Microstructure-refinement–driven enhanced tensile properties of high-pressure die-cast A380 alloy through friction stir processing

Samanta, Avik; Seffens, Rob J.; Das, Hrishikesh; Guzman, Anthony D.; Roosendaal, Timothy J.; Garcia, David; Song, Miao; Grant, Glenn J.; Jana, Saumyadeep

doi:10.1016/j.jmapro.2022.04.027

Title: Microstructure-refinement–driven enhanced tensile properties of high-pressure die-cast A380 alloy through friction stir processing

Journal Article · Fri Apr 29 00:00:00 EDT 2022 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2022.04.027· OSTI ID:1909180

^[1]; Seffens, Rob J. ^[1]; Das, Hrishikesh ^[1]; Guzman, Anthony D. ^[1]; Roosendaal, Timothy J. ^[1]; Garcia, David ^[1]; Song, Miao ^[1];

^[1]; Jana, Saumyadeep ^[1]

Pacific Northwest National Lab. (PNNL), Richland, WA (United States)

This work employs friction stir processing (FSP), a well-known severe plastic deformation technique, to selectively modify the microstructure of thin-walled, high-pressure die-cast (HPDC) aluminum alloy A380, a major HPDC alloy fabricated in the die casting sector. FSP effectively breaks down Al dendrites and acicular Si particles, creating a homogenized distribution of equiaxed Si particles in the aluminum matrix. After FSP, the refined Si particles (~1.5 µm) are smaller than the eutectic Si particles (3–8 µm) in HPDC condition. In addition, interparticle distance has decreased almost 50% compared to dendritic arm spacing, and FSP has reduced the aspect ratio of Si particles to ~2. Furthermore, FSP eliminates porosity, and breaks down needle-like second-phase Fe-Mn and Cu-rich particles, yielding a refined, homogeneous distribution. The FSP-induced microstructural refinement and porosity reduction improve bulk yield strength and ductility by 23% and 66%. Tensile properties are enhanced beyond those of the die skin of the HPDC plate, and the alloy possesses lower defect density and a highly refined microstructure. This study establishes the viability of FSP as a tool for microstructure modification and mechanical property improvement for HPDC Al alloys for the light-weighting goal of the automotive industries.

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Research Organization:: Pacific Northwest National Lab. (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 1909180

Report Number(s):: PNNL-SA-170274

Journal Information:: Journal of Manufacturing Processes, Vol. 78; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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