A New Recycled Al–Si–Mg Alloy for Sustainable Structural Die Casting Applications

Cinkilic, Emre; Moodispaw, Michael; Zhang, Jianyue; Miao, Jiashi; Luo, Alan A.

doi:10.1007/s11661-022-06711-4

A New Recycled Al–Si–Mg Alloy for Sustainable Structural Die Casting Applications

Journal Article · Wed May 18 00:00:00 UTC 2022 · Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science

DOI:https://doi.org/10.1007/s11661-022-06711-4· OSTI ID:2438413

Cinkilic, Emre ^[1]; Moodispaw, Michael ^[2]; Zhang, Jianyue ^[2]; Miao, Jiashi ^[2]; Luo, Alan A. ^[2]

Hakkari University (Turkey); The Ohio State University, Columbus, OH (United States); The Ohio State University
The Ohio State University, Columbus, OH (United States)

The use of secondary aluminum for structural components in the automotive industry is limited by the high Fe contents in recycled alloys which often result in the formation of brittle β-Al₅FeSi phase which reduces the ductility of aluminum castings. In this study, a new secondary Al-Si-Mg alloy with high Fe content (about 0.44 wt.%) was developed for die casting applications. Based on thermodynamic modeling, manganese was added to obtain a designed Fe-to-Mn ratio of 2 which successfully suppressed the formation of β-Al₅FeSi phase, by forming α-Al₁₅(Fe,Mn)₃Si₂ phase with rounded or hexagonal morphology. Additionally, a fine needle-like π-Al₈FeMg₃Si₂ phase was also formed within the eutectic regions. The new recycled alloy showed comparable mechanical properties in as-cast and heat treated (T5 and T6) conditions to three major primary die cast alloys (≤ 0.2 wt.% Fe) with similar composition. Ductility up to 7.4% from tensile elongation was achieved in as-cast recycled alloy due to the modification and refinement of α-Al₁₅(Fe,Mn)₃Si₂ by Mn and Sr additions. Tensile elongation was further improved to 9.1% after T6 treatment as a result of dissolution of π-Al₈FeMg₃Si₂ phase, defragmentation of α-Al₁₅(Fe,Mn)₃Si₂ and the spheroidization of Si phase. This new alloy provides a promising path for increasing usage of recycled aluminum with high Fe content in structural die castings for automotive and other applications.

View Accepted Manuscript (DOE)

Research Organization:: The Ohio State University, Columbus, OH (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)

Grant/Contract Number:: EE0007897

OSTI ID:: 2438413

Alternate ID(s):: OSTI ID: 1976727

Journal Information:: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science, Journal Name: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science Journal Issue: 8 Vol. 53; ISSN 1073-5623

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

References (29)

Microstructure and fracture behavior of Al‐Si‐Mg alloy prepared with recycled alloy Song, L. Y.; Liu, H. X.; Nie, S. N. Materialwissenschaft und Werkstofftechnik, Vol. 50, Issue 4 https://doi.org/10.1002/mawe.201800041	journal	April 2019
Interactions between iron, manganese, and the Al-Si eutectic in hypoeutectic Al-Si alloys Dinnis, C. M.; Taylor, J. A.; Dahle, A. K. Metallurgical and Materials Transactions A, Vol. 37, Issue 11 https://doi.org/10.1007/BF02586163	journal	November 2006
Effect of Strontium and Phosphorus on Eutectic Al-Si Nucleation and Formation of β-Al5FeSi in Hypoeutectic Al-Si Foundry Alloys Cho, Y. H.; Lee, H. -C.; Oh, K. H. Metallurgical and Materials Transactions A, Vol. 39, Issue 10 https://doi.org/10.1007/s11661-008-9580-8	journal	July 2008
Secondary Al-Si-Mg High-pressure Die Casting Alloys with Enhanced Ductility Bösch, Dominik; Pogatscher, Stefan; Hummel, Marc Metallurgical and Materials Transactions A, Vol. 46, Issue 3 https://doi.org/10.1007/s11661-014-2700-8	journal	December 2014
A Formation Map of Iron-Containing Intermetallic Phases in Recycled Cast Aluminum Alloys Cinkilic, E.; Ridgeway, C. D.; Yan, X. Metallurgical and Materials Transactions A, Vol. 50, Issue 12 https://doi.org/10.1007/s11661-019-05469-6	journal	September 2019
The role of iron in the formation of porosity in Al-Si-Cu-based casting alloys: Part III. A microstructural model Taylor, J. A.; Schaffer, G. B.; StJohn, D. H. Metallurgical and Materials Transactions A, Vol. 30, Issue 6 https://doi.org/10.1007/s11661-999-0103-z	journal	June 1999
Evolution of Fe-Rich Intermetallics in Al-Si-Cu 319 Cast Alloy with Various Fe, Mo, and Mn Contents Jin, Lanfeng; Liu, Kun; Chen, X. Grant Metallurgical and Materials Transactions B, Vol. 50, Issue 4 https://doi.org/10.1007/s11663-019-01584-2	journal	May 2019
The Development of High Strength and Ductility in High-Pressure Die-Cast Al-Si-Mg Alloys from Secondary Sources Lumley, Roger JOM, Vol. 71, Issue 1 https://doi.org/10.1007/s11837-018-3121-8	journal	September 2018
Diffusion coefficients of some solutes in fcc and liquid Al: critical evaluation and correlation Du, Yong; Chang, Y. A.; Huang, Baiyun Materials Science and Engineering: A, Vol. 363, Issue 1-2 https://doi.org/10.1016/S0921-5093(03)00624-5	journal	December 2003
The role of strontium in modifying aluminium–silicon alloys Timpel, M.; Wanderka, N.; Schlesiger, R. Acta Materialia, Vol. 60, Issue 9 https://doi.org/10.1016/j.actamat.2012.03.031	journal	May 2012
In situ quantification of the nucleation and growth of Fe-rich intermetallics during Al alloy solidification Puncreobutr, C.; Phillion, A. B.; Fife, J. L. Acta Materialia, Vol. 79 https://doi.org/10.1016/j.actamat.2014.07.018	journal	October 2014
Material design and development: From classical thermodynamics to CALPHAD and ICME approaches Luo, Alan A. Calphad, Vol. 50 https://doi.org/10.1016/j.calphad.2015.04.002	journal	September 2015
Evolution of Fe based intermetallic phases in Al–Si hypoeutectic casting alloys: Influence of the Si and Fe concentrations, and solidification rate Gorny, Anton; Manickaraj, Jeyakumar; Cai, Zhonghou Journal of Alloys and Compounds, Vol. 577 https://doi.org/10.1016/j.jallcom.2013.04.139	journal	November 2013
Influence of impurities, strontium addition and cooling rate on microstructure evolution in Al-10Si-0.3Fe casting alloys Yu, J. M.; Wanderka, N.; Rack, A. Journal of Alloys and Compounds, Vol. 766 https://doi.org/10.1016/j.jallcom.2018.06.372	journal	October 2018
Characterization of externally solidified crystals in a high-pressure die-cast AlSi10MnMg alloy and their effect on porosities and mechanical properties Jiao, X. Y.; Zhang, Y. F.; Wang, J. Journal of Materials Processing Technology, Vol. 298 https://doi.org/10.1016/j.jmatprotec.2021.117299	journal	December 2021
Evolution of sludge particles in secondary die-cast aluminum alloys as function of Fe, Mn and Cr contents Ferraro, Stefano; Fabrizi, Alberto; Timelli, Giulio Materials Chemistry and Physics, Vol. 153 https://doi.org/10.1016/j.matchemphys.2014.12.050	journal	March 2015
Effect of iron on the microstructure and mechanical property of Al–Mg–Si–Mn and Al–Mg–Si diecast alloys Ji, Shouxun; Yang, Wenchao; Gao, Feng Materials Science and Engineering: A, Vol. 564 https://doi.org/10.1016/j.msea.2012.11.095	journal	March 2013
Iron-Containing Intermetallic Phases in Al-Si Based Casting Alloys Taylor, John A. Procedia Materials Science, Vol. 1 https://doi.org/10.1016/j.mspro.2012.06.004	journal	January 2012
Improving aluminum recycling: A survey of sorting and impurity removal technologies Gaustad, Gabrielle; Olivetti, Elsa; Kirchain, Randolph Resources, Conservation and Recycling, Vol. 58 https://doi.org/10.1016/j.resconrec.2011.10.010	journal	January 2012
As-cast morphology of iron-intermetallics in Al–Si foundry alloys Dinnis, Cameron M.; Taylor, John A.; Dahle, Arne K. Scripta Materialia, Vol. 53, Issue 8 https://doi.org/10.1016/j.scriptamat.2005.06.028	journal	October 2005
The kinetics of Fe-rich intermetallic formation in aluminium alloys: In situ observation Wang, J.; Lee, P.; Hamilton, R. Scripta Materialia, Vol. 60, Issue 7 https://doi.org/10.1016/j.scriptamat.2008.11.048	journal	April 2009
Long-Term Strategies for Increased Recycling of Automotive Aluminum and Its Alloying Elements Løvik, Amund N.; Modaresi, Roja; Müller, Daniel B. Environmental Science & Technology, Vol. 48, Issue 8 https://doi.org/10.1021/es405604g	journal	March 2014
Thermodynamic Analysis of Contamination by Alloying Elements in Aluminum Recycling Nakajima, Kenichi; Takeda, Osamu; Miki, Takahiro Environmental Science & Technology, Vol. 44, Issue 14 https://doi.org/10.1021/es9038769	journal	June 2010
Removal of Iron From Aluminum: A Review Zhang, Lifeng; Gao, Jianwei; Damoah, Lucas Nana Wiredu Mineral Processing and Extractive Metallurgy Review, Vol. 33, Issue 2 https://doi.org/10.1080/08827508.2010.542211	journal	March 2012
Recent advances in light metals and manufacturing for automotive applications Luo, A. A. CIM Journal, Vol. 12, Issue 3 https://doi.org/10.1080/19236026.2021.1947088	journal	July 2021
Design for Recycling Gaustad, Gabrielle; Olivetti, Elsa; Kirchain, Randolph Journal of Industrial Ecology, Vol. 14, Issue 2 https://doi.org/10.1111/j.1530-9290.2010.00229.x	journal	March 2010
Materials for Automotive Lightweighting Taub, Alan; De Moor, Emmanuel; Luo, Alan Annual Review of Materials Research, Vol. 49, Issue 1 https://doi.org/10.1146/annurev-matsci-070218-010134	journal	July 2019
Effect of Mn/Fe ratio on Fe removal efficiency and tensile ductility of an Al–7.0Si–2.4Fe alloy Song, Dongfu; Zhao, Yuliang; Wang, Zhi Journal of Materials Research, Vol. 36, Issue 6 https://doi.org/10.1557/s43578-021-00194-6	journal	March 2021
Preparation and Melting of Scrap in Aluminum Recycling: A Review Capuzzi, Stefano; Timelli, Giulio Metals, Vol. 8, Issue 4 https://doi.org/10.3390/met8040249	journal	April 2018

Similar Records

The effect of Sr and Fe additions on the microstructure and mechanical properties of a direct squeeze cast Al-7Si-0.3Mg alloy

Journal Article · Sat May 01 04:00:00 UTC 1999 · Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science · OSTI ID:363993

Analyzing the microstructural evolution and hardening response of an Al-Si-Mg casting alloy with Cr addition

Journal Article · Wed Aug 15 04:00:00 UTC 2018 · Materials Characterization · OSTI ID:22805110

Related Subjects

36 MATERIALS SCIENCE
Al-Fe intermetallics
Al-Si-Mg alloys
Recycled aluminum
alloy development
solidification
structural castings

A New Recycled Al–Si–Mg Alloy for Sustainable Structural Die Casting Applications

Citation Formats

References (29)

Similar Records

Related Subjects