Graphite Mold Research Articles

Functional failure analysis of the graphite crystallizer used in horizontal continuous casting process of copper tube

The presence of a particular type of white powder has emerged as a significant challenge in the horizontal continuous casting process of copper. This white powder leads to the blockage of the graphite crystallizer, resulting in a functional failure that adversely affects the mold’s lifespan, increases production costs, and reduces overall efficiency. The issue has posed significant challenges for engineers due to its complex and unclear formation mechanism. This investigation employed various experimental characterization methods to analyze the composition, element distribution, phase properties, and other relevant factors of the white powder. Meanwhile, a high-temperature experiment was also designed to examine the potential reactions between copper oxide (Cu2O) and the furnace lining (3Al2O3·2SiO2). It is found that the main component of the white powder blocking the inlet hole of the graphite mold is SiO2, which is traced back to the furnace lining. Under high temperatures, oxygen reacts with liquid copper to form Cu2O. Subsequently, this Cu2O reacts with Al2O3 in the furnace lining to produce CuAlO2. Meanwhile, SiO2 becomes isolated as Al2O3 is deprived. The resultant SiO2 accumulates at the inlet hole of the graphite mold due to rapid cooling. The accumulated SiO2 in the form of white powder blocks the inlet hole of the graphite mold, leading to functional failure of the graphite mold. To address this issue, several improvement measures are proposed including drying the raw and protective material, enhancing the sealing of the furnace, and reducing the holding time.

Influence of manufacturing parameters on bioactive glass 45S5: Structural analysis and applications in bone tissue engineering

Bioactive glass (BG-45S5) production through the melting process is affected by a wide variety of parameters. This study investigated the synthesis of BG-45S5 granules and the process variables to produce a bioactive and osteoinductive BG for bone grafting applications. The melting process was initially analyzed by varying parameters such as crucible type and pouring environment using P2O5 as phosphorus precursor. The obtained products were characterized by crystalline phases, characteristic chemical groups, particle size distribution, and chemical composition. Materials poured into graphite or steel molds resulted in particle sizes more suitable for applications in granular form. Using a platinum crucible yielded a chemical composition closer to the target when compared with another ceramic crucible. Subsequently, the melting process was evaluated to different phosphorus precursor (P2O5 or Na2HPO4) and melting duration (1 or 2 h) in a platinum crucible verifying their effects on the thermal behavior, chemical composition and structure of BG-45S5. Employing Na2HPO4 as a precursor led to higher glass transition and crystallization temperatures as compared to P2O5, enhancing glass homogeneity and structural stability. The product with better characteristics in terms of composition and structure was further characterized for bioactivity and cell culture behavior, showing a greater amount of mineralization nodules when compared to commercial hydroxyapatite. This is particularly due to its behavior as the solubility and interaction in biological environments.

On tailored microstructure in AA 2024 alloy during in-situ microwave casting

In the present study, application of microwave energy was explored for tailoring the microstructure in AA 2024 alloy through directional solidification route. Microwave transparent (alumina) and absorbing (graphite) mould materials were utilized to investigate the effect of microwave interaction (electric and magnetic field components) with AA 2024 alloy on microstructure evolution in terms of dendrite size distribution and formation of eutectic phase. Results showed more pronounced eutectic phase gradient was developed using alumina mould. On the other hand, a more uniform distribution of the eutectic phase and grain size was observed with graphite mould. The development of the eutectic phase gradient is attributed to the effective microwave interaction with the AA 2024 alloy melt during solidification. This is primarily associated with the formation of an additional flux at the solid-liquid (S/L) interface of the alloy under the effect of magnetic field and an enhancement in diffusion flux due to mass transport caused by electric field component of microwave. Formation of AlCu, Al2Cu, and Al2CuMg intermetallic phases in both alumina and graphite mould casts was confirmed. Significantly higher hardness was observed at the higher eutectic phase sites within the alumina mould cast, whereas graphite mould casts exhibited better tensile properties.

Comparative study of microstructure and mechanical properties of Mg/B4C composites: Influence of sintering method and temperature

This present work compares the effect of heating methods including microwave and spark plasma sintering (SPS) process on the microstructure and mechanical properties of Mg–B4C. 5 wt%B4C mixed with Mg powders through high-energy mixer mill for 10 min at ethanol media. After mixing, the green bodies were prepared by uniaxially pressing the mixture. The microwave heating was done at sintering temperatures of 600, 650 and 700 °C without soaking time in graphite bed. While, in the case of SPS, the mixture of the powders was directly inserted into a graphite mold and sintering process was performed at 450 °C with initial and final pressures of 10 and 30 MPa at vacuum condition of 17 Pa, sequentially. The corresponding XRD patterns revealed Mg and B4C crystalline phase alongside the reaction product of MgB2 and also MgO byproduct. The FESEM investigations depict uniform distribution of B4C reinforcements at the Mg matrix. Moreover, increasing microwave sintering temperature led to decreasing pores at the microstructure of the prepared sample. The microstructure of SPSed sample revealed almost full densification compared to that of the microwave processed samples at all the sintering temperatures applied. Also, The XPS results show the presence of Mg, O, C and B elements on the surface of prepared composite, and HRTEM with HAADF-STEM images were obtained to study the interface of matrix and reinforcement. The highest bending strength and Vickers hardness of 116 ± 6 Hv and 231 ± 11 MPa were obtained for SPSed sample as well as for the highest relative density. Although the microwave sample was sintered at 700 °C at low pressure, sintering method demonstrated considerable mechanical properties in comparison to SPSed specimen, indicating a successful preparation method as a low-cost, energy- and time-saving process.

Tb3+ doped silicoborate glass scintillator for high resolution synchrotron X-rays imaging application

This research aims to develop a combination of SiO2 and B2O3 glass former (called, silicoborate glass) to be used as a scintillation material for digital radiography application. The silicoborate glass doped with different concentration of Tb2O3, xTb2O3–7.5Gd2O3–40Na2O–5SiO2– (47.5-x)B2O3, where x = 0, 1, 2, and 3 mol% (xTb:7.5Gd) were prepared by melting and then rapid quenching in graphite mold. The density of the prepared glasses was high with Tb2O3 concentration, indicating that the glass became denser and could strongly interact with X-rays. The molar volume increased with Tb2O3 concentration, suggesting the increase of Non-Bridging Oxygen (NBOs) in glass matrix. The xTb:7.5Gd glasses absorbed photons in visible and near-infrared regions and was observed that the absorption bands increased with Tb2O3 concentration, which was the result of the 4f6-4f6 transitions behavior of Tb3+ ions. The photoluminescence and radioluminescence results revealed the distinct emission occurring at 544 nm (5D4→7F5). The photoluminescence quantum yield (PLQY) of glass had the maximum efficiency at 30.85%. The luminescence peak area under X-rays excitation glass was maximum at 109% of BGO crystal. CIE 1931 chromaticity of the xTb:7.5Gd glasses showed the color coordinates in yellowish-green area. The decay time of the xTb:7.5Gd glasses were in the millisecond range for different excitations. The probability of energy transfer was investigated between Gd3+ and Tb3+ ions in glass and may occur mainly between the 6P7/2 level of Gd3+ and 5H7 level of Tb3+. The X-rays imaging using the developed glass as a scintillator was performed by Synchrotron X-rays and the spatial resolution 6 lp/mm was achieved. These results demonstrate that the 3 mol% of Tb2O3 doped silicoborate glass can be used as a scintillator and can be applied for a high-resolution Synchrotron X-rays imaging system.

An ultrasonic fabrication process for carbides reinforced Inconel 718 alloy composites

A novel approach was proposed to prepare carbides reinforced Inconel 718 alloy composites by ultrasonicating graphite mold to introduce carbon element into liquid phase. The graphite mold was designed to resonate with three-dimensional (3D) power ultrasounds, which stimulated cavitation effect and acoustic streaming to promote uniform carbon dispersion and the subsequent incorporation of various carbides with alloy solidification process. It was found that the carbon content infiltrated into liquid alloy increased with ultrasound amplitude and dimension, which attained the maximum of 2.64 wt% C. Ultrasound accelerated the peritectic L+TiC→NbC reaction, forming a blocky (Ti, Nb)C phase instead of shell-core structured (TiC+NbC) phases. A new (Cr, Fe)7C3 phase was produced due to the extended carbon solubility into liquid alloy under 3D ultrasounds. Meanwhile, the synergistic orientation relationships between γ(Ni) and carbide phases were enhanced by high-frequency vibration. The ultrasonically solidified composites exhibited excellent wear resistance and hardness as compared with other IN718 alloy-based composites.

Electrothermal Simulation of the Production of Alumina by Spark Plasma Sintering

Although the spark plasma sintering (SPS) method is a very advantageous technque in many aspects, the inability to clearly read the temperature formed on the material during sintering and heterogeneous temperature distributions are the biggest problems of this process. Therefore, it is a common situation that samples taken from different regions of the produced material have different densities and mechanical properties. In this study, the temperature distributions, current density and joule heating effect of the entire setup consisting of the alumina (Al2O3) sample to be sintered, inconel electrodes, graphite dies, punches and spacers, as well as the critical regions in this setup, are modeled by using finite element software. According to the results, the temperature is maximum at the centre of the Al2O3 sample and the temperature gradient along its radius is 22.4°C. The temperature difference between the inner wall of the hole which is opened in the graphite mold to measure the sintering temperature and the centre of the Al2O3 sample is around 40°C. In addition, during the SPS process, Al2O3 is not heated directly by the joule effect and the temperature gradient in the sample occurs due to mold surface radiation.

Fabrication of thermoelectric Bi2Te2·5Se0.5 with adjustable porosity

Porous structures have attracted considerable interest for their impact on the transport and mechanical characteristics of materials. The fabrication of porous materials, however, often involves intricate preprocessing steps and typically lacks the ability to tailor porosity with ease. In the present study, we present a straightforward method to prepare porous Bi2Te2·5Se0.5 samples by employing low-pressure spark plasma sintering, with the porosity regulated by preset mass density using a modified graphite mold. This approach resulted in a substantial decrease in thermal conductivity, attributed to the introduction of pores that reduce mass density and disrupt phonon transmission. An accompanying decrease in electrical conductivity was also noted, arising from reduced carrier concentration and mobility. Despite these variations, all porous samples maintained similar levels of thermoelectric performance, with a peak zT of ca. 0.9 at 373 K. The average zT within the temperature range of 298–500 K remained slightly above 0.8 for all samples. Furthermore, the porous samples exhibited greatly enhanced mechanical properties. This work demonstrates a versatile and adaptable method to produce porous materials with controllable porosity, potentially applicable to other porous thermoelectric systems.

Heterogenous Grain Nucleation in Al-Si Alloys: Types of Nucleant Inoculation

The objective of the current work is to establish, on the one hand, the conventional mechanisms of grain refining and, on the other hand, the effect of the refining-modification interaction in Sr-modified Al-Si alloys on the achieved grain refining and the modification of eutectic silicon. For this purpose, the hypereutectic alloy A390.1 (~17%Si) was used. Various grain refiners were used, namely, Al-10%Ti, Al-5%Ti-1%B, and Al-4%B. After the preparation of the liquid metal, several concentrations of these master alloys were added to the liquid bath according to the desired objective. The different melts prepared were heated at 750 °C and cast in a preheated graphite mold with a solidification rate of around 0.8 °C/s. The liquid metal was. The presence of strontium (added in the form of Al-10%Sr master alloy) and boron completely affects the microstructure of the alloy. An atom of Sr unites with 6 atoms of B to form a compound whose stoichiometric formula is of the SrB6 type, leading to a significant reduction in the modification. A strong relationship exists between the addition of B and the recovery level of Sr. The affinity between titanium and boron is stronger than the affinity between boron and strontium. Both B and TiB2 phase particles do not react with Si; it is only the Ti part of the Al-Ti-B master that forms (Al, Si)3Ti. Regardless of the amount of Si content in the alloy, the Al-4%B master alloy achieves the best grain refining compared to Ti-containing master alloys.

A hybrid approach towards evaluation of average heat transfer coefficient in twin-roll strip casting mold

Continuous casting stands out as one of the most efficient and productive methods for producing billets, slabs, or thin sheets while conserving energy. Understanding the solidification dynamics and achieving defect-free sheets in continuous casting necessitates the accurate prediction of heat transfer coefficient (HTC) at the mold metal interface. Accurate prediction of HTC helps in selecting process parameters such as superheat temperature and casting velocity, which directly affect the production rate and quality of the cast component. Determining the HTC is a complex process, as it is influenced by various process parameters such as casting size, casting speed, superheat temperature, surface roughness, type of water used as a coolant, nozzle design and wettability. Therefore, the present study proposed a hybrid approach for finding HTC in a twin roll strip casting mold through a solidified shell shape, which is influenced by the factors affecting the heat transfer at the mold-metal interface. This approach integrates the experimental and simulation investigations. The numerical investigation used a three-dimensional coupled fluid flow and heat transfer equations with an assumed range of HTC (100–2000 W/(m2K)). The solidified shell shape for different HTCs was compared with the experimental solidified shape form at the outer wall of the mold using the solidification criteria. Results indicate that the initial HTC range of 100–1000 W/(m2K) does not lead to blockage of the graphite mold outlet. However, as HTC values approach 1000 W/(m2K) to 1400 W/(m2K), the melt obstructs the mold exit based on solidification criteria. The HTC values (1350 ± 150 W/(m2K)) obtained from the proposed methodology for mold, align well with the HTC values (1183 ± 593 W/(m2K)) calculated using lamellar spacing of the Al-Mg2Si composite microstructure. This hybrid approach presents a novel and straightforward method for determining HTC, offering accurate predictions that can enhance the precision of continuous casting models and provide a more nuanced understanding of solidification behavior.

Certain investigation on feasibility of developing riser less ductile iron castings

The solidification mechanism of ductile iron is a bit complex due to the precipitation of graphite and silicon. These elements change the solidification pattern of cast iron. Density of these elements is less than iron leads to occupying more volume consequently increase the overall metal volume. There are two aspects on this increase in metal volume. One is, reducing this volume increase to reduce the creation of porosities at the earlier stage of solidification and second is, using this volume increase to remove porosity at the later stage of solidification. Proper understanding of this graphite expansion in cast iron solidification will bring insights on reducing or removing of the risers. The current study focus on correlating the net contraction and austenitic liquidus point with shrinkage. The average contraction found through this study is 1.36 % which is more than the net expansion of 0.25 % (without riser) reported in literature. The study found that properly balancing graphite precipitation, pouring temperature and mold strength can enable riserless casting of ductile iron by compensating for liquid contraction through graphite expansion.

Characterization of Na2Zn2TeO6 ceramic solid electrolyte densified by hot pressing

AbstractIn this work, we applied hot pressing (HP) for the densification of Na2Zn2TeO6 (NZTO) at lower temperature than conventional furnace sintering (FS). Calcined NZTO powder was densified by HP at 700°C for 1 h under uniaxial pressure of 20 and 60 MPa using a graphite mold. By increasing the uniaxial pressure to 60 MPa for HP, high relative density above 90% was obtained. As‐prepared NZTO by HP showed total (bulk + grain‐boundary) ionic conductivity of 0.29 mS cm−1 at room temperature, which is lower than NZTO prepared by FS at 800°C (=0.4 mS cm−1) with lower relative density (<85%). It was found that the contribution of grain‐boundary resistance in as‐prepared NZTO by HP is larger than NZTO by FS. We confirmed that the grain‐boundary resistance was significantly reduced by post‐annealing. Consequently, total conductivity at room temperature was improved to 0.42 and 0.56 mS cm−1 by annealing at 700 and 800°C for 2 h, respectively. X‐ray photoelectron spectroscopy analysis indicated that the residual carbon‐contained secondary phases were reduced by post‐annealing. These secondary phases could be formed by the carbon contamination from a graphite mold used for HP, and their removal by post‐annealing results in the improvement of ionic conduction at grain‐boundary.

Carbon Contamination Prevention during Spark Plasma Sintering.

Carbon contamination from graphite molds during spark plasma sintering (SPS) considerably affects the properties of the sintered materials, especially transparent ceramics. Herein, transparent Y3Al5O12 (YAG) ceramics were prepared via SPS using Mo and Ta foils, separately and in tandem, as protective barriers against carbon contamination. The effects of Ta and Mo foils on the transparency and microstructure of the ceramics, and their protection mechanisms were studied. Experimental results show that a reaction layer formed at the Ta-YAG interface with a YTaO4-Al2O3 eutectic composition suppresses carbon penetration into the ceramic, increasing its transparency. By contrast, Mo foils, when used as protective barriers, allow carbon diffusion into the ceramic, resulting in the formation of nonuniform microstructural features. However, it does not form a reactive layer and, hence, is removed easily from the YAG surface. Multilayered Ta-Mo barrier exhibits improved outcomes if the Ta thickness is more than ∼100 μm. This behavior is attributed to the interior diffusion-blocking mechanism of Ta. Similar optical performance was demonstrated by both approaches. The results prove that carbon contamination in SPS-derived samples can be effectively prevented. Additionally, this study reports on a novel strategy of bonding oxide ceramics to metals by adding a Ta layer at the joint interface.

The Influence of Manganese Addition on the Properties of Biodegradable Zinc-Manganese-Calcium Alloys.

This study focuses on the preparation and characterization of zinc-based alloys containing magnesium, calcium, and manganese. The alloys were prepared by the melting of pure elements, casting them into graphite molds, and thermo-mechanically treating them via hot extrusion. The phase compositions of the samples were analyzed using X-ray diffraction technique and SEM/EDX analysis. The analysis confirmed that in addition to the Zn matrix, the materials are reinforced by the CaZn13, MgZn2, and Mn-based precipitates. The mechanical properties of the alloys were ascertained by tensile, compressive, and bending tests, measurement of the samples microhardness and elastic modulus. The results indicate that an increase in Mn content leads to an increase in the maximum stress experienced under both tension and compression. However, the plastic deformation of the alloys decreases with increasing Mn content. This study provides valuable insights into the microstructural changes and mechanical behavior of zinc-based alloys containing magnesium, calcium, and manganese, which can be used to design alloys for specific biomedical applications.

Nonuniform Distribution of Crystalline Phases and Grain Sizes in the Surface Layers of WC Ceramics Produced by Spark Plasma Sintering

The research results conducted on binderless tungsten carbide (WC) ceramics obtained by spark plasma sintering (SPS) of WC powders with different average particle sizes (95, 800, 3000 nm) are presented. Nonuniform distribution of crystalline phases and microstructure of the WC ceramics was studied using layer-by-layer X-ray diffraction (XRD) analysis and scanning electron microscopy (SEM). Surface layers of the WC-based ceramics are characterized by nonuniform distribution of W2C crystalline phase and grain sizes, including the appearance of abnormally large grains. Thickness of the nonuniform layer was at least 50 μm. The effect under study is associated with an intense carbon diffusion from graphite foil. On the one hand, this contributed to a decrease in the intensity of W2C phase particle formation, which is transformed into α-WC phase due to the carbon. On the other hand, it caused abnormal grain growth in the layer where the carbon diffused. The obtained value of the carbon diffusion depth (50 μm) exceeds the values known from the literature (up to 1 μm in the case of volume diffusion even at temperature of 2370 °C and exposure time of ~60 h). The use of boron nitride (BN) as a protective coating on graphite mold parts did not prevent the formation of nonuniform layer on the ceramic surface.

New Al-alloys with dispersed stable quasicrystal approximant phases: Overcoming the barrier of conventional casting processing and microstructure design

Multi-stage manufacturing processes, high production costs and narrow two-phase field of Al-alloys containing Al-FCC and quasicrystals or approximants phases have been barriers to the widespread use of these alloys in technological applications. In the present work, we demonstrated that new Al-alloys with dispersed stable quasicrystal approximant phases can be produced by conventional metallurgical fabrication methods. Six alloys containing different volume fractions (5% up to 40%) of the approximant α-phase were designed and produced by conventional solidification in a graphite mold. The hardness and tribological properties of Al-FCC matrix with different volume fractions of the quasicrystal approximant phase were evaluated. A wide range of wear rates, from 2.1 × 10−3 mm3/Nm to 6.3 × 10−4 mm3/Nm, could be achieved by tuning the volume fraction of the α-phase ranging from 5% up to 40%, respectively. Low coefficient of friction values around 0.3 were observed after the running-in periods, regardless of the α-phase content, indicating that the quasicrystal approximant phase played a critical role. The alloy containing 25% of α-phase was chosen to be processed by different manufacturing processes to show that the morphology of the stable approximant α-phase can also be controlled. This finding opens new perspectives for the commercial application of products derived from such light- and wear-resistant materials.

The Effect of Casting Technique and Severe Straining on the Microstructure, Electrical Conductivity, Mechanical Properties and Thermal Stability of the Al-1.7 wt.% Fe Alloy.

This paper features the changes in microstructure and properties of an Al-Fe alloy produced by casting with different solidification rates followed by severe plastic deformation and rolling. Particularly, different states of the as-cast Al-1.7 wt.% Fe alloy, obtained by conventional casting into a graphite mold (CC) and continuous casting into an electromagnetic mold (EMC), as well as after equal-channel angular pressing and subsequent cold rolling, were studied. Due to crystallization during casting into a graphite mold, particles of the Al6Fe phase are predominantly formed in the cast alloy, while casting into an electromagnetic mold leads to the formation of a mixture of particles, predominantly of the Al2Fe phase. The implementation of the two-stage processing by equal-channel angular pressing and cold rolling through the subsequent development of the ultrafine-grained structures ensured the achievement of the tensile strength and electrical conductivity of 257 MPa and 53.3% IACS in the CC alloy and 298 MPa and 51.3% IACS in the EMC alloy, respectively. Additional cold rolling led to a further reduction in grain size and refinement of particles in the second phase, making it possible to maintain a high level of strength after annealing at 230 °C for 1 h. The combination of high mechanical strength, electrical conductivity, and thermal stability can make these Al-Fe alloys a promising conductor material in addition to the commercial Al-Mg-Si and Al-Zr systems, depending on the evaluation of engineering cost and efficiency in industrial production.

Effect of Melt Holding Time on the As-cast Microstructure and Hardness of Aluminum Alloy 2618

The effects of the melt holding time on the type, quantity and morphological distribution of aluminum alloy 2618 were investigated by means of OM, XRD and SEM. And the influence of the melt holding time on the hardness of alloy was explored. The results show that the heredity of the microstructure of the master alloy is not completely eliminated when the melt holding time is less than 10 min at 740 ℃. And it will make Al9FeNi phase coarse needle-like, and segregate with Al7Cu2Fe phase at the grain boundary or inside the grain. Properly prolonging the melt holding time can change the shape of Al9FeNi phase from coarse needle-like to fine needle-like and make the distribution of Al9FeNi phase and Al7Cu2Fe phase more uniform. Aluminum alloy 2618 was melted at 740 ℃ for 30 min and then poured into graphite molds at room temperature, which can make Al9FeNi phase fine and uniformly distributed in the matrix. With the extension of the melt holding time, the size of the nonequilibrium crystalline phase is basically unchanged, but the grain size will be slightly coarsened. The hardness of the alloy showed a trend of first increasing and then decreasing with the prolongation of the melt holing time within 10~60min, and when the melt was held for 30min, the hardness of the alloy reached the maximum HRB value of Rockwell hardness within the range of this test. The maximum value is 48.62HRB, and the hardness distribution of the alloy is relatively uniform. Therefore, it is beneficial to refine the precipitated phase, reduce the macro segregation, and refine the grain and improve the hardness of the alloy, while alloy 2618 was poured into the graphite casting at room temperature with melting at 740℃ and held for 30min.

Evaluating the dynamic characteristics of microwave-casted metal matrix composite material by using experimental modal analysis

This paper proposes an experimental modal analysis technique to measure the dynamic characteristics of microwave-casted metal matrix composite (MMC). To fabricate MMC, silicon carbide (SiC) is reinforced into the SS202 matrix. The damping capacities of MMC at different reinforcements of SiC powder such as 0.05%, 0.1% and 0.2% are measured through experimental modal analysis. The main objective is to study the effect of reinforcement on the damping capacity of SS202. The domestic microwave oven with the specification of 2.45 GHz and 900 W power is used to cast the MMC material. The graphite split mold is used for in-situ microwave casting. The mechanical characterization in terms of micro-hardness and scanning electron microscopy (SEM) of MMC is also examined. From SEM imagining, complete diffusion of the SiC in SS matrix is observed for 0.05% of SiC reinforcement; however, incomplete diffusion is observed for 0.1% and 0.2% of SiC reinforcement. It is observed that the hardness of the SS202 is increasing with the decrease in the percentage of SiC powder. The experimental modal analysis is carried out by using SO Analyzer. The response model in terms of the frequency response function (FRF) curve is measured when the specimen is excited at impact excitations. The half power bandwidth method is used to calculate the damping factor of the material from the measured FRFs. It is observed that the damping capacity increases with the increase in percentage of SiC in SS202. SS202 with 0.05%, 0.1% and 0.2% SiC have the hardness value of 155.33 HV, 107.33 HV and 58.33 HV, respectively.

Experimental Evaluation of Mechanical and Tribological Properties of Segregated Al-Mg-Si Alloy Filled with Alumina and Silicon Carbide through Different Types of Casting Molds

A 6061 aluminum alloy has almost 0.8–1.2 wt.% Mg and 0.4–0.8 wt.% Si content. These two components, along with other alloying elements, therefore, were characterized by high mechanical and abrasive strength. The aims of the present work were to understand the effect of different types of cooling rates through different molds materials and to investigate the effect of casting with ceramic additives on segregation of the aluminum alloy itself as a composite material forum. Therefore, a series of mechanical tests were conducted, such as compression test, Vickers hardness, and pin-on-disc wear test. The samples were cast at 650 °C and in electric furnaces for 2 h to ensure that the metal achieved adequate homogeneity and temperature. Then, abrasive macroparticles of Al2O3 and Sic with a size close to 40–60 µm were used. The particles were poured under constant stirring for 1 min. Then, they were cast in two types of molds: steel and graphite. The cast specimens were obtained as a reference without particles and with 0.5 wt.%, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, and 8 wt.%. The thermal effect and the heat due to conduction and radiation were calculated. The maximum compressive strength was found to increase by ≈21% with SiCp casted in graphite molds, and HV was found to increase by ≈29% with SiC casted in graphite molds. The same was found for wear resistance, which became good with SiC casted in graphite molds, and it was generally found that the cooling rate through the mold weakened the alloy due to the segregation effect. The presence of tough particulate through the aluminum matrix barrier created a number of loads. Additionally, the high specific heat of graphite, which plays a dominant role in the slaw cooling rate of casting, led to grain enlargement, whereas the higher cooling rate of steel led to grain refinement. These concepts are the main rules of heat treatments through the casting process itself, and they save time and effort.