Metal Quality - The Effects on Die Casters and End Users

Bakke, Per; Svalestuen, Jørild; Albright, Darryl

doi:10.4271/2002-01-0078

Cited by 6 publications

(5 citation statements)

References 7 publications

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“…Inclusions can also be generated during die casting from oxidation in the shot sleeve, entrapment of air during casting, and absorption of lubricants spread on the die surface [20,47,48]. In sand casting, turbulent flow may cause sand grains to detach from the mould wall and be entrained within the Mg melt, with which they react.…”

Section: Reactions During Castingmentioning

confidence: 99%

Inclusion removal and grain refinement of magnesium alloy castings

Elsayed¹

2021

Preprint

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Magnesium alloys show promise to be materials for lightweighting of automotive and aerospace vehicles improving fuel efficiencies and vehicle performance. A majority of magnesium alloy components are produced using casting where susceptibility to forming inclusions and coarse grain sizes could result. Development of effective inclusion removal techniques and better understanding of grain refinement of magnesium alloys could help in improving their mechanical properties to advance them to more structurally demanding applications. This research aimed to develop an environmentally friendly alternative to the grain refinement and inclusion removal capabilities of carbon based hexachloroethane as it releases dioxins, chlorine gas and corrodes foundry equipment. A secondary aim was to pioneer in-situ neutron diffraction to examine the solidification of magnesium alloys. The research involved preparing tensile samples of AZ91E magnesium alloy using permanent mould casting. Inclusion removal was conducted by using filtration and argon gas bubbling. Castings grain refined using hexachloroethane (0.25, 0.50 and 0.75 wt.%) were compared against ex-situ aluminum-silicon carbide and in-situ aluminum-carbon based grain refiners combined with filtration and argon gas bubbling. Further, in-situ neutron diffraction was utilized for phase analysis and fraction solid determination of magnesium-zinc and magnesium-aluminum alloys. There was a significant improvement in yield strength, ultimate tensile strength and elongation with filtration plus argon bubbling, carbon inoculation or both filtration plus argon bubbling and carbon inoculation. The results indicated that the mechanism of the observed ~20% reduction in grain sizes with carbon inoculation (hexachloroethane, ex-situ aluminum-silicon carbide and in-situ aluminum-carbon) was explained through duplex nucleation of Mn-Al and Al-Mg-C-O (likely Al2MgC2) phases. Finally, in-situ neutron diffraction was used to follow the formation of Mg17Al12 eutectic phase in a magnesium-9 wt.% aluminum alloy. For the magnesium-zinc alloys, in-situ neutron diffraction enabled characterization of the effects of zirconium to the fraction solid growth of (1010), (0002) and (1011) α-Mg planes. The societal and environmental impact of this research is significant. There is a clear demonstration of alternatives to the universally used hexachloroethane grain refiner promoting harmful emissions. Improved mechanical properties resulting from new grain refinement and iv inclusion filtration are a major advancement in promoting weight reduction, improved castability and decreased environmental impact for automotive and aerospace industries.

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Section: Reactions During Castingmentioning

confidence: 99%

Inclusion removal and grain refinement of magnesium alloy castings

Elsayed¹

2021

Preprint

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“…Inclusions can also be generated during die casting from oxidation in the shot sleeve, entrapment of air during casting and absorption of lubricants spread on the die surface. 1,11,14,31 In sand casting, turbulent flow may cause sand grains to detach from the mould wall and be entrained within the Mg melt, with which they react. The inclusions formed are called 'reacted sand inclusions'.…”

Section: Reactions During Castingmentioning

confidence: 99%

“…will affect the homogeneity and quality of the final product in terms of mechanical properties or surface appearance. 10,11…”

Section: Introductionmentioning

confidence: 99%

Inclusions in magnesium and its alloys: a review

Sin¹,

Elsayed²,

Ravindran³

2013

International Materials Reviews

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High volume application of lightweight materials is the key to improving fuel efficiency and vehicle performance, and decreasing exhaust emissions to address environmental concerns. Currently, magnesium alloys, which are the lightest structural materials, represent only y0?3% of an automobile weight. One of the most important parameters in controlling the properties of magnesium and its alloys is melt cleanliness, manifested mainly in inclusions. The presence of such inclusions will strongly influence the mechanical properties and corrosion resistance of structural components. This paper gives an overview of the current state of knowledge pertaining to magnesium melt cleanliness. It describes the nature and origin of the inclusions, the methods for assessing the cleanliness of magnesium, the methods used to control inclusions in the melt and the relationship between melt cleanliness and the properties of magnesium castings.

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“…The metal quality of the anode is paramount to the magnesium utilization efficiency. The metal quality [39] may be defined as (i) chemical composition, (ii) inclusions and porosity inside the anode, (iii) the surface appearance, and (iv) consistency. Magnesium anodes are generally specified with respect to strict chemical compositions because of harmful impurities such as iron, copper, and nickel which can impair the corrosion performance of the anode and lead to nonuniform dissolution.…”

Section: Anodementioning

confidence: 99%

Metal–Air Technology

Downing¹

2011

Electrochemical Technologies for Energy Storage and Conversion

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This chapter is a general introduction to the more common types of metal-air batteries, with emphasis on using the magnesium-air technology as an example in understanding the various components that make up a metal-air battery, and some of the limitations, challenges, manufacturing, and further research. Much of what has been learned can be applied to the other aqueous metal-air technologies. Products that utilize metal-air technology as their power source are or have been developed. Various theoretical calculations of the metal-air types have been compared in many published articles, but they do not reflect the actual operating conditions for commercial products. Similar to any commercial product, first to market is a test of consumer acceptance indicating product and financial returns to the manufacturer. The consumer has accepted battery types such as lead-acid, and zinc alkaline batteries for years and is only being introduced to the concept of metal-air batteries, though the zinc-air button cell for hearing aids has been around for years. Metal-air battery types may have certain niche commercial products, and no one metal-air type reigns supreme.Metal-air batteries [1-4] are one of the more promising, but less well known, alternatives to conventional and future power sources as primary cells. Metal-air systems are typically very high in energy density but low in power, have an open cell structure, and use oxygen from the air. Great strides have been made and are continuing to be made in the metal-air technology. They have the potential to replace conventional batteries (e.g., zinc alkaline) and high cost hydrogen-based fuel cells because of their high energy density, relatively flat discharge voltage potential, long shelf life, and relatively low manufacturing cost.Metal-air batteries are an attractive power source for stand-alone power supplies (e.g., for stand-by or emergency power and portable power). They feature the electrochemical coupling of a metal anode to an air-diffusion cathode through a suitable electrolyte. This combination produces a cell with an inexhaustible cathode reactant from the oxygen in atmosphere air. Metal-air batteries also have the versatility of an aqueous or nonaqueous electrolyte. The more common type Electrochemical Technologies for Energy Storage and Conversion, First Edition. Edited

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Metal Quality - The Effects on Die Casters and End Users

Cited by 6 publications

References 7 publications

Inclusion removal and grain refinement of magnesium alloy castings

Inclusion removal and grain refinement of magnesium alloy castings

Inclusions in magnesium and its alloys: a review

Metal–Air Technology

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