Squeeze Casting Research Articles

Experimental and numerical evaluation of squeeze cast Al-Si-Cu-Ni-Mg alloy for piston applications

ABSTRACT Al-12% Si is the commercial alloy commonly used to make pistons by using gravity casting method. When this alloy was modified with Ni, Cu, and Mg (modified alloy), it showed an adequate fluidity during casting and achieved higher strength. However, the addition of alloying elements reduces its thermal characteristics. Therefore, an attempt has been made to improve the thermal conductivity through modifying the microstructure. It was done by changing the cast method to squeeze cast, adding 0.04%Sr (Sr-modified alloy) and post-heat treatment (T6 and T7). Results highlighted that the sample of gravity cast-Sr-modified alloy showed enhancement in thermal conductivity. Even though squeeze cast-Sr-modified alloy showed reduction in thermal conductivity of few percentage, it possessed better strength, however the heat treatment (T7 condition) showed a noticeable increment in thermal conductivity. Therefore, it is concluded that T7-heat-treated squeeze cast-Sr-modified alloy showed an excellent combination of strength and thermal conductivity making it an ideal material for piston applications. The piston component was studied by numerical steady state thermal analysis using ANSYS Workbench, obtained a maximum heat flux of 1.80 W/mm2 for Al-Si piston alloy aged for 11 h (T7), which is in agreement with the experimental results.

Effect of Runner Distance on Microstructure and Properties of Semi-Solid Squeeze Casting CuSn10P1 Alloy

It is easy to form reverse segregation and shrinkage porosity defects during the solidification of CuSn10P1 alloy, which leads to the poor properties and limits its application in high strength and toughness parts. In this paper, semi-solid CuSn10P1 alloy slurry was prepared by enclosed cooling slope channel (for short ECSC). The effect of runner distance on microstructure and properties by liquid squeeze casting and semi-solid squeeze casting was studied. The results showed that the microstructure of semi-solid squeeze casting is finer than that of liquid squeeze casting, and the shrinkage defects are improved. The solid fraction with 65 mm runner is lower than that without runner in liquid squeeze casting and semi-solid squeeze casting due to the retention effect of solid phase in semi-solid slurry flow, but the properties with 65 mm runner is better than that without runner. The ultimate tensile strength, yield strength and elongation of semi-solid squeeze casting CuSn10P1 alloy with 65 mm runner distance reached 466.5 MPa, 273.6 MPa and 13.4%, which were improved by 26%, 19% and 97%, respectively, as compared to that of liquid squeeze casting.

The Effect of Solution Time on the Microstructure of A356.2 Aluminum Alloy Provided by Rheocasting and Squeeze Casting

The evolution of the microstructure of A356.2 alloys prepared by the rheocasting and squeeze casting during solution heat treatment was investigated. In contrast with the conventional solution heat treatment process (3 hours at 540oC), a short time solution treatment process (less than 1 hour at 540oC) is applied in this paper. The results show that the rheocastings require a shorter solution time than the squeeze-castings to obtain spheroidized Si particles. After solution for 10 min, the X-ray diffraction inspection results show that the Mg2Si phase completely is dissolved in both rheocastings and squeeze-castings. However, a small amount of Mg2Si is found at the edge of the Si particle by scanning electron microscope observation. After solution for more than 20 min, the Mg2Si phase is completely dissolved. Fe-rich phases, including AlSiFeMg and AlFeSi, exist throughout the solution process. The developed T6 heat treatment with a short solution time can effectively improve production efficiency and decrease process cost for the rheocasting process. Key words: A356.2 alloy, microstructure, short solution time, rheocasting, squeeze casting

Revealing the influence of Fe on Fe-rich phases formation and mechanical properties of cast Al-Mg-Mn-Fe alloys

In this study, the recycled Al-Mg-Mn-Fe alloys having different Fe levels (0.1%, 0.5%, and 0.8%) were successfully developed by applying squeeze casting without heat treatment. Optical and scanning electron microscopy, synchrotron X-ray tomography and radiography, X-ray diffraction, and tensile tests combined with thermodynamic calculations were used to study the correlation between the microstructural evolution and mechanical properties. The results showed that for the alloys with an applied pressure of 75 MPa, as the Fe increase from 0.1% to 0.8%, the yield strength (YS), and ultimate tensile strength (UTS) increased from 122 MPa and 244–146 MPa and 289 MPa, and elongation decreased from 34% to 12%. Even though Fe additions increased the volume fraction of Fe-rich intermetallic phases, it significantly increased the UTS and YS. The synchrotron X-ray tomography and deep-etched results both show that the 3D morphology changed from individual Chinese-script to interconnected plate-like. The 3D morphology of 0.8Fe alloy clearly demonstrate that the hole partially or whole penetrated the entire rectangle-shaped Al6(FeMn) phases, which is due to the close-packed plane growth. In-situ synchrotron X-ray radiography results showed the facet growth behaviour of Al6(FeMn) in 0.8Fe alloys during solidification with a long needle-like shape. The size of primary Al6(FeMn) phases decreases, whereas their number increases with increasing cooling rate. Moreover, the applied pressure was beneficial in refining the size of α-Al grains and Fe-rich phases and reducing the volume fraction of pores, thus contributing to the improvement of strength and elongation. The in-situ tensile test results indicated that the crack initiated in the Fe-rich phases and pores, and the slip lines were blocked by the Fe-rich phases resulting in the strengthening of the secondary phases.

Influence of Fly Ash and Emery based particulate reinforced AA7075 surface composite processed through friction stir processing

The novel friction stir technology is adopted in modern automotive industries to meet the desired properties like hardness, impact toughness and tribological behaviour over the conventional techniques like stir casting, compo casting, squeeze casting, electroplating and infiltration methods. AA7075 surface composites fabricated with different volume fractions of fly ash and emery particles is said to enhance the aforementioned properties. The composites are processed through friction stir process (rotational speed −1200 rpm, transverse speed – 56 mm/min, tool tilt angle – 2 °). During characterization, the Microstructural examination of surface composites depicts fine and homogenous distribution of reinforcements in the friction stir process region owing to severe plastic deformation and dynamic recrystallization process. Substantially, good interface is formed between the reinforcement particulates and base substrate. Inclusion of Fe3O4, Al2O3 and SiO2 constituents through fly ash and emery reinforcements associated with the homogenous dispersion strengthening mechanism favours for the superior hardness of surface hybrid composite specimen 50E50FA. Decremented grain size and load bearing capacity of the reinforcements is beneficial for the crack propagation resistance that enhances the impact toughness behaviour (17.4 J/cm2) of the same specimen. Wear rate of the specimens are evaluated through pin on disc tribometer. The decrease in the wear rate of hard specimen 50E50FA is observed due to the reduced contact area between its surface and counter disc. The morphology of worn specimens using SEM analysis shows the combined abrasive and adhesive wear as the worn mechanism.

Mechanical properties and wear behavior of Al5083 matrix composites reinforced with high amounts of SiC particles fabricated by combined stir casting and squeeze casting; A comparative study

Combined stir casting and squeeze casting processes were used to fabricate Al5083 matrix composites reinforced with 20, 25, and 30 wt% SiC p . The microstructure, mechanical properties and wear behavior of the composites fabricated by combined stir casting and squeeze casting were compared with those fabricated by stir casting. The results revealed that the combined casting method improved the distribution of SiC particles through the reduction of the agglomeration of SiC particle and reduced the porosities of the samples from 2.32% to 1.29% in the sample containing 30 wt% SiC. These modifications led to the enhancement of mechanical properties i.e. increased the hardness to 85 BHN and the compressive strength to 350 MPa for the sample containing 30 wt% SiC fabricated by the combined casting method. In addition, the wear resistance of the samples fabricated by the combined casting method improved because of the reduced size of the wear debris as well as the smaller worn region. The dominant wear mechanism of all the composite samples fabricated by both methods was the delamination of the tribological layer while adhesion wear was dominant in the monolithic Al alloy.

Microstructure and Mechanical Behaviour of Ti‐6Al‐4V Matrix Reinforced with WCp Developed by Squeeze Casting

The aim of this study is to evaluate the wear and micro hardness of a Ti‐6Al‐4V matrix reinforced with 10% and 15% tungsten carbide particle (WCp) composite manufactured using the squeeze casting process. Optical microscopy is used to determine the microstructures of the composite. A pin‐on‐disc wear test equipment and Vickers hardness at atmospheric temperature were used to examine the wear behaviour wear rate, CoF, and micro hardness qualities of primed samples. Loads of 10 N to 80 N, velocities of 4 m/s, and distances of 1000 m to 2000 m are considered for analyzing the wear behaviour of Ti‐6Al‐4V composites. The wear rate values are 25.683 for 10% WCp, 30.957 for 15% WCp, and 37.683 and 30.957 for 20% WCp. A scanning electron microscope (SEM) is utilized to examine the worn surface of the composites. For 10% WCp, the CoF values are 0.82 and 0.87, and for 15% WC, 0.88 and 0.956. The micro hardness values are 692 VHN for 10% WCp and 835 VHN for 15% WCp. The wear rate, microstructure, SEM images, coefficient of friction, and hardness of TMCs for totaling reinforcing tungsten carbide particle (WCp) possessions were discovered to be improved.

Modelling and analysis of two-wheeler connecting rod with different materials using FEA

Connecting rod which includes of big end, small end, and rod, is most important aspects of a gasoline engine. Generally, the connecting rods are manufactured by carbon steel; presently, aluminium alloys are the finest replacement material for connecting rod production. Aluminium alloys that are light in weight but also have high impact strength. The focus of this study analysis modal of two-wheeler connecting rod with different material viz., A356, A356-5 %SiC-10% Fly ash stir cum squeeze casting, AA7068 and AA2014. Static structural properties, i.e., total deformation, equivalent elastic strain and von-misses stress is calculated, and deformation and stiffness are calculated from analytical and ANSYS result. So, the material having low deformation and higher stiffness are recommended to produce connecting rods for automobiles.

Stirring Squeeze of Aluminium Alloy metal matrix composites using optimal prediction process

Aluminum is regarded as a widely used material for manufacturing components in the industrial and other manufacturing sectors due to the necessity for lightweight and strong materials. But over the years, aluminium materials have been studied in an effort to improve their mechanical characteristics. Due to the incorporation of reinforcements, hybrid matrix composites are thus introduced to enhance the mechanical properties. In this study, nanoscale reinforcing particles are used to prepare an aluminium hybrid metal matrix composite. Aluminum is regarded as an effective manufacturing material, and metal production involves multiple levels of hybridization. In the current study, titanium carbide, aluminium oxide, and silicon nitride nanoparticles hybridise with aluminium alloy 2219 with 94 % of the original material. The proposed reinforced material is produced using the stirring-squeeze casting process, an innovative type of casting that is used to construct the reinforcements. The benefit of this squeeze casting method is that it has a lower defect rate than traditional casting methods. After fabrication, mechanical testing is done to check the manufactured specimens' qualities under loading circumstances. With an intender ball of 5 mm diameter and a 250 kg loading condition, the material's tensile strength and hardness are tested on a universal testing equipment. One of the simplest ways to determine the error rate of a result from experiments using machine learning is to use the statistical approach of analysis. So, in order to improve the mechanical properties, this research develops a statistical analytic method for optimising the process parameters. For optimising the stirring-squeeze casting process's process parameters, the meta-heuristic method is proposed. Finally, the comparison of experimental and expected results brings the result to a close. According to the comparison's findings, the suggested material composition has the highest level of mechanical qualities for producing components in a real-world setting.

Effect of lanthanum addition on microstructure and hardness of brass alloys produced by rheological squeeze casting

The effect of La addition (0–0.30 wt%) on the microstructure and hardness of rheological squeeze casting brass alloys was experimentally investigated. The rheological squeeze casting process is improved by controlling the wall surface crystals and melt flow rate to realise the preparation of semi-solid melt with flow, and a brass alloy workpiece with La is produced. The microstructure and properties of the brass alloy samples were investigated using metallography, scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction and hardness testing. The results indicate that the hardness of the rheological squeeze casting brass alloy is increased by 20.4% from 108 to 130 HBW with an increase in the La content from 0 to 0.30 wt%. The microstructural analysis results show that La significantly refines the primary α-phase grains, and the main mechanism is the constitutional undercooling and heterogeneous nucleation caused by the La enrichment in the front of the solid–liquid interface. The squeeze pressure promotes undercooling, which improves the nucleation rate and affects the solute diffusion and nucleus growth. The dual effects of these two aspects aggravate the grain refinement process, consequently increasing the number of grain boundaries and improving the hardness of the brass alloy.

Micro-mechanism of simultaneous improvement of strength and ductility of squeeze-cast Al–Cu alloy

In this paper, the strength and ductility of Al–Cu–Mn–Ti alloy prepared by squeeze casting have been simultaneously increased after heat treatment. The effects of solution and aging treatment on the microstructure evolution and mechanical properties of squeeze cast Al–Cu alloy are investigated to discuss its micro-mechanism using various methods, including SEM, XRD, EBSD and TEM. The results show that the Al2Cu phase disappeared completely after solution treatment at 530 °C for 10h. During aging, nano-sized or submicron-sized Al12Mn2Cu precipitates and much smaller nano-sized θ'' phase were uniformly distributed throughout the alloy, and the interface between the two phases and the matrix was coherent. After solution + aging treatment (i.e., T6 treatment) the ultimate tensile strength, yield strength and elongation of the alloy were 445 MPa, 265 MPa and 17.9%, which were increased by 71.2%, 65.6% and 70.5%, respectively, compared with the as-cast alloy. The precipitation strengthening caused by the two kinds of precipitates θ'' and Al12Mn2Cu is the most important factor for the simultaneous increase in the strength and elongation.

Wear and Friction properties of H-Al-17Si alloy with dry, lubrication and coated (DLC-Star) conditions under HFRR

Dry, lubrication (SAE15W40), and coated (DLC-Star) reciprocating tribological tests on rapid solidified AlSi17Cu3.5-4Mg0.6-0.8 alloy was conducted using a high frequency linear reciprocating rig (HFRR) at ambient temperature. The alloy fabricated with the rheo-stir squeeze casting procedure under T-6 condition. However, at different loading (0-30 N) conditions, wear and friction properties of rapid solidified H-Al-17Si alloy are investigated. It is observed that the lower friction coefficient value obtained for DLC-Star coated H-Al-17Si alloy compared to dry and lubrication conditions. Though, for dry and lubricated sliding, the obtained wear coefficient values are 2.9X10-3 mm3/N.m and 4.0X10-4 mm3/N.m. A lower coefficient of wear value of 5.4X10-5 mm3/N.m was recorded with DLC-star coating under dry conditions. The alloy wear coefficient values first increases with applied load (up to 20 N) and then decreases (20 N to 30 N). EDS, AFM surface roughness profilometer, SEM, and advanced metallurgical microscope (AMM) analysis techniques used for the characterization of surface morphologies. The developments in friction and wear coefficients were fundamentally ascribed to the dispersion and size of primary Si elements and the development of tribo-oxide films on the rapid solidified AlSi17 alloy coated (DLC-Star) surfaces.

Tensile and Hardness Properties of Cast 6063 Aluminium Rods produced from Sand and Squeeze Casting Moulds

This work presents experimental analysis to determine the effect of sand and squeeze casting methods on the Tensile and Hardness properties of AA6063 Aluminium. Sand and squeeze cast moulds were fabricated and used to produce Aluminium rods. The test samples from cast rods were subjected to Tensile and Hardness tests. The results obtained showed better Tensile and Hardness properties, in the squeeze cast samples that were produced under varied pressure. The hardness of squeeze casting varied from 72.9 to 82.3Hv, while that of sand casting had 70.0Hv. Also, Ultimate Tensile Strength increased with increased pressure in squeeze castings from 178.01 to 194.04MPa and 161.97 in sand castings. Conversely, the mechanical properties of the cast products improved from those of sand casting to squeeze casting. Therefore, squeeze cast products could be used in as-cast condition in engineering applications requiring high quality parts while sand casting may be used in as-cast condition for non- engineering applications or engineering applications requiring less quality parts

On the Part Quality, Process Parameters and In-Die Pressures in Indirect Squeeze Casting

Squeeze casting is a process that can produce the highest quality castings. In the current study, the effect of the process settings and the in-die conditions on rejection rates is studied through a full-scale experimental study. Factors affecting the as-cast part quality were investigated in the current study from two different viewpoints. The first part of the study was to investigate the influence of the process settings on the part rejection rate, and the second was to understand the conditions in the die and the effects on the part rejection rate to understand better the reasons and sensitivity of the squeeze casting process.

Research on the Secondary Forgeability of High Volume Fraction Whisker Reinforced Aluminum Matrix Composites of Original Squeeze Casting

The poor formability of high volume fraction whisker reinforced aluminum matrix composites of original squeeze casting is an important factor restricting its further development and application. Currently, there are no reports on the secondary forgeability of aluminum matrix composites of original squeeze casting, although some papers on its first forgeability are published. The secondary forgeability is very important for most metals. This study aims to investigate the secondary forgeability of aluminum matrix composites. In this study, the secondary upsetting experiments of 20 vol% SiCw + Al18B4O33w/2024Al composites, treated by the original squeeze casting and extrusion, were carried out. The first upsetting deformation is close to the forming limit, the secondary upsetting deformation under the same deformation conditions was carried out to investigate the secondary forgeability. The experimental results show that, unlike aluminum alloys, the 20 vol% SiCw + Al18B4O33w/2024Al composites at the original squeeze casting and extrusion states have no secondary forgeability due to the whisker rotating and breaking during the secondary upsetting. The high volume fraction whisker reinforced aluminum matrix composites of original squeeze casting cannot be formed by the multiple-forging method since the cavities and cracks caused by whisker fracture continue to expand during secondary processing, which leads to further extension of macroscopic cracks.

Influence of Nanographite on Dry Sliding Wear Behaviour of Novel Encapsulated Squeeze Cast Al-Cu-Mg Metal Matrix Composite Using Artificial Neural Network

This paper investigates the dry sliding wear behaviour of squeeze cast Al-Cu-Mg reinforced with nanographite metal matrix composites. The experimental study employed the Taguchi method. The Taguchi method plays a significant role in analyzing aluminium matrix composite sliding tribological behaviour. Specifically, this method was found to be efficient, systematic, and simple relative to the optimization of wear and friction test parameters such as load (10, 20, and 30), velocity (0.75, 1.5, and 2.25 m/s), and nanographite (1, 3, and 5 wt%). The optimization and results were compared with the artificial neural network. An orthogonal array L27 was employed for the experimental design. Analysis of variance was carried out to understand the impact of individual factors and interactions on the specific wear rate and the coefficient of friction. The wear mechanism, surface morphologies, and composition of the composites have been investigated using scanning electron microscopy with energy-dispersive X-ray spectroscopy. Results indicated that wt% addition of nanographite and increase of sliding speed led to a decrease in the coefficient of friction and wear rate of tested composites. Furthermore, individual parameter interactions revealed a smaller impact. The interactions involved wt% of nano-Gr and sliding speed, sliding speed and normal load, and wt% of nano-Gr and normal load. This inference was informed by the similarity between the results obtained ANN, ANOVA, and the experimental data.

Effect of Sc on the Hot Cracking Properties of 7xxx Aluminum Alloy and the Microstructure of Squeeze Castings.

In this paper, the effect of adding the refiner Sc to the high Zn/Mg ratio 7xxx series aluminum alloy melt on the hot tearing performance, microstructure, and mechanical properties of the alloy is studied. The hot tearing performance test (CRC) method is used to evaluate the hot tearing performance of the alloy. The squeeze casting process was used to form solid cylindrical parts to analyze the structure and properties of the alloy. This study shows that the hot cracking sensitivity of the alloy after the addition of the refiner Sc is significantly reduced. The ingot grain size is significantly reduced, and the average grain size is reduced from about 86 μm to about 53 μm. While the mechanical properties are significantly improved, and the tensile strength reduced from 552 MPa is increased to 571 MPa, and the elongation rate is increased from 11% to 14%.

Effect of temperature, time, and shear force on the morphology and size of dendrites in A356-Al2O3 composites

Dendrite arm spacing (DAS) plays a vital role in determining mechanical properties of aluminum casting composites. In this study, the effects of three different methods of gravity sand casting, squeeze casting, and semi-solid compo-casting with different electromagnetic stirring currents and times on the microstructural morphology of A356-Al2O3 composites were investigated. In order to investigate effects of shear forces on the formation of the globular-like structure, samples with different stirring electric current and times were produced by compo-casting in semi-solid state and analyzed. Optical emission microscopy was used to study the microstructure and DAS of nanocomposites. Quantitative analysis of microstructure was performed by utilizing an image analysis system. In this study, the optimum temperature for composite fabrication for this type of composite was calculated to obtain the most appropriate morphology and size of the microstructure. Also, the appropriate time to keep this composite at this temperature was obtained, and finally the relevant microstructures were fully discussed.

Effect of lanthanum content on microstructure and mechanical properties of Al–5Mg–2Si-0.6Mn alloy in squeeze casting

The effect of Lanthanum content on the microstructure and mechanical properties of Al–5Mg–2Si-0.6Mn alloy in squeeze casting was studied. The microstructure of the alloy was characterized by scanning electron microscope (SEM) and X-ray diffractometer (XRD). The mechanical properties of the alloy were tested by tensile testing machine. The results show that the rare earth Lanthanum has a significant effect on the secondary dendrite spacing and the volume fraction of α-Al + Mg2Si eutectic phase, both of which increase at first and then decrease with the increase of Lanthanum. When the content of Lanthanum is 0.05 wt.%, the maximum volume fraction of eutectic phase is 45.09%. When the content of Lanthanum is 0.05 wt.%, the minimum secondary dendrite spacing is 25.85 μm. When the addition of Lanthanum is more than 0.2 wt.%, the bulk LaAlSi phase is formed in the alloy, which is not coherent with the matrix, which reduces the mechanical properties of the alloy. When the addition of Lanthanum is 0.1 wt.%, the microstructure and mechanical properties of the alloy are the best. The ultimate tensile strength, yield strength and elongation of the alloy reached the maximum, which were 274 MPa, 197.2 MPa and 5.7%, respectively.

Improvement of thermal conductivity of diamond/Al composites by optimization of liquid-solid separation process

Diamond/Al composites have been considered as the new generation of thermal management material. The critical challenge is that Al4C3 with deteriorating properties is easily generated at the interface of composites by conventional powder metallurgy and infiltration processes. This paper presents an independently developed liquid-solid separation (LSS) technology for fabricating diamond/Al composites with Cr-coated diamond particles. The key parameters of the LSS process such as the blank heating rate and its heating mode, the squeeze casting temperature and pressure, and pressurization time were optimized. Cr coating of the diamond particles led to improved interface characteristics. The higher thermal conductivity of diamond/Al composite with Cr-coated diamond particles is attributed to the favorable interfacial products of Al13Cr2 and AlCr2. Thermal conductivity of 40 vol.% Cr-coated diamond particles reinforced diamond /Al composites prepared by LSS with the optimal process was 309.20 W m−1 K−1, 108.06 % higher than that of the composite without the Cr coating. The results showed that relative density is a critical factor in optimizing of the bending strength, compressive strength, and thermal conductivity of the composites. No harmful intermetallic Al4C3 is generated at the interface of the composite. LSS technology is the new low-cost and compact method for the fabrication of diamond/Al composites with high thermal conductivity, which has the prospect of industrial application.