Search Results (121)

The effects of the gas tungsten arc (GTA) welding process on the microstructure and microhardness of two Mg-5Al-3RE and Mg-5Al-5RE experimental alloys (RE—rare earth elements) are presented. Both alloys were gravity-cast in a steel mould and GTA-welded in the same conditions. Analyses of the alloys’ microstructure were carried out by scanning electron microscopy (SEM+EDX) as well as X-ray diffraction (XRD). In as-cast conditions; both alloys were mainly composed of α-Mg; Al₁₁RE₃; and Al₁₀RE₂Mn₇ intermetallic phases. Additionally; α+γ eutectic (where γ is Al₁₂Mg₁₇) in the Mg-5Al-3RE alloy and an Al₂RE phase in the Mg-5Al-5RE material were revealed. The same phase composition was revealed for both alloys after the GTA welding process. The results of the dendrite arm size (DAS) and Vickers microhardness measurements were also described. Both welded materials exhibited an intensive size reduction of the structural constituents after GTA welding. About 75% smaller values of the dendrite arm spacing were revealed in the fusion zones of the investigated materials than in the as-cast conditions. The GTA welding process also influenced the microhardness of the experimental alloys and increased them by about 21% compared to the base metal; which was the consequence of the refinement of the structural constituents. Full article

Recycled aluminum–silicon alloys provide significant environmental benefits by reducing the consumption of raw materials and lowering carbon emissions. However, their industrial application is limited by the presence of iron-based intermetallic compounds and the insufficient investigation in the literature regarding their effects on mechanical behavior. This study focuses on a recycled EN 42000 alloy, comprising 95% recycled aluminum, with a focus on the effect of its elevated iron content (0.447 wt%) on aging behavior and mechanical performance. Laboratory-scale specimens were produced through gravity die casting and subjected to T6 heat treatment, consisting of solution, quenching, and artificial aging from 160 °C to 190 °C for up to 8 h. To investigate overaging, analyses were conducted at 160 °C and 170 °C for durations up to 184 h. Tensile tests were conducted on specimens aged under the most promising conditions. Based on innovative quality indices and predictive modeling, aging at 160 °C for 4.5 h was identified as the optimal condition, providing a well-balanced combination of strength and ductility (YS = 258 MPa, UTS = 313 MPa, and e% = 3.9%). Mechanical behavior was also assessed through microstructural and fractographic analyses, highlighting the capability of EN 42000 to achieve properties suitable for high-performance automotive components. Full article

This study presents a simulation modeling of the gravity filling of a sand casting mold with gray cast iron EN-GJL-250. An analysis of the fluid flow, the nature of the filling of the casting mold, and the possibility of forming defects, such as voids and porosity due to metal shrinkage during the crystallization process, was performed. The simulation was performed using specialized software for simulating metal casting processes. The software allows the modeling of fluid dynamics and thermal conditions during the filling of the casting mold. The results obtained show the influence of the design of the sprue system, pouring temperature, and casting geometry on the movement of the fluid flow and the crystallization of the metal. The simulation also allows the visualization of turbulence and temperature gradients, helping to localize areas prone to defects. The results of this study could improve the quality of the specific casting and aid in selecting appropriate technology for the casting of a small series of high-quality castings. Full article

This research presents the results of different periods of T6 heat treatment (homogenization and artificial aging) for A356 aluminum alloy used in the fabrication of motorcycles. The samples were cast using gravity die casting, and industrial furnaces for T6 were used in the experiment. Two heat treatment conditions were used, with a total time of 7 h and 12 h, and the results were compared with the alloy without heat treatment. The effects of the reduction of treatment time on mechanical behavior were evaluated in terms of hardness, Charpy and tensile tests, as well as morphological analysis of fractures and microstructural behavior via optical microscopy, SEM-EDS, measurement of eutectic Si evolution, and XRD. Excellent mechanical properties were achieved with a treatment period of 7 h, which achieved a yield strength of 226.58 (±3.76) MPa, tensile strength limit of 264.78 (±4.27) MPa and elongation of 3.41 (±0.47) %. This is competitive with other cast alloys subjected to T6 heat treatment in longer treatment cycles. The peak of hardness and highest impact resistance was recorded for the sample treated for 12 h; however, in the impact test, there was no significant difference between the two experiments. Full article

This article evaluates the possibility of replacing creep-resistant magnesium Mg-Zn-RE-Zr alloys (EZ33) with Mg-Al-Ca-Sr alloys. (1) Background: Mg alloys with RE metals show excellent properties. Due to their high cost, new, more economical Mg alloys are being developed. Replacing RE metals with cheaper elements such as Al and Ca allows us to obtain high mechanical properties at elevated temperatures due to the tendency to form stable intermetallic phases. (2) Methods: Microstructure analysis (LM, SEM, TEM, and XRD) was performed and mechanical properties were tested at ambient and elevated temperatures. (3) Results: Increasing the Ca content and decreasing the Al content leads to the formation of a continuous skeleton of high-melting and brittle Ca-rich Laves phases and Sr-rich intermetallic phases and the formation of plate-like precipitates of the C15 phase inside the α-Mg solid solution. The crystallographic orientation of plate-like precipitates contributes to the blocking of dislocations in slip systems activated at elevated temperatures. Increasing the Ca and Sr content allows for the regulation of the Al concentration in the α-Mg, providing solution strengthening and stability of the α-Mg solid solution. These factors contribute to a significant improvement in creep resistance of Mg-Al-Ca-Sr alloys. (4) Conclusions: The strength properties and elongation at ambient temperature of the Mg alloys with Ca and Sr addition are comparable to those of the EZ33 alloy, and due to the presence of lighter alloying elements, a better specific strength is achieved. Ca-rich Mg-Al-Ca-Sr alloys exhibit better creep resistance at temperatures of up to 200 °C compared to the EZ33 alloy. Full article

Increasing the share of circulating scrap in produced castings is not only due to optimizing production costs, but also the need to protect the environment realized by reducing production energy intensity, generating less waste, mitigating greenhouse gas emissions, and consuming fewer natural resources. However, this is associated with maintaining the required properties of castings and considering the impact of impurities on the formation of the structure of aluminum alloys. This research concerns the AlSi10MnMg alloy, which introduces 50 to 75% (every 5%) of circulating scrap. This alloy is one of the most commonly used for producing gravity and pressure die-castings (HPDC), including engine parts and transport structural elements. Based on microscopic research, it was found that the increase in scrap content causes an increase in the share of iron, which results in pre-eutectic (from about 0.45 wt.% to 0.7 wt.% Fe) or even primary crystallization of iron phases (over 0.7 wt.% Fe), mainly the plate–needle phase β-Al₅FeSi. Its unfavorable morphology and size cause the formation of numerous shrinkage porosity areas, which has an impact on the reduction in mechanical properties (reduction in UTS and YS by approx. 16% and elongation by approx. 18%, compared to the AlSi10MnMg alloy with 50% scrap content). It was found that the increase in the share of recycled scrap (from 50 to 75%) can be used only when the manganese content is increased. Its effect is to change the morphology of the β-Al₅FeSi phase into α-Al₁₅(Fe,Mn)₃Si₂, whose crystallization occurs in the temperature range of 540 to 555 °C and increases slightly with increasing manganese addition. It is essential to consider the appropriate value of the Mn/Fe quotient, which should be about 1/2, because a higher value may cause the formation of a sludge factor. This work aimed to determine the limiting iron content (contained in the scrap) at which the sequence of the β-Al₅FeSi phase release (pre-eutectic or primary crystallization) changes. This sequence mainly affects the form of morphology, the dimensions of the β-Fe phase, and the proportion of shrinkage porosity. Full article

The effects of red mud on the microstructures and high-temperature tensile properties of the ZL109 aluminum alloy have been investigated. Red mud/ZL109-based composite materials with added red mud (a major byproduct of the aluminum industry), which has been coated with nickel by chemical deposition, have been prepared through gravity casting. The results show that the addition of red mud promotes the alloy’s microstructure and helps to uniformly distribute the eutectic silicon. It also increases the content of heat-resistant phases, such as the Q-Al₅Cu₂Mg₈Si₆ and γ-Al₇Cu₄Ni phases. These changes significantly enhance the alloy’s high-temperature tensile properties. The alloy with 1% (wt.%) red mud exhibits the best tensile strength at both room temperature and 350 °C, reaching 295.4 MPa and 143.3 MPa, respectively. The alloy with 1.5% (wt.%) red mud demonstrates excellent performance at 400 °C, achieving a tensile strength of 86.2 MPa through the cut-through method and Orowan mechanism. As a reinforcing material, red mud not only improves the high-temperature resistance of the aluminum alloy but also provides a way to recycle industrial waste. This study offers a new way to address the red mud waste problem and helps develop high-performance, heat-resistant aluminum alloys. It shows the potential of these alloys in high-temperature applications. Full article

In this work, kaolin processing waste (KW) and columbite–tantalite waste (CTW) from mining activities were used to manufacture sustainable self-supporting ceramic membranes using the freeze-casting technique. The wastes were characterized, and formulations using only wastes were developed. Gelatin was used in the freeze-casting as a processing aid to avoid dendritic or lamellar pores. The membranes were sintered at different temperatures (1100 °C, 1200 °C and 1300 °C) and analyzed by X-ray diffraction, scanning electron microscopy, flexural strength measurement, and mercury porosimetry. The flux through the membranes was measured using a gravity-driven dead-end filtration system. The membranes containing 80% KW and 20% CTW sintered at 1200 °C showed high porosity (59%), a water permeate flux of 126.5 L/hm², and a mechanical strength of 1.5 MPa. Filtration tests demonstrated effective turbidity removal (>99%) for synthetic water consisting of tap water and bentonite, reaching 0.1 NTU. The use of mining waste has shown considerable promise for the development of sustainable and affordable membranes for water treatment applications. Full article

Nowadays, with the development of electromobility, the requirements not only for the mechanical properties but also for the thermal conductivity of castings are increasing. This paper investigates the influence of casting and heat treatment technology on the thermal diffusivity and thermal conductivity of an AlSi10MnMg alloy. The thermal diffusivity was monitored as a function of temperature in the range of 50–300 °C for the material cast by high-pressure die casting (HPDC) and also by gravity sand casting (GSC) and gravity die casting (GDC). This study also investigated the effect of the T5 heat treatment temperature (artificial ageing without prior solution treatment—HT200, HT300, and HT400) on the thermal conductivity of the material cast by different technologies. Experiments confirmed that the thermal diffusivity or thermal conductivity of the alloy depends on the casting technology. The slower the cooling rate of the casting, the higher the thermal conductivity value. For the alloy in the as-cast condition, the thermal conductivity at 50 °C is in the range of about 125 to 138 [W·m⁻¹·K⁻¹]. Regardless of the casting method, the thermal conductivity tends to increase with temperature (50–300 °C). Furthermore, a positive effect of heat treatment without prior solution treatment (HT200, HT300, and HT400) on the thermal conductivity was demonstrated. Regardless of the casting method of the samples, the thermal conductivity also increases with increasing heat treatment temperature. The results further showed that when artificial ageing is performed in industrial practice on castings to increase mechanical properties in the temperature range of 160–230 °C, this heat treatment has a positive effect on thermal conductivity. Full article

Tin-based Babbitt alloys are a widely used bearing bushing material which have good comprehensive properties. However, problems such as high-temperature softening and insufficient bearing capacity occur during their use, so the optimization of tin-based Babbitt alloys has become a research hotspot. In this paper, ZChSnSb11-6 alloy was mainly prepared by the gravity casting method, and different amounts of Zn were added to the alloy (the mass fraction values were 0 wt.%, 0.05 wt.%, 0.1 wt.%, 0.15 wt.%, and 0.2 wt.%, respectively). Through the hardness test, the tensile test, the friction and wear test, and the microstructure observation of the prepared alloy, the influence of Zn on the organization and properties of the ZChSnSb11-6 alloy was analyzed. The results show that the size of the SnSb hard phase changed with the increasing content of Zn. The size of the hard phase of the SnSb tended to increase first and then decrease, and the number of phase particles increased first and then decreased, resulting in changes in performance. Through comparison, it was learned that the addition of Zn can effectively improve the hardness, tensile strength, yield strength, and wear resistance of the alloy, but the elongation rate was reduced. When the Zn content was 0.1 wt.%, the hardness value of the alloy reached the maximum value, 25.82 HB, which increased by 7.3% when compared with the sample without Zn. The hardness of the Zn, 0.15 wt.%, is close to that of the Zn, 0.1 wt.%. Compared to the sample without Zn, the tensile strength and elongation of the alloy were maximized at a Zn content of 0.15 wt.%. Compared to the sample without the Zn, the tensile strength was increased by 21.29%, and the elongation rate was increased by 46%. An analysis showed that the alloy has good comprehensive mechanical properties when the Zn content is 0.15 wt.%. Full article

This paper employed squeeze-casting (SC) technology to develop a novel Al-7Si-1.5Cu-1.2Ni-0.4Mg-0.3Mn-0.15Ti heat-resistant alloy, addressing the issue of low room/high temperature elongation in traditional gravity casting (GC). Initially, the effects of SC and GC processes on the microstructure and properties of the alloy were investigated, followed by an examination of the evolution of the microstructure and properties of the SC samples over thermal exposure time. The results indicate that the SC process significantly improves the alloy’s microstructure. Compared to the GC alloy, the secondary dendrite arm spacing of the as-cast SC alloy is refined from 50.5 μm to 18.5 μm. Meanwhile, the size and roundness of the eutectic Si phase in the T6-treated SC alloy are optimized from 11.7 μm and 0.75 μm to 9.5 μm and 0.85 μm, respectively, and casting defects such as porosity are reduced. Consequently, the ultimate tensile strengths (UTSs) at room temperature and at 250 °C of the SC alloy are 5% and 4.9% higher than that of GC alloy, respectively, and its elongation at both temperatures shows significant improvement. After thermal exposure at 250 °C for 120 h, the morphology of the residual second phase at the grain boundaries in the SC alloy becomes more rounded, but the eutectic Si and nano-precipitates undergo significant coarsening, resulting in a 49% decrease in UTS. Full article

ZG25MnCrNiMo steel samples were prepared by squeeze casting under pressure ranging from 0 to 150 MPa. The effects of pressure on the microstructure, low-temperature toughness, hardness, and impact wear performance of the prepared steels were experimentally investigated. The experimental results indicated that the samples fabricated under pressure exhibited finer grains and a significant ferrite content compared to those produced without pressure. Furthermore, the secondary dendrite arm spacing of the sample produced at 150 MPa decreased by 45.3%, and the ferrite content increased by 39.1% in comparison to the unpressurized sample. The low-temperature impact toughness of the steel at −40 °C initially increased and then decreased as the pressure varied from 0 MPa to 150 MPa. And the toughness achieved an optimal value at a pressure of 30 MPa, which was 65.4% greater than that of gravity casting (0 MPa), while the hardness decreased by only 6.17%. With a further increase in pressure, the impact work decreased linearly while the hardness increased slightly. Impact fracture analysis revealed that the fracture of the steel produced without pressure exhibited a quasi-cleavage morphology. The samples prepared by squeeze casting under 30 MPa still exhibited a large number of fine dimples even at −40 °C, indicative of ductile fracture. In addition, the impact wear performance of the steels displayed a trend of initially decreasing and subsequently increasing across the pressure range of 0–150 MPa. The wear resistance of samples prepared without pressure and at 30 MPa was superior to that at 60 MPa, and the wear resistance deteriorated when the pressure increased to 60 MPa, after which it exhibited an upward trend as the pressure continued to rise. The wear mechanisms of the samples predominantly consisted of impact wear, adhesive wear, and minimal abrasive wear, along with notable occurrences of plastic removal, furrows, and spalling. Full article

Against the backdrop of climate policy goals and the EU’s aim for a resource-efficient economy, the foundry industry must rethink product range, energy consumption, and production technologies. Light metal casting, which is performed through processes like gravity die casting and high-pressure die casting, requires effective thermal management, which is crucial for optimising mould filling, solidification, cycle times, and part quality. Against this background, this study presents the development and characterisation of a cooling system that completely dispenses with energy-intensive heating/cooling devices. The system is based on a mask shape combined with internal spray cooling. This paper shows the simulation workflow for developing the mould mask and the design of the cooling system and compares the performance with conventional temperature control using channels. In the tests, an 82% higher cooling rate was achieved with Cool-Spray than with conventional temperature control, which was approx. 2.5 mm below the cavity surface. In addition to the more dynamic temperature control, the potential for process control was utilised, and the component quality of the test part was significantly improved compared to conventional temperature control. Full article

The development of bioabsorbable implants from Zn alloys is one of the main interests in the new generation of biomaterials. The main drawbacks of Zn-based materials are their insufficient mechanical properties. In the presented studies, a quaternary alloy composed of zinc with magnesium (0.2–1 wt. %), calcium (0.1–0.5 wt. %) and strontium (0.05–0.5 wt. %) was prepared by gravity casting followed by hot extrusion and then by hydrostatic extrusion. Microstructural characterization using scanning electron microscopy (SEM) and X-ray diffraction (XRD) phase analysis was performed. The mechanical properties were examined, using static tensile tests. Corrosion properties were analyzed using immersion tests. Samples were immersed in Hanks’ solution (temperature = 37 °C, pH = 7.4) for 14 days. All alloys were subjected after corrosion to SEM observations on the surface and cross-section. The corrosion rate was also calculated. The microstructure of the investigated quaternary alloy consists of the α-Zn grains and intermetallic phases Mg2Zn11, CaZn13 and SrZn13 with different grain sizes and distribution, which impacted both mechanical and corrosion properties. Thanks to the alloying by the addition of Mg, Ca, and Sr and plastic deformation using hydrostatic extrusion, outstanding mechanical properties were obtained along with improvement in uniformity of corrosion rate. Full article

This study analyses the heat transfer performance of metal foam heat exchangers through experimental measurements. Using counter-gravity infiltration casting, open-cell aluminium foam elements were manufactured to embed a copper tube for internal mass flow containment. Heat transfer experiments were conducted under natural and forced convection conditions, with the airflow controlled in a wind tunnel. A stream of warm water within the internal foam component served as the heat source, transferring thermal energy to the surrounding air flowing through the external foam component of the heat exchanger. The results showed a significantly enhanced heat transfer performance with aluminium foam compared to a single copper tube. Thermal resistance models were developed to elucidate the heat transfer mechanisms, highlighting the effectiveness of air-cooled metal foam heat exchangers. These findings underscore the potential of metal foam heat exchangers as cost-effective alternatives for various thermal management applications. Full article