Enhanced Refinement of Al-Zn-Mg-Cu-Zr Alloy via Internal Cooling with Annular Electromagnetic Stirring above the Liquidus Temperature

Effects of ESMT on Microstructure and Mechanical Properties of Al-8Zn-2Mg-1.5Cu-0.15Sc-0.15Zr Cast Alloy in Squeeze Casting Process

Al-8Zn-2Mg-1.5Cu-0.15Sc-0.15Zr alloy with high-strength performance as well as good castability has been developed. In this study, effects of electromagnetic stirring melt treatment (ESMT) on microstructure and mechanical properties of the alloy in the squeeze casting process were investigated. The results show that solidification structure and mechanical properties are significantly improved by ESMT; compared with the conventional squeeze casting, the average grain size decreases from 112 μm without ESMT to 53 μm with ESMT. Meanwhile coarse primary Al3(Sc, Zr) particles unavoidably occurred in cases without ESMT disappear, and segregation degree of the main elements of Zn, Mg, Cu are greatly alleviated; the tensile strength increases from 590 MPa to 610 MPa, and the elongation increases from 9% to 11%. The structure refinement and homogenization should owe to uniform temperature and composition distribution by ESMT under squeeze casting with rapid solidification.

Research on Microstructure and Mechanical Properties of Rheological Die Forging Parts of Al-6.54Zn-2.40Cu-2.35Mg-0.10Zr(-Sc) Alloy

High-strength aluminum alloy (mainly refers to the 7xxx series) is the optimum material for lightweight military equipment. However, this type of aluminum alloy is a wrought aluminum alloy. If it is directly formed by traditional casting methods, there will inevitably be problems such as coarseness, unevenness, looseness, and hot cracking in the structure, which will greatly affect the final performance of the part. Based on the internal cooling with annular electromagnetic stirring (IC-AEMS) method, a new technology of rheological die forging is developed in this paper, and the scale-reduced parts of a brake hub of Al-6.54Zn-2.40Cu-2.35Mg-0.10Zr aluminum alloy were prepared. The influence of IC-AEMS and the addition of rare element Sc on the structure and mechanical properties of the parts was studied. An optical microscope and scanning electron microscope (SEM) were used to observe the microstructure evolution, energy dispersive spectroscopy (EDS) was used to analyze the phase distribution and composition, and the mechanical properties of the parts were tested by uniaxial tensile tests. The results show that the addition of Sc element can effectively refine the grains and improve the strength and elongation of the material; the application of IC-AEMS improves the cooling rate of the melt, increases the effective nucleation rate, and the grains are further refined. Through process optimization, scale-reduced parts of a brake hub with good formability and mechanical properties can be obtained, the ultimate tensile strength is 597.2 ± 3.1 MPa, the yield strength is 517.8 ± 4.3 MPa, and the elongation is 13.7 ± 1.3%.

Effect of Cooling Rates on the Microstructure and Mechanical Property of La Modified Al7SiMg Alloys Processed by Gravity Die Casting and Semi-Solid Die Casting

Rare earth (RE) additions are capable of refining the α-Al phase as well as modifying the eutectic Si particles of alloys. The cooling rate in casting process should be carefully concerned when the Al-Si alloys are refined and modified by adding RE elements. In this study, the effect of cooling rates on the microstructure and mechanical properties of La modified Al-7.0Si-0.3Mg alloys was studied in gravity die casting and semi-solid die casting. It is found that in La modified Al-7.0Si-0.3Mg alloys, with increasing the cooling rate from 0.2 to 9 K/s in gravity die casting, the α-Al grains are greatly refined and the Si particles are modified to branching morphology, which evidently increases the UTS and elongation of alloys. In addition, when increasing the cooling rate from 30 to 130 K/s in semi-solid die casting, the α-Al grains are refined from 140 to 47 μm, and the Si particles are modified to fibrous morphology, which increases the UTS from 190 to 230 MPa and elongation from 10% to 11%. However, the 0.4 wt.% La addition results to La-rich phases formed in microstructure, which impairs the mechanical properties of Al-7.0Si-0.3Mg alloys in semi-solid die casting.