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Title: Replication of engine block cylinder bridge microstructure and mechanical properties with lab scale 319 Al alloy billet castings

In recent years, aluminum alloy gasoline engine blocks have in large part successfully replaced nodular cast iron engine blocks, resulting in improved vehicle fuel efficiency. However, because of the inadequate wear resistance properties of hypoeutectic Al–Si alloys, gray iron cylinder liners are required. These liners cause the development of large tensile residual stress along the cylinder bores and necessitate the maximization of mechanical properties in this region to prevent premature engine failure. The aim of this study was to replicate the engine cylinder bridge microstructure and mechanical properties following TSR treatment (which removes the sand binder to enable easy casting retrieval) using lab scale billet castings of the same alloy composition with varying cooling rates. Comparisons in microstructure between the engine block and the billet castings were carried out using optical and scanning electron microscopy, while mechanical properties were assessed using tensile testing. The results suggest that the microstructure at the top and middle of the engine block cylinder bridge was successfully replicated by the billet castings. However, the microstructure at the bottom of the cylinder was not completely replicated due to variations in secondary phase morphology and distribution. The successful replication of engine block microstructure will enable the futuremore » optimization of heat treatment parameters. - Highlights: • A method to replicate engine block microstructure was developed. • Billet castings will allow cost effective optimization of heat treatment process. • The replication of microstructure in the cylinder region was mostly successful. • Porosity was more clustered in the billet castings compared to the engine block. • Mechanical properties were lower in billet castings due to porosity and inclusions.« less
Authors:
 [1] ; ;  [1] ;  [2]
  1. Centre for Near-net-shape Processing of Materials, Ryerson University, 101 Gerrard Street East, Toronto, Ontario M5B2K3 (Canada)
  2. Nemak of Canada Corporation, 4600 G.N. Booth Drive, Windsor, Ontario N9C4G8 (Canada)
Publication Date:
OSTI Identifier:
22288726
Resource Type:
Journal Article
Resource Relation:
Journal Name: Materials Characterization; Journal Volume: 87; Other Information: Copyright (c) 2013 Elsevier Science B.V., Amsterdam, The Netherlands, All rights reserved.; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; ALUMINIUM ALLOYS; CAST IRON; CASTINGS; FRACTOGRAPHY; HEAT TREATMENTS; INTERNAL COMBUSTION ENGINES; MICROSTRUCTURE; RESIDUAL STRESSES; SCANNING ELECTRON MICROSCOPY; WEAR RESISTANCE