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Casting Alloy Design and Characterization

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (20 April 2024) | Viewed by 14190

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Dr. Carlos Alexandre Dos Santos

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Guest Editor

School of Technology, Pontifícia Universidade Católica do Rio Grande do Sul, Porto Alegre 90619-900, Brazil
Interests: materials science and engineering; solidification; material testing; wear; manufacturing processes
Special Issues, Collections and Topics in MDPI journals

Dr. Eleani Maria Da Costa

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Guest Editor

School of Technology, Pontifícia Universidade Católica do Rio Grande do Sul, Porto Alegre 90619-900, Brazil
Interests: materials science and engineering; solidification; material testing; corrosion sciences; microscopy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metal casting processes normally used in the foundry industry (e.g., gravity or pressure casting) are subjected to a wide range of operational parameters. Consequently, a variety of solidification microstructures are formed, directly affecting mechanical, physical and chemical properties, strength–ductility response, corrosion and wear resistance, electrical conductivity, and others. In general, aspects such as the phase and microconstituents present, grain size, macrostructure morphology, porosity, and alloying segregation are responsible for defining the main properties of the final casting. Since there is a close correlation between solidification conditions, microstructure and properties, the effects of solidification conditions and alloying elements on microstructure design and the resulting properties in cast alloys have stimulated new research interest. In addition, it is fundamental to understand the influence of these characteristics on subsequent manufacturing processes such as heat treatment, forming, welding and machining.

The possibility of replacing wrought alloys with cast alloys, with associated cost reduction and improved mechanical properties, has motivated the modern industry to design new alloys by adding new elements or by using additive manufacturing techniques. Thus, this Special Issue aims to collect research articles focused on the design and characterization of cast alloys, especially on the interrelationship between solidification, microstructure and properties; both experimental and theoretical research are welcome.

The scope of the Special Issue includes, but is not limited to, the following technical topics:

Casting processes and novel techniques;
Solidification: experimental and theoretical studies;
Microstructures and properties characterization;
Numerical and analytical simulations;
Heat and mass transfer;
Processing-structure-property relations;
Industrial applications.

Dr. Carlos Alexandre Dos Santos
Dr. Eleani Maria Da Costa
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

casting
solidification
microstructures
properties
characterization
casting design

Related Special Issue

Casting Alloy Design and Characterization—2nd Edition in Metals

Published Papers (11 papers)

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Editorial

Jump to: Research, Review

4 pages, 347 KiB

Open AccessEditorial

Casting Alloy Design and Characterization

by Eleani Maria Da Costa and Carlos Alexandre Dos Santos

Metals 2022, 12(7), 1228; https://doi.org/10.3390/met12071228 - 20 Jul 2022

Cited by 1 | Viewed by 1196

Abstract

Metal casting processes routinely used in the foundry industry (e.g., gravity or pressure casting) are subject to a wide range of operational parameters. Since there is a close correlation between solidification conditions, microstructure, and properties, the effects of the solidification thermal parameters and alloying elements on microstructure designs and the resulting properties in cast alloys have stimulated new research interest. Thus, this Special Issue aims to collect research articles focused on the design and characterization of cast alloys, especially on the interrelationship between solidification, microstructure, and properties; both experimental and theoretical research are welcome for contribution. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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Research

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12 pages, 7617 KiB

Open AccessArticle

Study on the Optimization of Investment Casting Process of Exhaust Elbow for High-Power Engine

by Shiyu Xie, Zhaozhao Lv and Shengquan Dong

Metals 2024, 14(4), 481; https://doi.org/10.3390/met14040481 - 20 Apr 2024

Viewed by 240

Abstract

The high-power engine exhaust elbow has a complex construction, which makes it susceptible to casting flaws that could negatively impact its functionality. Therefore, the investment casting scheme was established and optimized in this study in order to cast structurally complete exhaust elbows for high-horsepower engines. ProCAST software was used to simulate and optimize the casting and solidification processes. The optimal process parameters were determined as follows: pouring temperature of 1650 °C, pouring speed of 1.5 kg/s, and shell preheating temperature of 1050 °C. The optimization of the primary parameters of the casting process, along with the results of dimensional accuracy analysis, shape and positional deviation, and defect detection, were validated through testing. The results indicated that the optimized castings had no casting defects and complied with the design specifications. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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13 pages, 13477 KiB

Open AccessArticle

Semi-Solid Slurries for Rheocasting of Hypoeutectic Al-Si-X Alloys Produced by Self-Stirring in Serpentine Channels

by Hernández Alfredo, Chávez José Federico, Hernández Aldo and Suárez Miguel Ángel

Metals 2024, 14(4), 413; https://doi.org/10.3390/met14040413 - 30 Mar 2024

Viewed by 564

Abstract

Nowadays it is common to see the production of complex and critical automotive and aeronautical components reduced in weight for energy efficiency using light alloys with improved microstructural and mechanical properties. The casting processes involved in this trend are strong; in this study, an optimized design of a vertical serpentine channel and a novel design of a horizontal serpentine channel to produce semi-solid slurry (S2S) with thixotropic behavior by self-stirring for rheocasting of A380 and A356 alloys are tested. Simultaneously, chilling during solidification, flow development, and shearing on the alloys to improve the performance of solid fractions and self-stirring at high shear rate are applied. The effects of these conditions on the modification of the morphology transition of the α(Al) phase from dendrite to equiaxed grain are discussed. The results suggest the ability of the mentioned processes to promote the morphological transition of the primary solid due to the produced equiaxed grains of α(Al) phase having sizes between 25–50 µm from A380 alloy processed by vertical self-stirring. On the other hand, the treatment of the A356 alloy using the new horizontal serpentine channel produces equiaxed grains with an average size of 39 µm. Unexpected Si crystals, trapped in the α(Al) phase using both methods with both alloys, are detected. The applied operation parameters were aided by gravity-pouring close to the liquidus temperature, and the obtained microstructural results show the ability for S2S to form alongside thixotropic behavior and non-dendritic solidification by mean of self-stirring in the serpentine channels, suggesting the potential for further experiments under die-casting conditions. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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16 pages, 6661 KiB

Open AccessArticle

Effect of the Fe/Mn Ratio on the Microstructural Evolution of the AA6063 Alloy with Homogenization Heat Treatment Interruption

by Adolfo Galván Avalos, Jesús Torres Torres and Alfredo Flores Valdés

Metals 2024, 14(4), 373; https://doi.org/10.3390/met14040373 - 23 Mar 2024

Viewed by 564

Abstract

The casting structure of the AA6063 alloy contains intermetallic particles of β-Al₅FeSi, which can result in the fragility of the cast pieces. However, with heat treatment, the β phase transforms from a needle or plate form into an intermetallic phase known as α, which resembles Chinese-script in its morphology. To analyze the effect of the ratio of Fe/Mn with different ratios of 0.5, 0.75, and 1, a heat treatment process is used with intermittent interruptions. The alloy is subjected to a temperature of 575 °C for 12 h to determine the microstructural evolution of the β-Al₆FeMn and α-Al₁₅(FeMn)₃Si₂ phases. This study used scanning electron microscopy to conduct point analyses and elemental mappings of the intermetallics found in the casting and heat treatment samples. Additionally, X-ray diffraction was employed to determine the stoichiometry of the present phases. The results indicated that the cast structure contains β-Al₆FeMn and α-Al₁₅(FeMn)₃Si₂ phases and that the β-Al₆FeMn phase transforms into the α-Al₁₅(FeMn)₃Si₂ phase upon completion of the heat treatment process. By using specific Fe/Mn ratios, the formation of the needle-shaped Al₅FeSi phase in the casting structure of the alloy can be inhibited, leading to the precipitation of phases such as β-Al₆FeMn and α-Al₁₅(FeMn)₃Si₂ instead. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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18 pages, 13922 KiB

Open AccessArticle

Effect of Gating System Design on the Quality of Aluminum Alloy Castings

by Marek Brůna, Marek Galcik, Richard Pastircak and Elena Kantorikova

Metals 2024, 14(3), 312; https://doi.org/10.3390/met14030312 - 07 Mar 2024

Viewed by 777

Abstract

In this paper, a naturally pressurized gating system has been designed to reduce the turbulence of the melt during casting. The influence of gate dimensions, foam filters, a trident gate and a vortex element were evaluated. Their effect on melt velocity, flow characteristics, number of oxides, casting properties and mechanical properties were observed. ProCAST Simulation software v.2023 and a water flow test were also evaluated to assist in the experimental evaluation of the castings. Melts showed a relationship between melt velocity and porosity of castings. Quantitative evaluation of the surface porosity showed a trend of decreasing porosity with decreasing melt velocity. The greatest reduction in the melt velocity was achieved by a M4 design, which was associated with the highest reduction in the oxides. The pores analyzed proved the presence of oxide layers on their inner surface and a possible theory of pore formation when the initiator of porosity is entrained double oxide layers. The best metal yield was achieved with M1, but the difference between M2 and M4 was negligible (2–5% yield difference), so it can be stated that the beneficial effect of the M4 design in providing the best quality castings is not negated by the increase in metal yield. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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18 pages, 6060 KiB

Open AccessArticle

Electrical Equivalent Circuit Model Prediction of High-Entropy Alloy Behavior in Aggressive Media

by Jose Cabrera-Peña, Santiago Jose Brito-Garcia, Julia Claudia Mirza-Rosca and Gustavo M. Callico

Metals 2023, 13(7), 1204; https://doi.org/10.3390/met13071204 - 29 Jun 2023

Viewed by 890

Abstract

Due to the optimistic outcomes of the research on high-entropy alloys, new designs of these alloys are being encouraged. We studied the high-entropy CoCrFeMoNi alloy and the CoCrFeMoNi alloy doped with Zr. In order to choose the best electrical equivalent circuit for the prediction of the behavior of these high-entropy alloys at various potentials in artificial seawater, electrochemical impedance spectroscopy (EIS) measurements were conducted on samples with and without Zr-doped CoCrFeMoNi. At various potential levels, the impedance spectra were measured between −1.0 and +0.8 V vs. SCE. The study consists of a preliminary section with microstructure by metallography, open-circuit potential, and linear polarization curves by direct-current tests followed by visual analysis of the impedance spectra, and, finally, the selection of an equivalent electrical circuit model to fit the experimental data. By leveraging the advantages of EIS analysis, the information is essential for materials development, corrosion-mitigation strategies, and the successful implementation of these alloys in practical applications. It is important to note that selecting an equivalent circuit is often an iterative and subjective process, as it involves a balance between model complexity and the ability to accurately represent the system’s behavior. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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22 pages, 10044 KiB

Open AccessArticle

Microstructure, Hardness, and Linear Reciprocating Sliding Wear Response of Directionally Solidified Al–(2.5, 3.5, 4.5)Cu–(0.25, 0.50)Cr Alloys

by Rafael V. Lantmann, André M. S. Mariante, Tiago V. Pinheiro, Eleani M. da Costa and Carlos A. dos Santos

Metals 2023, 13(7), 1178; https://doi.org/10.3390/met13071178 - 24 Jun 2023

Cited by 1 | Viewed by 814

Abstract

Aluminum alloys containing transition metal alloying elements have attracted interest from researchers. The effect of Cr additions of 0.25 and 0.50% on the thermal profile, microstructure, hardness, and linear reciprocating sliding wear response of as-cast hypoeutectic Al–Cu alloys with 2.5, 3.5, and 4.5% Cu (wt.%) was investigated. The binary Al–Cu and ternary Al–Cu–Cr alloys were directionally solidified under upward non-steady state heat transfer conditions using a dedicated solidification apparatus. Thermal analysis based on differential thermal analysis (DTA) and cooling curve profiles was performed to determine solidification thermal parameters such as Liquidus temperature (T_L), transformation enthalpy (ΔH), and liquid cooling rate (Ṫ_L). Samples extracted from the solidified ingots were submitted to optical microscopy, hardness measurement, and linear reciprocating sliding wear test using a high-frequency reciprocating rig (HFRR). The results showed a decrease at the beginning of solidification (T_L) and of the transformation enthalpy (ΔH) when both alloy Cu and Cr contents increased, with a higher influence of Cu. The addition of Cu decreased cooling rates, whereas the increase in the alloy Cr concentration showed an opposite behavior, increasing cooling rates. The refinement of the primary dendrite arm spacing (λ₁), as a consequence of the increase in alloying elements and solidification cooling rates, enhanced the hardness of the alloys, with the maximum value of 58 HB achieved in the ternary Al–4.5Cu–0.50Cr alloy. The wear tests indicated a better response to wear associated with microstructure refinement for the alloys with 2.5% Cu, for both Cr contents, an almost constant behavior for the 3.5% Cu alloys, and an opposite performance for the alloys with 4.5% Cu alloys that showed better wear resistance with coarsening of the λ₁ and with the increase in the amount of the eutectic microconstituent. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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14 pages, 8171 KiB

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Novel Cast and Wrought Al-3Zn-3Mg-3Cu-Zr-Y(Er) Alloys with Improved Heat Resistance

by Maria V. Glavatskikh, Ruslan Yu. Barkov, Leonid E. Gorlov, Maxim G. Khomutov and Andrey V. Pozdniakov

Metals 2023, 13(5), 909; https://doi.org/10.3390/met13050909 - 08 May 2023

Cited by 3 | Viewed by 1251

Abstract

The main weaknesses of commercial high-strength Al-Zn-Mg-Cu-based alloys are the low casting properties, corrosion and heat resistance. Al-Zn-Mg-Cu-based alloys with Zn/Mg ratio equal to 1 combine good strength, corrosion and heat resistance. Al alloys with atomic ratio Cu/Y(Er) equal to 4 have a narrow solidification range and high solidus temperature. Two basic principles were taken into consideration to develop novel heat-resistant Al-Zn-Mg-Cu-based alloys with improved casting properties: 1—mass ratio of Zn/Mg = 1, and 2—atomic ratio of Cu/Y(Er) = 4. The microstructure, phase transformation and tensile properties of the novel cast and wrought Al–3Zn–3Mg–3Cu–0.2Zr–Y(Er) alloys were investigated. The structure and phase composition were investigated via thermodynamic calculation, optical and scanning electron microscopy and X-ray diffraction methods. A two-step solution treatment with higher temperature in the second step provides a microstructure with better elongation, making possible to increase the hot rolling temperature of the Y or Er-containing alloys. The yield strength (YS) of the alloys decreased insignificantly from 270 to 290 MPa at room temperature to 225 to 260 MPa at 200 °C after casting, solution treatment, water quenching and aging. A better combination of the YS = 291–345 MPa and elongation (El.) (11–14.8%) was achieved in the Al3Zn3Mg3CuY and Al3Zn3Mg3CuEr alloys after solution treatment, rolling, recrystallization annealing, water quenching and aging compared with the Al3Zn3Mg3Cu alloy with YS = 245–340 MPa and El. = 6.8–12.5%. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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18 pages, 9013 KiB

Open AccessArticle

Influence of Minor Additions of Be on the Eutectic Modification of an Al-33wt.%Cu Alloy Solidified under Transient Conditions

by Adilson Vitor Rodrigues, Rafael Kakitani, Cássio Silva, Leonardo Giovanetti, Marcelino Dias, Hani Henein, Amauri Garcia and Noé Cheung

Metals 2023, 13(1), 94; https://doi.org/10.3390/met13010094 - 02 Jan 2023

Cited by 2 | Viewed by 1268

Abstract

Al-based alloys are often selected for use in various engineering applications as well as in the aircraft and aerospace industry. The improvement of their performances under severe conditions have required the use of alloying elements. In the present work, Be is added to the eutectic Al-33 wt.%Cu alloy with a view to investigating the resulting effects on microstructural features and hardness. A directional solidification technique is used, yielding a wide range of solidification cooling rates. This permits microstructural features to be investigated with emphasis on the role of Be on the eutectic morphology. The directionally solidified microstructures are formed by eutectic colonies for the Al-33 wt.%Cu alloy, however, with additions of both 0.05 and 0.5 wt.% Be, the original cell-like morphology is transformed into a trefoil-like morphology. This together with the α-Al dendritic pattern characterize the microstructure of the Al-33Cu-Be alloys examined. Solidification growth laws are experimentally derived relating dendritic and eutectic colony spacings to solidification cooling rates and growth rates. The length scale of such spacings is shown not to affect the Vickers hardness of the Al-33Cu-Be alloys examined; however, the additions of Be are shown to improve the brittle behavior of the Al-33 wt.%Cu alloy. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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14 pages, 5164 KiB

Open AccessArticle

Phase Prediction, Microstructure and Mechanical Properties of Fe–Mn–Ni–Cr–Al–Si High Entropy Alloys

by Essam R. I. Mahmoud, Awaluddin Shaharoun, Mohamed A. Gepreel and Saad Ebied

Metals 2022, 12(7), 1164; https://doi.org/10.3390/met12071164 - 08 Jul 2022

Cited by 4 | Viewed by 2283

Abstract

The selection of high-entropy alloys (HEAs), which are relatively lightweight and have unique mechanical properties, remains a substantial challenge. In this study, six new HEAs were designed from the relatively low-cost Fe–Mn–Ni–Cr–Al–Si system using Thermo-Calc software, and then manufactured using a casting process. The effects of the atomic ratio of the alloying elements on the microstructures and mechanical properties of these alloys in the as-cast condition were systematically investigated. Brittle body-centered cubic BCC/B2 and silicide phases were found in relatively large amounts in the form of dendritic structure within large equiaxed grains with fine needle-shaped phases in the Fe₃₀Mn₁₅Ni₂₀Cr₁₅Al₁₀Si₁₀ and Fe₃₅Mn₁₅Ni₂₀Cr₁₅Al₁₀Si₅ alloys, in addition to the face-centered cubic (FCC) phase. When the contents of Mn and Ni were increased in the Fe₃₅Mn₂₅Ni₁₅Cr₁₅Al₅Si₅ and Fe₃₅Mn₂₀Ni₂₀Cr₁₅Al₅Si₅ alloys, the amounts of brittle phases were reduced; however, the ductile FCC phase is not significant. The FCC phase amount, which appeared as a honeycombed structure, was more than enough when the Si content was decreased to 3%. Broad relationships between the chemical composition of the alloys, especially the Si content, and the hardness and compression properties’ measurements were established. As the Si content decreased, both the hardness and compression properties of the resulting alloy also decreased. The experimental observation of the six HEAs matched the equilibrium phases predicted by the Thermo-Calc calculations. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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Review

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28 pages, 5454 KiB

Open AccessReview

Technological Insights into the Evolution of Bronze Bell Metal Casting on the Korean Peninsula

by Chun-Soo Won, Jae Pil Jung, Kwang-Sik Won and Ashutosh Sharma

Metals 2022, 12(11), 1776; https://doi.org/10.3390/met12111776 - 22 Oct 2022

Cited by 2 | Viewed by 3265

Abstract

Bronze cast bells have been designed and developed for hundreds of years, with the worldwide spread of several faiths and religions such as Buddhism, Catholicism, and Protestantism. The exceptional ringtones of bronze bell metals have scientific healing and cultural importance. In this review article, we highlight the evolution of bronze bell metal over the decades, its composition, and the complex fabrication technologies used to date. Furthermore, we overview ancient and modern casting alloy technology, especially bronze bell castings in Asia. The bell shape, materials, and alloy casting technology have undergone dramatic change over the years. For comparison, we include different bronze cast bells and their characteristics produced from the Middle Ages to the present times. Based on the data obtained from the bell casting technology surrounding the Korean Peninsula, the major trends in the evolution of bronze bell castings and long-standing traditions of mold materials and alloys are described. In the present review, the effects of different elements on bell materials are qualitatively overviewed, with an assessment of the material and casting properties, service life, and bell sound. We also highlight the challenges of conventional bronze casting and possible solutions for future investment castings and rapid prototyping of bronze bells. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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