Semisolid Die Casting of Wrought A6061 Aluminium Alloy

Abstract

The mechanical properties achieved with high performance wrought aluminium alloys are superior to cast aluminum alloys. To obtain an intricate shaped component, wrought alloys are commonly subjected to forging followed by subsequent machining operation in the automobile industry. As machining of such high strength wrought aluminium alloys adds to cost, productivity gets affected. Shortening the process by near net shaped casting would tremendously enhance productivity. However, casting of such alloys frequently encounter hot tear defect. Therefore, circumventing hot tear to successfully die cast near net shaped wrought alloy components is industrially relevant. A recent advanced casting process, namely ‘Semisolid Die casting’, is proposed as a likely solution. Hot tearing originates due to lack of liquid flow in the inter-dendritic region. To reduce hot tear susceptibility, fine and non-dendritic grain structure is targeted, amenable for processing by semisolid route. For semisolid processing an adequate freezing range for processing is required. Accordingly A6061 wrought alloy whose composition is tuned with higher silicon and magnesium content within the grade limits, is chosen for the study. With the objective of obtaining fine and non-dendritic microstructured billets, electromagnetic stirring (EMS) and cooling slope (CS) methods are employed. On conducting a parametric study with EMS, a finest possible primary α-Al grain size of about 70 μm is obtained at low stirring time at stirring current levels of 175 A and 350 A, with the addition of grain refiner. CS, on the other hand, rendered a grain of 60 μm at a slope length of 300 mm at a slope angle of 45° with grain refiner addition. Of the two methods, CS billets are chosen for subsequent induction heating. A 3-step induction heating cycle has been devised to attain a temperature of 641°C in the billet on the basis of factors including coherency point, viscosity of the slurry and solid fraction sensitivity with temperature. The billet microstructure is found to be homogenous throughout after quenching in water. The characterization of phase along primary α-Al grain boundary and its composition analysis is done by SEM and EPMA respectively, after billet casting as well as induction heating. In addition, the bulk hardness is determined in BHN. The induction heated billets are semisolid die cast to produce an engine connecting rod used in automobiles. The microstructure is characterized at various locations, and is found to consist of smooth α-Al grains in a background matrix of fine grains formed due to secondary solidification. The component hardness is found to be 66 BHN comparable with A6061 alloy under T4 heat treated condition. X-ray radiography does not confirm presence of surface hot tear, which is the normal defect associated with casting of wrought aluminium alloys. No defects are observed along the constant cross-sectional area of the connecting rod, suggesting that the processing could be suitable for semisolid extrusion.