The Effect of Si Content on the Mechanical Properties of Rheocast Al Components Using the RHEOMETAL^TM Process

Abstract:

The RHEOMETALTM process is a commercially used semi-solid process for production of high integrity cast components. The process differs from most other semi-solid casting processes in that temperature control is not necessary during processing and large amount of slurry with required solid fraction can be quickly produced. The simplicity of this process has led to a large commercial interest during the last year. This work is based on an investigation regarding the variation of as-cast mechanical properties for secondary Al-Si based alloys (~2.5 % Cu) with a Si content varying from 4.55 to 8.90 % using the RHEOMETALTM process. The purpose was to find the most suitable Al-Si alloy for rheocasting, in comparison with the common HPDC-alloy A380 (EN-AC46000). It was found that lower Si containing alloys exhibited better elongation but slightly lower yield strength. The alloy containing 5.39 wt% Si showed the highest ultimate tensile strength in this investigation. The lower Si containing alloys also demonstrated better feedability in the rheocasting process, which is contrary to what normally is found for normal liquid casting processes. Based on the results in this investigation it is recommended to use an alloy containing about 5-7 wt% Si for rheocasting purposes.