Identification of Casting Conditions Influence on the Structure and Properties of Al-Si-X Alloy Castings by Experimental and Virtual Way

Abstract

The paper describes influence of the structure type and its parameters on the mechanical properties of cast products (not subjected to plastic forming), made out of Al-Si-X alloys. The special attention has been focused on the dendritic structure parameters: dendritic arms spacing of the first order (DAS 1) and the second order (DAS 2). The results of investigations of mechanical properties of the test castings made using three basic casting technologies: gravity sand casting (GSC), gravity die casting (GDC) and high pressure die casting (HPDC), are presented. All the castings were made out of the same AlSi9Cu3 alloy. The test castings (adherent samples and separately cast samples) were subjected to a static tensile test and their mechanical properties were determined. In the next stage, the samples fractures and zones near the fractures (metallographic specimen) were subjected to visual testing, penetrating testing PT and metallographic microscopic tests. The microstructure, including the size of the DAS 2, was determined. Evaluation of the porosity state was also undertaken. A customer casting was also manufactured and subjected to the metallographic, tomographic (CT) and strength tests. The castings solidification simulation tests were performed for all the three casting technologies (GSC, GDC and HPDC) using the Nova Flow &Solid system. The results were used for estimation of the correlation between the cooling rate of the particular casting solidifying in the above mentioned mould types and for the DAS size. The coupled influence of the structure parameters on the mechanical properties, regarding the occurrence of porosity, was also analyzed.