaibyshev, R. O., Mazurina, I.A. and Gromov, D.A., (2006). Mechanisms of grain refinement in aluminum alloys in the process of several plastic deformation. Metal Science and heat transfer,48,2, Kashyap, K.T. and Chandrashekhar, T. (2001). Effects and mechanism of grain refinement in aluminum alloys. Bull. mater. sci.,24,4, Li, H., Sritharan, T., Lam, Y. M. and Leng, N. Y. (1997). Effects of processing parameters on the performance of Al grain refinement master alloys Al-Ti and Al-B in small ingots. Journal of materials processing technology, , Lu, H. T., Wang, L.C. and Kung, S. K. (1981). Grain refining in A356 alloys. J. chinese foundrymen s association, 29, Maxwell, I. and Hellawell, A. (1975). Analysis of the peritectic reaction with particular referancce to Al-Ti alloys. Acta Metallurgica, 23, 8, McCartney, D. G. (1989). Grain refining of aluminium and its alloys using inoculants. International material reviews, 34, 5, Mohanty, P.S. and Gruzleski, J.E. (1995). Mechanism of grain refinement of aluminum. Acta metallurgica et materialia,43, Pasciak, K. and Sigworth, G.K. (2001). Role of alloy composition in grain refining of 319 alloy. AFS transcations, 109, Quested, T. E. (2004). Understanding mechanisms of grain refinement of aluminium alloys by inoculation. Materials and science technology, 20,

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