Synthesizing and Hot Deformation Behavior of Novel Al-X Wt.% Zn Alloys for Advanced Casting Industries

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The present paper investigates the synthesizing routes and best method to explain the hot deformation behavior of novel Al-x wt.% Zn alloys (x = 0, 10, 20, 30, 40 and 50 wt.%). Based on several synthesizing routes, it was studied that the liquid metallurgy route followed by squeeze casting and extrusion is the best manufacturing method of the novel Al-Zn castings. These novel Al-Zn casting alloys would give more benefits as it possesses lower value of melting temperature; which is best suited for die-casting parts. To explore the mechanical behavior of Al-Zn castings, hot deformation studies by developing the processing map is best method by which complete information related to these alloys bahaviour could be obtained. From the literature, it was found that the hot workability behavior can be examined by developing the processing map using dynamic material modelling (DMM) and constitutive models (sine-hyperbolic Arrhenius kinetic rate equation). The step by step procedure to be followed for hot deformation analysis was explained in this work. From this analysis, the peak flow stress, stability region, instability region, power dissipation efficiency, activation energy and dynamic recrystallization region can be explored. In addition, as a pilot study related to these Al-Zn alloy, several castings, namely, pure Aluminium(Al), Al-10Zn, Al-20Zn, Al-30Zn, Al-40Zn, and Al-50Zn were successfully casted using electric furnace and then all these castings were squeezed followed by extruded to have improved densification. The hardness of casted samples was revealed that Al-40Zn casting exhibited a vicker’s hardness strength (VHS) of 1326 MPa which was 4 times higher than pure Al.