Alcoa Primary Metals/Center of Excellence

1 Boul. Des Sources Deschambault

Qubec, Canada G0A 1S0
Tel: 418-286-5276 # 6515
Fax: 418-286-5411

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Report date:
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Francis Caron, Project Manager Alcoa Global Primary Product

Yves Cauchon, Guy Lalibert
Billet from Electromagnetic Casting Technology (Alloy 6082)
2011-06-03

Description:
A billet's sample of alloy 6082 cast with Electromagnetic Casting Technology was received from Eling,
Serbia for complete characterization and comparison with material produced with standard AirSlip
casting table and homogenized. The internal laboratory identification 2011-57B was assigned to this
study and samples were taken according to the sampling diagram shown in page 8 of this report.
According to the supplier , the advantages consideration for Electromagnetic Casting Technology are:
Smooth surface.
The structure is very fine with very good homogeneity and small globular grain.
Segregation zones absence.
ECT eliminates macro porosity and has good influence on grain refining.
All these points indicate homogeneity within structure and absence of segregation, so extrusion
without heat treatment is possible.

Chemical Composition :

AA Alloy:
Alcoa Alloy:

6082
6082

Chemical composition meets 6082 specification for both material.

Sample I.D. #
6082 ECT
6082 Airslip
6082 spec.

Si %

Fe %

Cu %

Mn %

Mg %

Cr %

Zn %

Ti %

1.06

0.18

0.03

0.58

0.76

0.146

0.020

0.023

0.95

0.20

0.01

0.54

0.62

0.152

0.006

0.031

0.7 - 1.3

0.50 max

0.10 max

0.40 - 1.0

0.6 - 1.2

0.25 max

0.20 max

0.10 max

Alcoa Inc. Confidential

2011-06-03

Page 1

Macrostructure :

Surface of the sample cast with electromagnetic table was machined and etched with a tri-acid
solution in order to reveal grains structure and measure shell zone. Grains look uniform
without any abnormal feature. Shell zone is similar to typical values found in regular material
cast with Airslip table.

Sample I.D. #
6082 ECT

Grain structure
(Figure 1 )

Uniform distribution

Shell Zone (mm)

maximum thickness
(Figure 2)
< 100 m

Figure 1 - Grain structure - 6082 ECT

Original magnification: 1X
Etchant: Tri-Acid

Figure 2 - Shell zone - 6082 ECT

Original magnification: 10X
Etchant: Tri-Acid

Microstructure:

Sub-samples were taken on surface (D8) and in bulk (D2) from each material and prepared for
microstructural evaluation. Inverse segregation layer is deeper on the sample coming from
electromagnetic casting technology and even above internal limit stated in Alcoa . Average
dendrite arms spacing of the alloy 6082 ECT is also higher than the maximum target stated
across Alcoa which is 25 m. Large part of the Iron particles observed in the sample 6082 ECT
are in as-cast phase form which is typical of an non-homogenized material but we also
observed many Chinese script (as-cast phase) in the microstructure. For the material from
Eling, Mg2Si particles are visible only in D2 position and they are in grains segregated
distribution. Grains size are also bigger in the material cast from Electromagnetic process.

Alcoa Inc. Confidential

2011-06-03

Page 2

Inverse Segregation (m)

Maximum depth (Figure 3 & 4)

Sample I.D. #

Max. depth

6082 ECT

Chinese script, Porosity, Rosette or other

observation (Figure 3 & 4)

334 m

Presence of Chinese scripts, primary silicon

and porosities

63 m

Few oxidized magnesium particles near the

surface

non-uniform
Max. depth

6082 AirSlip

Uniform

Figure 3 - 6082 ECT

Inverse segregation
Original magnification: 50X
Etchant: HF 0.5% 12 sec.

Figure 4 - 6082 Airslip

Inverse segregation
Original magnification: 100X
Etchant: HF 0.5% - 12 sec.

Dendrite Arms Spacing (DAS):

Sample I.D. #

DAS ( D8)
(Average of 40 measures)

DAS (D2)
(Average of 26 measures)

6082 ECT

26.1 m

Not enough defined

Figure 5 - DAS - 6082 ECT (D8)

Original magnification: 100X
Etchant: HF 505%

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Figure 6 - DAS - 6082 ECT (D2)

Original magnification: 100X
Etchant: HF 50%

2011-06-03

Page 3

Iron phases (1/8 position):

Sample I.D. #

Iron phase
transformation
and length

6082 ECT (D8)

Fe phase (figure 7)
Transformation
Refinement

6082 Airslip (D8)

Morphology

Fe phase (figure 8)
Transformation
Refinement

% Trans.
Not possible to evaluate but very low transformation
level, large quantity of elongated Iron phase. Presence % < 10 m
of Chinese scripts and rosettes (eutectic remelting).
% > 10 m

Figure 7 -Iron phases 6082 ECT (D8)

Original magnification: 400X
Etchant: 0.5% HF - 12 sec.

99.3%
97.4%
2.6%

Morphology

Mostly rounded/broken
particles

Figure 8 -Iron phases 6082 AirSlip (D8)

Original magnification: 400X
Etchant: 0.5% HF - 12 sec.

Iron phases (1/2 position):

Sample I.D. #

Iron phase
transformation
and length

6082 ECT (D2)

Fe phase (figure 9)
Transformation
Refinement

6082 Airslip (D2)

Morphology

Fe phase (figure 10)

Transformation
Refinement

% Trans.
Not possible to evaluate but very low transformation
level, large quantity of elongated Iron phase. Presence % < 10 m
of Chinese script and rosettes (eutectic remelting).
% > 10 m

Alcoa Inc. Confidential

2011-06-03

98.3%
99.6%

Morphology

Mostly rounded/broken
particles

0.4%

Page 4

Figure 9 -Iron phases 6082 ECT (D2)

Original magnification: 400X
Etchant: 0.5% HF - 12 sec.

Figure 10 -Iron phases 6082 AirSlip (D2)

Original magnification: 400X
Etchant: 0.5% HF - 12 sec.

Mg2Si distribution & grains size:

Sample I.D. #

Mg2Si
Grains size
D8 position

6082 ECT
Mg2Si distribution
(Figure 11)
Type
-

In solid solution

6082 Airslip

Grain size (m)

(Figure 13)
Size (m)
127.3

Equiaxe and uniform

Figure 11 - Mg2Si - 6082 ECT (D8)

Original magnification: 200X
Etchant: Kroll - 20 sec.

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Mg2Si distribution
(Figure 12)
Type
3-4
Uniform distribution,
mostly beta prime
precipitates smaller than
1 m

Grain size (m)

(Figure 14)
Size (m)
86.2

Equiaxe and uniform

Figure 12 - Mg2Si - 6082 Airslip (D8)

Original magnification: 200X
Etchant: Kroll - 20 sec.

2011-06-03

Page 5

Figure 13 -Grains size - 6082 ECT (D8)

Original magnification: 50X
Etchant: Barker's

Sample I.D. #

6082 ECT
Mg2Si distribution
(Figure 15)
Type
1

Mg2Si
Grains size
D2 position

Figure 14 -Grains size - 6082 airslip (D8)

Original magnification: 50X
Etchant: Barker's

Grains segregated

6082 Airslip

Grain size (m)

(Figure 17)
Size (m)
124.1

Equiaxe and uniform

Mg2Si distribution
(Figure 16)
Type
4
Uniform distribution,
mostly beta prime
precipitates smaller than
1 m

Grain size (m)

(Figure 18)
Size (m)
116.8

Equiaxe and uniform

Figure 15- Mg2Si - 6082 ECT (D2)

Original magnification: 200X
Etchant: Kroll - 20 sec.

Figure 16 - Mg2Si - 6082 Airslip (D2)

Original magnification: 200X
Etchant: Kroll - 20 sec.

Figure 17 -Grains size - 6082 ECT (D2)

Original magnification: 50X
Etchant: Barker's

Figure 18 -Grains size - 6082 airslip (D2)

Original magnification: 50X
Etchant: Barker's

Alcoa Inc. Confidential

2011-06-03

Page 6

Thermal treatment :

Some sub-samples were taken to evaluate thermal treatment response of each material. The
samples were first solution heat treated at 530C for one hour, quench and an aging treatment
at 175C for 8 hours was applied to the material. Both material show similar hardness after
thermal treatments.

Sample I.D. #
6082 ECT
6082 Airslip

Before SHT
57.2
38.5

Hardness (HRB)
After SHT
47.2
43.9

After aging
97.1
97.1

Conclusion :

This analysis show clearly that the submitted material cast with Electromagnetic Casting
Technology used without homogenization will not meet the same billet quality than
homogenized material cast with Airslip table. The main factor is the large presence of
elongated particles of iron phase and as-cast phase in form of Chinese scripts which could
induce pick-up defects during extrusion process. It is good to note than these Chinese scripts
will not be dissolved by homogenization treatment. Grains size, dendrite arms spacing as well
as inverse segregation are not as good than characteristics shown by typical Airslip casting
operation and these characteristics will not be improved by homogenization.

Alcoa Inc. Confidential

2011-06-03

Page 7

Sampling diagram:

Glossary:
Chemical composition :
Grain structure
Shell zone
Hardness
Inverse segregation
Other observation
Dendrites Arm Spacing

Iron phases

Mg2Si distribution

Grains size

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Percentage weight of major element done on an Optical Emission Spectrometer

according to ASTM standard E-1251.
Evaluation of the grains size uniformity and orientation on the billet's cross section.
Measure of the deepest section on the billet slice.
Airslip and maxicast : < 2 mm
Typical values are:
Conventional: < 5 mm
Brinell's hardness (10 mm ball\500 Kg load\12 seconds) according to ASTM
standard E10-10.
Measure of the deepest section of the studied sample (2.5 mm)
Tolerance
depth < 250 m
Verification of the presence of porosity, void, rosette, Chinese script or other
condition that could be detrimental for the process
Average dendrites arm spacing.
Target (air slip): < 25m
Evaluation of the level of transformation and of the refinement of the iron phases.
95% transformed
Targets
70% smaller than 10 m
Evaluation of the type and the distribution of the Mg2Si precipitates
Grade 1:
Not uniform - mostly grain segregated
Grade 2:
Not so uniform. Mix of ' and
Grade 3:
Fairly uniform. Mix of ' and
Grade 4:
Uniform and rich. Mostly '
Grade 5;
Very uniform and rich. All '
Average grains size done with linear intercept method (ASTM # E112).
Target : < 150m
2011-06-03

Page 8