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Key Laboratory of Automobile Materials (Jilin University), Ministry of Education, and College of Materials Science and Engineering,
Jilin University, No. 5988 Renmin Street, Changchun 130025, PR China
b School of Materials and Metallurgy, Northeastern University, Shenyang 110004, PR China
a r t i c l e
i n f o
a b s t r a c t
Article history:
The hypereutectic Al23%Si alloy was treated with ultrasonic wave. A novel horn crucible
was designed specially for this experiment. The horn crucible was a part of ultrasonic
horn, and the molten alloy was treated direct in this crucible. The morphology, size, and
26 October 2007
distribution of the microstructures of the AlSi alloy were observed by means of an opti-
cal microscope. The results show that after the hypereutectic Al23%Si alloy was treated
by ultrasonic wave, the hydrogen bubbles in the alloy melt were removed, the primary Si
phase was rened, the morphology of the primary -Al dendritic crystal was changed to
Keywords:
equiaxial crystal, and the eutectic lamellar spacing increased. The mechanisms of ultrasonic
treatment improving the microstructures of the hypereutectic AlSi alloy were discussed.
Ultrasonic treatment
Microstructure
1.
Introduction
Corresponding author. Tel.: +86 431 85095862; fax: +86 431 85095876.
E-mail address: yusr@jlu.edu.cn (S.R. Yu).
0924-0136/$ see front matter 2008 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.12.121
improve the property of AlSi alloys (Tomida et al., 2003). Several practical techniques, such as rapid solidication of the
melt, adding nucleating agent and rheocasting, are currently
used to form the ne microstructure (Haque and Maleque,
1998; Criado et al., 1997; Tomida et al., 2003; Abu-Dheir et
al., 2005; Liao et al., 2002; Wang et al., 2003). In recent years,
mechanical modication, including electromagnetic mixing
and mechanical vibration to induce forced convection in the
melt, has been successfully developed and applied to rene
grains in the industry (Wang et al., 2003), and other new techniques for rening grains are also being developed. Ultrasonic
treatment, as a new method for improving the solidication
structure and mechanical property of alloys, is obtaining more
and more attention. The injection of ultrasonic energy into
molten alloys can bring about some nonlinear effects, such
as cavitation, acoustic stream, emulsication, and radiation
pressure, which can be used to rene microstructure, reduce
segregation and degas (Jian et al., 2005; Eskin, 2001). However,
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 8 ( 2 0 0 8 ) 330335
23
0.01
0.08
0.02
0.5
0.005
0.101
Balance
2.
Experimental
2.1.
end. So, the special horn was named horn crucible (Fig. 1).
The length and cross-section area of the horn crucible were
determined according to the theory that the stress passes
continuously through the length of the horn (Lal and White,
1996; Lin, 2005). The horn crucible was vertically bolted with
a 20 kHz transducer, and the diameter of the horn crucible
was smaller than that of the transducer. During the course
of the ultrasonic treatment of a metal melt, the ultrasonic
wave emitted from the transducer and passed through the
acoustic horn (horn crucible) is propagated direct into the
melt. The alloy melt becomes a part of acoustic horn, so
the action of energy on the melt is raised remarkably. In
contrast with ordinary ultrasonic treatment, because the
novel horn crucible was invented and applied, no radiator was inserted into the melt, and the impurity from the
radiator was avoided. The microstructures of alloys treated
by this new ultrasonic treatment system were more uniform, and the segregation of the chemical composition was
avoided.
The temperature of the ultrasonic treatment of the metal
melt was monitored with a temperature sensor.
2.2.
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Experimental procedures
Al23%Si alloy melt of 200 g was heated to 800 C and then held
at this temperature for 30 min. The melt was stirred slightly
and poured into a preheated horn crucible (680 C), and then it
was treated with ultrasonic wave for 10 min at the temperature
of 680700 C. The ultrasonic power was 50 W, and the amplitude was 4 m. After that, the horn crucible was moved out the
temperature control system and was immediately quenched
into water of 25 C.
The microstructures of the samples were investigated
using Olympus GX51 optical microscope. The sizes of various
phases were measured statistically by means of the quantitative metallography analysis method.
3.
3.1.
Porosity is one of the major defects in aluminum alloy castings. The presence of porosity can be detrimental to the
mechanical properties and corrosion resistance of the castings. So the degassing of aluminum alloy is very important.
The microstructures of as-cast Al23%Si alloy without and
with ultrasonic treatment were shown in Fig. 2. It can be found
that some gas holes existed in the specimen not treated by
ultrasonic wave (Fig. 2(a)). This indicates that the gas bubbles could not oated out the AlSi alloy melt in the course
of cooling and solidication under the condition of normal
gravity casting. However, the gas holes were not found in
the specimen treated with ultrasonic wave (Fig. 2(b)), i.e., the
ultrasonic wave has the function of degassing. This result
is in accordance with Eskin (2001). The mechanism of ultrasonic degassing is closely related to the cavitation in the melt.
An ultrasonic wave propagating through a melt can generate alternate regions of the compression and rarefaction. In
the rarefaction region of the melt, a large number of small
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j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 8 ( 2 0 0 8 ) 330335
3.2.
Effect of ultrasonic treatment on the morphology
of the primary Si phase
The distribution of the primary Si phase in the hypereutectic
AlSi alloy not treated by ultrasonic wave was homogeneous,
and no aggregation was found over the section of the samples
(Fig. 2(a)). The shapes of the primary Si phase included mostly
coarse ower crystal, polygon or blocky crystal, and ne crystal, and the ower crystal was commonly composed of the club
crystal with 56 petals. The edges and corners of the primary
Si phase were clear (Fig. 3(a)). The largest size of the primary
Si phase was up to 500 m.
After the hypereutectic AlSi alloy was treated by the
ultrasonic wave, most of the primary Si phase distributed
homogeneously in the section of the specimen (Fig. 2(b)). As
compared with the microstructures without ultrasonic treat-
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 8 ( 2 0 0 8 ) 330335
333
3.3.
Effect of ultrasonic treatment on the morphology
of -Al
Under the condition of non-equilibrium solidication, the primary -Al phase can also produce in hypereutectic AlSi alloy
(Tomida et al., 2003). Fig. 4 shows the morphology of the primary -Al phase in as-cast Al23%Si alloy. It can be seen that
the primary -Al phase, not treated by ultrasonic wave, was
developed obviously into dendritic crystal and the length of
its primary arm was even up to 120 m (Fig. 4(a)). After the
alloy was treated by ultrasonic wave, the morphology of the
primary -Al dendritic crystal was changed to equiaxial crystal (Fig. 4(b)), and the size of the primary -Al phase reduced
obviously from 120 m to about 40 m.
The modication of the primary -Al phase resulted mainly
from the action of the cavitation and acoustic stream of ultrasonic wave. The transient caviation produced strong impact
and broke up the primary -Al dendritic crystal, and then
acoustic stream dispersed uniformly them to the melt. So the
growth of the primary -Al dendritic crystal was restrained
and resulted in the formation of the primary -Al equiaxial
crystal.
3.4.
Effect of ultrasonic treatment on the relation
between the primary Si and -Al phases
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3.5.
4.
Conclusion
After the hypereutectic Al23%Si alloy was treated by ultrasonic wave, the hydrogen bubbles in the alloy melt were
removed, the primary Si phase was rened, the morphology of the primary -Al dendritic crystal was changed to
equiaxial crystal, the primary arm size of the primary -Al
phase reduced obviously, and the eutectic lamellar spacing
increased.
j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 8 ( 2 0 0 8 ) 330335
Acknowledgements
This work was supported by The Specialized Scientic
Research Foundation for Doctor Subject in Colleges and Universities by the Ministry of Education of China (Grant no.
20030183019), Program for New Century Excellent Talents in
University, and 985 project of Jilin University of China.
references
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