Abstract
The impact of high shear melt conditioning on the morphology and distribution of Fe intermetallic compounds was investigated in the processing of recycled AA6111 alloy by the twin roll casting process.The optical and scanning electron microscope (SEM) micrograph studies were carried out on twin roll casting (TRC) and melt conditioning twin roll casting (MC-TRC) samples. The microstructural analysis showed fine and uniformly distributed Fe-rich intermetallic phases for MC-TRC strips compared with the TRC strips. There was a significant improvement in the mechanical properties of MC-TRC strips after applying melt conditioning. The as-cast MC-TRC samples showed 18.7%, 19.2% and 9.8% increases in elongation, yield strength and ultimate tensile strength, respectively, in the longitudinal direction, while in the transverse section, the MC-TRC samples showed 32.3%, 2.2% and 3.8% increases in elongation, yield strength and ultimate tensile strength, respectively.
Highlights
Iron is one of the unavoidable impurity elements that exist in primary or secondary aluminium alloys, and it is problematic in recycling aluminium scrap
The mechanical properties of aluminium alloys are highly affected by the morphology and distribution of these intermetallic phases.[1] b-Al5FeSi Fe-rich intermetallics usually form as faceted large platelets, and this brittle structure causes the loss of strength and ductility of the aluminium alloy, while the a-Al8Fe2Si phase appears with many different types of morphology
Centreline segregation, macroscopic buckling and surface defects are very common.[6]. To minimize these defects in casting recycled aluminium alloys and improve the quality of the strip, a new technique was tested by using high shear melt conditioning before casting, and the developed process is known as melt conditioning twin roll casting (MC-TRC).[7,8,9]
Summary
Iron is one of the unavoidable impurity elements that exist in primary or secondary aluminium alloys, and it is problematic in recycling aluminium scrap. Centreline segregation, macroscopic buckling and surface defects are very common.[6] To minimize these defects in casting recycled aluminium alloys and improve the quality of the strip, a new technique was tested by using high shear melt conditioning before casting, and the developed process is known as melt conditioning twin roll casting (MC-TRC).[7,8,9] In this newly developed technology, a rotor–stator mixer was used to apply intensive melt shearing This rotor–stator type technology has been tested as a multi-purpose device for degassing, grain refinement, metal matrix composite casting and industrial casting processes such as direct chill casting and twin roll casting.[10] Because of its advantages in chemical and thermal homogenization, HSMC technology can be used for microstructure control, especially morphological control of Fe-rich intermetallic phases. We investigated the impact of HSMC on the size and distribution of Fe-rich intermetallic compounds within the recycled AA6111 strips formed by the twin roll casting process and in addition reported the measured mechanical properties of TRC and MC-TRC processed strips
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