Abstract
The possibility of replacing the piston eutectic alloy of the Al-Si-Cu system AK12M2MgN, which was produced at OJSC "Zaporizhsky Aluminum Combine" from primary aluminum, with AK12M2MgNZH with an increased iron content, which will allow expanding the raw material base of production due to the use of scrap and waste. It is proposed to solve this problem by introducing into the technological process of processing the melt with a unipolar pulsed electric current during pouring according to specially developed modes. To investigate this possibility, experiments were conducted on the effect of electric current on the microstructure, phase composition of AK12M2MgN and AK12M2MgNZH alloys and their mechanical properties at temperatures of 20 oC and 300 oC. The melt was treated with an electric current in the following modes: electric current density (j) 100 - 400 A/cm2, pulse frequency (ν) 50 - 2000 Hz. The phase composition of alloys is considered. It is shown that the main iron-containing phase of the AK12M2MgN alloy is (Fe,Mn)3Si2AI15 (α) in the form of branched eutectic crystals. The acicular β-FeSiAI5 phase is practically absent. Unlike AK12M2MgN, the composition of AK12M2MgNZH alloy includes β-FeSiAl5 intermetallic and primary coarse crystals of (Fe,Mn)3Si2AI15 phase. After treatment of alloys in the liquid state with pulsed electric current in different modes, their microstructure and phase composition change significantly. The degree of differentiation of eutectic components increases. In particular, the linear size of eutectic silicon crystals, depending on the density and frequency of the electric current, decreases by 2-3 times. Primary crystals of the intermetallic (Fe,Mn)3Si2Al15 are formed in the AK12M2MgN alloy, which in cross-section have the appearance of compact, close to globular crystals. X-ray spectral studies have shown that despite the same crystallographic structure, eutectic and primary crystals of the (Fe,Mn)3Si2Al15 phase differ in the higher concentration of iron, manganese, copper and nickel in the latter. In the composition of the AK12M2MgNZH alloy, there is practically no acicular intermetallic β-FeSiAl5, the formation of which is one of the main reasons for the decrease in mechanical properties. Similar to the AK12M2MgN alloy, compact crystals of the primary phase (Fe,Mn)3Si2Al15 and a significant amount of the π-FeMg3Si6Al8 phase appear. Such structural changes ensured an increase in the mechanical properties at 20 and 300 oC of both the AK12M2MgN alloy and AK12M2MgNZH. The highest properties of both alloys are achieved at j = 100 A/cm2; ν = 1000 ‒ 2000 Hz. The characteristics of mechanical properties increase from 25 % to 40 %. The structural and phase changes caused by the processing of the AK12M2MgNZH melt with an electric current according to experimentally established modes provide it with mechanical properties at the level of the AK12M2MgN alloy with several higher heat resistance indicators. In addition, treatment of the melt with electric current allows to reduce the consumption of sodium-potassium fluxes by 15-50%; time of heat treatment for T1 from 10-12 hours. up to 2-3 hours.
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