Microstructural refinement in ultrasonically modified A356 aluminum castings

Rader, Katherine E.; Sabau, Adrian S.; Rohatgi, Aashish

doi:10.1007/s10853-023-08999-y

Microstructural refinement in ultrasonically modified A356 aluminum castings

Journal Article · Thu Nov 23 00:00:00 EST 2023 · Journal of Materials Science

DOI:https://doi.org/10.1007/s10853-023-08999-y· OSTI ID:2246591

^[1]; Sabau, Adrian S. ^[2]; ^[1]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Two A356 aluminum alloys (Al-Si-Mg), one with 0.09 wt.% Fe and one with 0.91 wt.% Fe, were cast in a graphite mold with the simultaneous application of local ultrasonic intensification to refine the as-cast microstructure. Ultrasonication during casting transformed the morphology of primary Al grains from dendritic (~140-290 microns in size) to globular (~33-36 microns in size). The alloy with high Fe exhibited globular grains at distances up to 45 mm away from the ultrasound probe, while the alloy with low Fe exhibited globular grains at distances only up to 6 mm away from the ultrasound probe. Near the location of the ultrasound probe (< 2 mm away), a second non-dendritic microstructural morphology was observed with fine aluminum grains (~9-25 microns in size). This unique fine-grained morphology has not been previously reported, contains a greater concentration of Si relative to the globular microstructure, and may be a large, fully eutectic region. Ultrasonication during casting also transformed the morphology of the ß-Al₅FeSi phase particles (which are deleterious to the strength and ductility of the alloy) in the high Fe alloy from needle-like to rectangular, which could enable the greater use of secondary Al alloys. Thermodynamic simulations conducted to calculate the solidification paths of the two alloys studied predict that the ß-Al₅FeSi phase begins to form earlier in the alloy with high Fe. Finally, data suggest that the ß-Al₅FeSi phase (which is more abundant in alloys with high Fe content) may enhance ultrasonically-induced grain refinement.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: AC05-00OR22725; AC05-76RL01830

OSTI ID:: 2246591

Alternate ID(s):: OSTI ID: 2251614

Report Number(s):: PNNL-SA--186579

Journal Information:: Journal of Materials Science, Journal Name: Journal of Materials Science Journal Issue: 45 Vol. 58; ISSN 0022-2461

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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