Removal of Iron from a Secondary Al–Si Die‐Casting Alloy by Metal Melt Filtration in a Laboratory Filtration Apparatus

Schoß, Johannes Paul; Becker, Hanka; Keßler, A.; Leineweber, Andreas; Wolf, Gotthard

doi:10.1002/adem.202100695

Cited by 6 publications

(34 citation statements)

References 26 publications

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“…The base materials have been represented in preliminary investigations for the detection of Fe‐rich intermetallic phases. [ 24 ] Table 1 and 2 show the element contents of the two obtained series of alloy compositions.…”

Section: Methodsmentioning

confidence: 99%

“…However, preliminary studies established an alternative procedure for reducing the Fe content to avoid the use of high‐cost alloys. [ 24 ] This procedure comprises two operational steps. First is the addition of alloying elements, such as Mn and Cr, leading to the formation of Fe‐rich intermetallics.…”

Section: Introductionmentioning

confidence: 99%

“…DSC analysis provides advantageously high accuracy for determining the formation temperature of Fe‐rich intermetallics, which is reported as standard deviations of ≈1.9 K [ 21 ] and/or ≈3.8 K, [ 24 ] respectively, for a wide range of cooling rates and chemical compositions. [ 10,11,24 ] However, several problems emerge using DSC analysis.…”

Section: Introductionmentioning

confidence: 99%

“…In addition, a second series of trials with a predetermined chemical composition with target values of 0.8 wt% Fe, Mn, and Cr each provided a real‐time validation on the formation temperature of the primary Fe‐rich intermetallics by self‐written Python programs. The method of real‐time detection thus allows the initiation of a potential filtration process, as presented in preliminary work, [ 24 ] for separating the primary Fe‐rich intermetallic phases from the Fe‐reduced residual melt.…”

Section: Introductionmentioning

confidence: 99%

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Investigation of the Formation of Iron‐Rich Intermetallic Phases in Al–Si Alloys via Thermal Analysis Cooling Curves, Including a Real‐Time Detection for Filtration Process

et al. 2023

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Iron (Fe) is perceived as an accompanying impurity in aluminum silicon (AlSi) casting alloys. However, the formation of Fe-containing intermetallic phases, which mostly exhibit a plate-like morphology, impairs both the mechanical and casting properties. [1,2] This structural plate-like compound is referred to as the β-Al 4.5 FeSi phase. By increasing initial Fe content in the melt, the plate-like formation is promoted into a coarse lamellar morphology mainly due to diffusion. [3] Consequently, effective feeding with residual melt is hindered, and shrinkage porosity can be enhanced during solidification. [4][5][6] Furthermore, the platelike β-Al 4.5 FeSi morphology leads to stress concentrations at the coarse plate tips, significantly diminishing the casting ductility. [5,7,8] In fatigue crack propagation studies, the crack initiation site has been demonstrated on the plate-like β-morphology, where the plates can be either split longitudinally or completely separated during crack propagation. [1] Conversely, crack propagation at the star-like morphology is merely bypassed. [1]

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Investigation of the Formation of Iron‐Rich Intermetallic Phases in Al–Si Alloys via Thermal Analysis Cooling Curves, Including a Real‐Time Detection for Filtration Process

et al. 2023

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“…The analytical methods were also used in preliminary studies for the detection of iron-rich intermetallic phases. 36…”

Section: Numerical Simulationmentioning

confidence: 99%

Filtration Efficiency in the Recycling Process of Particle-Reinforced Aluminum Alloys Using Different Filter Materials

et al. 2022

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In this study, filtration of aluminum alloy (Al) with different weight fractions of SiC particles (SiCp) was investigated. Therefore, three different filter materials of 20 pores per inch (ppi) ceramic foam filters (CFF) were tested. A special three-chamber furan mold was used for the casting trials to provide uniform filling and flow conditions for the filtration process. Samples from sections of the gating system, as well as from the filter, were analyzed by optical light microscopy to determine the amount, size, and distribution of SiCp. A scanning electron microscope (SEM) with energy-dispersive X-ray spectroscopy (EDS) was used for obtaining the element distribution in the composite. The filtration efficiency increased by decreasing the weight fraction from 20 to 5% of SiCp and reached a significant particle reduction of over 90%. Investigations of CFFs with a weight fraction of 10% have shown a clogging effect and metal flow interruption through the 20 ppi filter. An oxide layer was detected around the respective SiCp in the EDS. Moreover, a strong accumulation effect was observed, indicated by a steadily flattening curve of the density functions after each additional remelting cycle of the same composite material.

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Precipitation of Iron-Containing Intermetallic Phases from Aluminum Alloys by Metal Melt Filtration

Schoß,

Keßler,

Dommaschk

et al. 2024

Springer Series in Materials Science

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Iron (Fe) provides a non-reactive dissolved impurity in aluminum (Al) alloys, which forms a coarse, plate-shaped intermetallic β-phase during solidification. This β-phase is detrimental to the mechanical and casting properties. Therefore, the reduction of Fe by binding in Fe-containing intermetal-lics (sludge phase) was realized via a two-stage procedure, which consisted of conditioning of the melt by manganese (Mn) and chromium (Cr) with subsequent-ly applied metal melt filtration. For this purpose, the formation characteristics of the Fe-rich intermetallic phases were investigated regarding the temperature, time, and initial chemical composition to separate these intermetallics from the residual melt. To evaluate the different process parameters of Fe removal for a potential implementation in lightweight metal foundries, a process technology on an indus-trial scale was developed in cooperation with an industrial partner. The examina-tion of samples in optical microscopy (OM) using image analysis were conducted to determine the area fractions of Fe-rich intermetallics. In addition, optical emis-sion spectrometer (OES) measurements were performed. Complementary investi-gations were achieved by scanning electron microscopy (SEM), with energy dis-persive spectroscopy (EDS), and electron backscatter diffraction (EBSD) to measure the partial chemical composition and for phase identification. The for-mation characteristics of the Fe-containing phases were investigated using DSC cooling curves and selective sampling in quenching experiments. In the experi-mental trials, a maximum reduction of iron of ≈50% was revealed compared to the unfiltered sample, whereby greater influence on the formation of α-intermetallics was inferred by temperature than by time. Moreover, the elements Mn and Cr were reduced by about 66% and 86% at 620 °C, respectively, thus, the element contents in the filtered samples approached the chemical composition of the standard alloy (EN-AC-AlSi9Cu3(Fe)).

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Removal of Iron from a Secondary Al–Si Die‐Casting Alloy by Metal Melt Filtration in a Laboratory Filtration Apparatus

Abstract: The ORCID identification number(s) for the author(s) of this article can be found under https://doi.org/10.1002/adem.202100695.

Cited by 6 publications

References 26 publications

Investigation of the Formation of Iron‐Rich Intermetallic Phases in Al–Si Alloys via Thermal Analysis Cooling Curves, Including a Real‐Time Detection for Filtration Process

Investigation of the Formation of Iron‐Rich Intermetallic Phases in Al–Si Alloys via Thermal Analysis Cooling Curves, Including a Real‐Time Detection for Filtration Process

Filtration Efficiency in the Recycling Process of Particle-Reinforced Aluminum Alloys Using Different Filter Materials

Precipitation of Iron-Containing Intermetallic Phases from Aluminum Alloys by Metal Melt Filtration

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