Enhanced mechanical properties of Al–Si–Cu–Mg(-Fe) alloys by a deformation-semisolid extrusion process

Kim, DaeHan; Kim, Jae Hwang; Kobayashi, Equo

doi:10.1016/j.msea.2021.141667

Cited by 8 publications

(3 citation statements)

References 35 publications

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“…However, no cracks were observed at the fracture of both the alloys recycled by spark plasma sintering and hot extrusion after hot compress. Furthermore, the size of the dimples is like that of the second-phase particles revealing that the main fracture mechanism before the final damage of the recycled alloy is the cracking and debonding of these particles [28]. More and smaller dimples are observed in the fracture surface of the alloys recycled by hot extrusion from the refinement of the Al matrix and second phase, resulting in a significant improvement in the ductility of the alloy.…”

Section: Mechanical Propertiesmentioning

confidence: 89%

Comparison between spark plasma sintering and hot extrusion for solid-state recycling of Al-Si-Cu-Fe alloy chips

Wang¹,

Gao²,

Jiang³

et al. 2023

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To investigate the low-cost and short-process recycling technologies for aluminium alloys, recycled chip-based Al-Si-Cu-Fe alloys were fabricated by spark plasma sintering (SPS) and hot extrusion. Microstructural observations by optical microscopy and scanning electron microscopy indicated that the recycled alloys could achieve good metallurgical bonding between the chips by fragmenting the alumina films on the chip surface by spark plasma sintering and hot extrusion after hot compress. The hot extruded recycled alloy has a smaller matrix grain size and second phase size than that of spark plasma sintered recycled alloys, due to the dynamic recrystallization and fragmentation of strong plastic deformation that occurs during the hot extrusion process. As a result, the chip-based Al-Si-Cu-Fe alloy recycled by hot extrusion after hot compress exhibited the best mechanical properties, with ultimate tensile strength, yield strength, and elongation of 258 and 132 MPa, and 8.6 % than that recycled by spark plasma sintering because of the effective metallurgical bonding between the chips, refinement of matrix grains, fragmentation and dispersion reinforcement of the oxide film and the second phase.

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Section: Mechanical Propertiesmentioning

confidence: 89%

Comparison between spark plasma sintering and hot extrusion for solid-state recycling of Al-Si-Cu-Fe alloy chips

Wang¹,

Gao²,

Jiang³

et al. 2023

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“…In this case, the liquid acts as a lubricant, resulting in better flow, lower viscosity, and forces required to form the raw material [16]. SSMP offers numerous advantages, including lower energy consumption [17], reduced mould wear due to lower shaping temperatures [18], casting without turbulence and thus lower porosity in the castings due to a more viscous mixture [19], and improved mechanical properties [18,[20][21][22]. There are many methods to explain the microstructure of the slurry, which can be categorised into two main categories: rheo processes and thixo processes.…”

Section: Introductionmentioning

confidence: 99%

Corrosion Behaviour of Recycled Aluminium AlSi9Cu3(Fe) Machining Chips by Hot Extrusion and Thixoforming

Gudić,

Vrsalović,

Krolo

et al. 2024

Sustainability

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The corrosion properties of an EN AC AlSi9Cu3(Fe) alloy (reference sample (RS)) and samples produced by recycling chips of RS by direct hot extrusion (DHES) and subsequent thixoforming (TFS) were tested in 0.5 M NaCl solution. The plastic deformation changes the microstructure of RS, and brittle, coarse Si particles and intermetallic compounds (IMCs) were effectively broken into ultrafine-grained particles and redistributed homogeneously into the α-Al matrix in DHES. TFS exhibits a globular structure, and polyhedral clusters rich in Si and IMCs were observed along the grain boundary. Electrochemical measurements combined with surface characterisation show that the microstructure significantly influences the tested samples’ corrosive properties. It was confirmed that corrosion resistance increased in the following order: RS < TFS < DHES. Similarly, the corrosion potential becomes nobler, the corrosion current decreases, the passive area increases, and the oxide layer becomes more stable (higher resistance and thickness). Also, the percentage of the surface affected by corrosion and the volume of pits reduce. The effect of microstructure is particularly pronounced in the level of the corrosion current and the volume of pits formed. The corrosion current of DHES and TFS decreases by 4–5 times, while the pit volume of DHES and TFS decreases by several orders of magnitude compared to RS. The corrosion stability of DHES and TFS in relation to RS is a consequence of the comminution of the Si particles and the IMC. The refined and homogeneous microstructure contributes positively to forming a stable oxide film on DHES and TFS and increases their corrosion resistance in an aggressive environment. The applied recycling method represents an innovative and sustainable process for the recycling of semisolid materials, with lower energy consumption and less greenhouse gas emissions compared to conventional recycling. The fact that the products obtained through recycling have a significantly higher corrosion resistance further increases the economic and environmental impact of the process.

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“…It makes good use of the characteristics of semi-solid metal materials during development and can ensure the quality and mechanical properties of the formed parts [2]. At present, semi-solid processing has been deeply studied and applied in many alloys, such as aluminum alloys [3][4][5][6], magnesium alloys [7][8][9][10], titanium alloys [11][12][13], and steels [14][15][16], but the research on semi-solid forming of nickel-based superalloys is relatively few. Semi-solid processing is a complex forming process involving multiple physical fields, including stress field, strain field, temperature field, and velocity field [17].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experimental Verification of Nickel-Based Superalloy Disc-Shaped Parts Formed by Semi-Solid Thixoforming

Xiao,

Jiang,

Wang

2023

Metals

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Numerical simulation of the thixoforming process of GH4037 nickel-based superalloy disc-shaped components is performed using DEFORM-3D software (Defrom V11). The complete numerical simulation process includes three stages in this work: heat transfer to air, heat transfer on the ejector rod, and the semi-solid thixoforming process. The effects of billet placement, billet temperature, and extrusion velocity on the numerical simulation of thixoforming were investigated. Furthermore, some disc-shaped components were produced through thixoforming to verify the results of numerical simulation. The simulation results indicate that horizontal billet placement is beneficial to the thixoforming of the GH4037 part. A higher billet temperature is good for the filling of disc-shaped components, and the formed part is completely filled when the billet temperature is higher than 1360 °C. Higher extrusion velocity leads to lower effective stress of the disc-shaped component. However, high extrusion velocity easily leads to the separation of solid and liquid phases and aggravates the wear and impact of the dies. The experimental results of thixoforming are in good agreement with the results of numerical simulation, and GH4037 nickel-based superalloy disc-shaped components with complete filling and good surface quality are obtained under the optimized process parameters.

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Enhanced mechanical properties of Al–Si–Cu–Mg(-Fe) alloys by a deformation-semisolid extrusion process

Cited by 8 publications

References 35 publications

Comparison between spark plasma sintering and hot extrusion for solid-state recycling of Al-Si-Cu-Fe alloy chips

Comparison between spark plasma sintering and hot extrusion for solid-state recycling of Al-Si-Cu-Fe alloy chips

Corrosion Behaviour of Recycled Aluminium AlSi9Cu3(Fe) Machining Chips by Hot Extrusion and Thixoforming

Numerical Simulation and Experimental Verification of Nickel-Based Superalloy Disc-Shaped Parts Formed by Semi-Solid Thixoforming

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