L Journal of Alloys and Compounds 287 (1999) 284294
Microstructure and mechanical properties of hypo/ hyper-eutectic AlSi
alloys synthesized using a near-net shape forming technique * M. Gupta , S. Ling Department of Mechanical and Production Engineering, National University of Singapore, 10 Kent Ridge Crescent, Singapore 119260, Singapore Received 30 May 1998; received in revised form 30 January 1999 Abstract In the present study, three aluminumsilicon alloys containing 7, 10 and 19 wt % silicon were synthesized using a novel technique commonly known as disintegrated melt deposition technique. The results following processing revealed that a yield of at least 80% can be achieved after defacing the shrinkage cavity from the as-processed ingots. Microstructural characterization studies conducted on the as-processed samples revealed an increase in the volume fraction of porosity with an increase in silicon content. Porosity levels of 1.07, 1.51 and 2.65% attained in the case of Al7Si, Al10Si, and Al19Si alloys indicates the near-net shape forming capability of the disintegrated melt deposition technique. The results of aging studies conducted on the aluminumsilicon alloys revealed similar aging kinetics irrespective of different silicon content. Results of ambient temperature mechanical tests demonstrate an increase in matrix microhardness and 0.2% yield stress and decrease in ductility with an increase in silicon content in aluminum. Furthermore, the results of an attempt to investigate the effect of extrusion on Al19Si alloy revealed that the extrusion process signicantly assists in reducing porosity and improving microstructural uniformity, 0.2% yield strength, ultimate tensile strength and ductility when compared to the as-processed Al19Si alloy. The results of microstructural characterization and mechanical properties of aluminumsilicon alloys were nally correlated with the amount of silicon in aluminum and secondary processing technique. 1999 Elsevier Science S.A. All rights reserved. Keywords: Disintegrated melt deposition; Microstructure; Mechanical behavior; Aluminumsilicon alloys 1. Introduction depends on the level of microstructurally governed end properties, cost effectiveness, industrial adaptability and The ability of silicon to reduce the density and coef- reproducibility in terms of microstructure and properties cient of thermal expansion and to improve the hardness, (such as physical, electrical, magnetic, mechanical etc.) ambient temperature mechanical properties such as [10]. For example, liquid phase processes such as conven- modulus and strength, thermal stability and wear resistance tional casting are cost effective but can not be used to of aluminum had been catalytic in engendering consider- make components for critical applications since the prop- able interest in the materials science community to explore erties level that can be obtained are inferior as a result of the AlSi family of alloys for possible applications in coarser microstructural features commonly associated with automotive, electrical and aerospace industries [14]. The conventionally cast materials. The solid phase processes, addition of silicon is made in both the hypoeutectic and such as powder based techniques, helps in realizing hypereutectic range depending primarily on the end appli- superior properties but have limitations related to the cation [16]. dimensions of the component and in addition involves high The existing literature survey indicates that the synthesis cost. Two phase processes, on the other hand, are techni- of AlSi alloys is carried out principally by liquid phase cally innovative and hold the promise to synthesize bulk [7], liquidsolid phase [24], solid phase [1], and rapid materials with superior properties, however, very limited solidication [8,9] techniques. The selection of processing information is available regarding the processing, micro- technique for a given constitutional formulation, however, structure and properties of materials synthesized using them. In order to circumvent the disadvantages associated with these techniques, a relatively new technique common- *Corresponding author. Tel.: 165-874-6358; fax: 165-779-1459. E-mail address: mpegm@nus.edu.sg (M. Gupta) ly known as disintegrated melt deposition (DMD) is used 0925-8388/ 99/ $ see front matter 1999 Elsevier Science S.A. All rights reserved. PI I : S0925- 8388( 99) 00062- 6 M. Gupta, S. Ling / Journal of Alloys and Compounds 287 (1999) 284294 285 in the present study to synthesize AlSi alloys in both as the lubricant. Extrusion was conducted in order to study hypo- and hypereutectic composition range. This tech- the effect of secondary processing on the microstructural nique, in the past, has been successfully utilized to and mechanical properties variation of as-processed AlSi synthesize monolithic and reinforced materials [11,12] and alloy. involves, in principal, the disintegration of superheated molten metal slurry using inert gas jets followed by its 2.4. Quantitative assessment of silicon subsequent deposition on the metallic substrate. The dynamic disintegration and deposition steps enables this Quantitative assessment of Si in the as-processed and technique to synthesize bulk materials with improved extruded AlSi samples was carried out using standardized microstructural homogeneity when compared to conven- energy dispersive spectroscopy (EDS) method. tional casting techniques [11,12]. Accordingly, the objective of the present study was to investigate the microstructure and mechanical properties of 2.5. Density measurement the disintegrated melt deposited AlSi alloys (both in hypo- and hypereutectic composition range) in order to The densities of the as-processed and extruded AlSi assess the feasibility of the disintegrated melt deposition samples were measured by Archimedes principle to technique to synthesize the AlSi family of alloys. Par- quantify the volume fraction of porosity [6,11,12]. The ticular emphasis was placed, in addition, to study the effect density measurements involved weighing polished cubes of of secondary processing on the microstructure and me- the extruded samples in air and when immersed in distilled chanical properties of the hypereutectic (Al19Si) alloy water. The densities, derived from the recorded weights, synthesized in the present study. were then compared to the theoretical densities from which the volume fractions of porosity were calculated. The samples were weighed using an A&D ER-182A electronic 2. Experimental procedure balance to an accuracy of 60.0001 g. 2.1. Materials 2.6. Aging studies In this study, an aluminum alloy AA1050 ($99.5 wt % Al) was used as the base alloy and silicon ($98.5 wt % Si) Aging studies were carried out in order to obtain the was used as an addition element to synthesize hypo- and peak hardness time for the as-processed and extruded hypereutectic AlSi alloys. AlSi samples. Specimens (10 mm diameter37 mm height) were solutionized for 1 h at 5298C, quenched in 2.2. Processing cold water and aged at 1608C for various intervals of time. Rockwell supercial hardness measurements were made In the present study, synthesis of hypo- and hypereutec- using a 1.58 mm diameter steel ball indenter with a 15 kg tic AlSi alloys with starting weight percentages of 7, 10 load using a GNEHM HORGEN digital hardness tester and 20 wt % of Si was carried out using the DMD following ASTM standard E18-92. A minimum of three technique. The synthesizing procedure involved: super- hardness readings were taken for each specimen. heating of properly cleaned elemental materials to a temperature of 9506108C in graphite crucible, impeller assisted stirring to ensure complete mixing of elemental 2.7. Microstructural characterization materials followed by argon gas-assisted melt disinte- gration at 0.18 m from the melt pouring point and Microstructural characterization studies were conducted subsequent deposition in a metallic mould (55 mm on the as-processed and extruded AlSi samples in the diameter375 mm long) located at 0.25 m from the gas peak aged condition to investigate the grain morphology, disintegration point. The experiment was carried out under presence of porosity, morphological characteristics and controlled atmospheric conditions. The AlSi alloy ingots distribution of the secondary phases, and SiAl interfacial obtained following processing were weighed in order to characteristics. determine the deposited yield of the starting raw materials. Microstructural characterization studies were primarily accomplished using an optical microscope and a JEOL 2.3. Secondary processing scanning electron microscope equipped with EDS. The samples were metallographically polished prior to exami- AlSi alloy ingot with starting weight percentage of nation. Microstructural characterization of the samples was 20% silicon was machined to a diameter of 35 mm and conducted in both etched and unetched conditions. Etching then hot extruded at 3508C employing a reduction ratio of was accomplished using Kellers reagent [0.5 HF1.5 13:1 on a 150 ton hydraulic press using colloidal graphite HCl2.5 HNO 95.5 H 0]. 3 2 286 M. Gupta, S. Ling / Journal of Alloys and Compounds 287 (1999) 284294 Table 1 2.8. Mechanical behavior Results of the density and porosity determination Alloy Processing Wt % Si Density Porosity Vickers microhardness of the matrix of as-processed and 23 designation condition (g cm ) (vol %) extruded AlSi samples was determined on a Matsuzawa MXT50 Automatic Digital microhardness tester using an Al7Si As-processed 7 2.6460.01 1.07 Al10Si As-processed 10 2.6260.02 1.51 indentation load of 100 g. Vickers microhardness measure- Al19Si As-processed 19 2.5560.01 2.65 ments were made in order to provide insight into the Al19Si(Ext) Extruded 19 2.6060.06 0.65 ability of secondary phases to strengthen the metallic matrix. Smooth bar tensile properties were determined on the 3.3. Quantitative assessment of silicon as-processed and extruded samples in the peak aged condition following ASTM standard E8M-91. Tensile tests The results of standardized EDS chemical analysis were conducted using an automated servohydraulic Instron conducted for Si element determination in the as-processed 8501 testing machine on 4 mm diameter specimens using a AlSi alloys with starting silicon weight percentages of 7, crosshead speed of 0.254 mm per minute. 10 and 20 and extruded AlSi alloy (with starting silicon weight percentages of 20) revealed that approximately 7, 10, 19 and 19 wt % Si was retained, respectively, follow- 2.9. Fracture behavior ing DMD processing (see Table 1). Accordingly, these materials will now be referred as Al7Si, Al10Si, Al Fracture surface characterization studies were carried 19Si, and Al19Si(Ext) in the forthcoming sections. out on the tensile fractured samples in order to provide insight into the various fracture mechanisms operative 3.4. Density measurement during tensile loading of the peak aged samples. Fracture surface characterization studies were primarily accom- The results of density measurements conducted on the plished using a JEOL scanning electron microscope Al7Si, Al10Si, Al19Si, and Al19Si(Ext) samples and equipped with EDS. the volume percent of the porosity computed using the experimentally determined density values are shown in Table 1. 3. Results 3.5. Aging studies 3.1. Processing The results of aging studies conducted on the as-pro- The deposited yield of the AlSi alloys with starting cessed and extruded samples are shown in Fig. 1. The weight percentages of 7, 10, and 20 wt % of silicon was results exhibit the presence of a hardness peak at 9 h for all found out to be 89, 88 and 86%, respectively. The the samples. Both the as-solutionized and peak hardness preforms in all the three cases were associated with a small values were found to increase with an increase in the shrinkage cavity on the top. After defacing the ingots so as silicon content in aluminum and from the as-processed to to remove the shrinkage cavity, the nal yield was extruded condition in the case of hypereutectic Al19Si determined to be 85, 84 and 80%, respectively. The overall alloy. The results also reveal an increase in the magnitude dimensions of the disintegrated melt deposited preforms of age hardening with an increase in the weight percentage following defacing were approximately 35 mm in height of silicon in the case of as-processed samples. The and 55 mm in diameter. The preform of the AlSi alloy with starting weight percentage of 20 wt % Si was subsequently machined to a diameter of 35 mm so as to t in the extrusion container. The specimens for heat treat- ment, microstructural analysis and mechanical properties characterization were removed randomly from the as-pro- cessed and extruded rods. 3.2. Macrostructure Macrostructural characterization conducted on the ma- chined and polished surfaces of as-DMD processed sam- ples did not reveal the presence of either macropores or the macrosegregation of silicon across the vertical and horizontal sections. Fig. 1. Aging curves of as-processed and extruded AlSi samples. M. Gupta, S. Ling / Journal of Alloys and Compounds 287 (1999) 284294 287 percentage increase in hardness of the peak aged samples when compared to that in the as-solutionized condition, for example, was found to be 8.74, 19.91 and 29.91 for Al7Si, Al10Si and Al19Si samples, respectively. The magnitude of age hardening, however, was found to be minimum (5.65%) in the case of Al19Si(Ext) samples (see Table 2). 3.6. Microstructural characterization The results of optical and scanning electron microscopy revealed the presence of a-Al dendrites and eutectic silicon phase in the case of Al7Si and Al10Si samples. The presence of dendritic structure precluded the determination of matrix grain size. Figs. 2 and 3 show the representative Fig. 2. Optical micrograph showing the salient microstructural features optical micrographs showing the salient microstructural exhibited by DMD processed Al7Si samples. features exhibited by Al7Si and Al10Si samples, re- spectively. In the case of hypereutectic as-processed Al 19Si alloy, the results of microstructural characterization (see Fig. 4) revealed the presence of primary silicon (Si) and eutectic silicon phases. The primary Si exhibited the blocky morphology while the eutectic silicon exhibited needle shape morphology. The size of the eutectic Si was, however, found to be comparatively larger when compared to the hypoeutectic (Al7Si and Al10Si) alloys (see Table 3). For the extruded Al19Si samples, the results of microstructural characterization studies revealed an in- crease in the volume fraction of the primary and eutectic silicon phases and a reduction in their size when compared to the as-processed Al19Si samples (see Fig. 5 and Table 3). Microstructural characterization studies, in addition, also revealed the presence of nearly equiaxed, randomly distributed, non-connected micron size porosity in all the samples investigated in the present study. The interfacial integrity between primary Si and the aluminum matrix was Fig. 3. Optical micrograph showing the salient microstructural features found to be good and only in some instances interfacially exhibited by DMD processed Al10Si samples. located voids were observed. The results of EDS point analyses conducted in the near-vicinity of primary Si particles in the case of as-processed Al19Si samples and 3.7. Mechanical behavior extruded Al19Si samples revealed the presence of segre- gation of silicon. One such representative variation in the The results of ambient temperature microhardness and amount of silicon with increasing distance from primary tensile testing on the as-processed AlSi samples, aged to SiAl interface observed in the case of Al19Si(Ext) peak hardness, are summarized in Table 4. The results in samples is shown in Fig. 6. Table 4 reveal an increase in microhardness and 0.2% Table 2 Results of the aging studies Alloy As-solutionized Peak hardness Peak aging Magnitude of age hardness (HR15T) (HR15T) time (h) hardening (HR15T) Al7Si 41.261.2 44.860.9 9 3.6 Al10Si 43.761.5 52.461.4 9 8.7 Al19Si 44.861.3 58.261.8 9 13.4 Al19Si(Ext) 56.660.3 59.860.8 9 3.2 288 M. Gupta, S. Ling / Journal of Alloys and Compounds 287 (1999) 284294 Fig. 5. Optical micrograph showing the salient microstructural features Fig. 4. Optical micrograph showing the presence of primary silicon and exhibited by DMD processed Al19Si(Ext) samples. eutectic silicon in the case of DMD processed Al19Si samples. yield stress (0.2% YS) and decrease in ductility with an increase in the amount of silicon in the aluminum matrix. The ultimate tensile strength (UTS), however, increased with an increase in silicon content from 7 to 10 wt % and was found to be minimum in the case of as-processed Al19Si samples. Following extrusion, Al19Si samples exhibited the highest 0.2% YS, UTS, ductility and mi- crohardness when compared to all the as-processed AlSi samples investigated in the present study (see Table 4). 3.8. Fracture behavior Fig. 6. Graphical representation of variation in silicon weight percent in The tensile fracture surfaces of the as-processed and the SiAl interfacial region in the case of Al19Si(Ext) samples. extruded samples are shown in Figs. 710. The fractured surfaces of the as-processed AlSi samples revealed an Table 4 increase in the degree of brittleness with an increase in the Results of tensile properties measurements made on peak aged samples silicon content in the matrix (see Figs. 79). In the case of Material 0.2% YS UTS Ductility Microhardness as-processed Al19Si samples (see Fig. 9), fracture surface (MPa) (MPa) (%) (HV) revealed the presence of cracked primary Si particles and minimal evidence of matrix undergoing plastic deforma- Al7Si 55.362.1 141.762.1 12.260.5 38.561.2 Al10Si 75.461.6 154.763.4 10.360.8 39.260.4 tion. For the Al19Si(Ext) samples, the fracture surface Al19Si 80.863.2 129.668.7 2.361.9 43.462.1 revealed the presence of broken primary Si particles Al19Si(Ext) 82.763.1 189.0612.1 21.468.8 59.260.5 similar to that observed in as-processed Al19Si samples Table 3 Results of microstructural characterization a Material Microstructural feature V Parameter Roundness f b Eq. size (mm) l (mm) Al7Si Eutectic silicon 0.065 2.6 10.2 N.D Al10Si Eutectic silicon 0.162 2.7 6.7 N.D Al19Si Primary silicon 0.093 77.5 254.0 7.34 Eutectic silicon 0.074 7.5 27.5 3.21 Al19Si(Ext) Primary silicon 0.131 65.5 181.0 5.13 Eutectic silicon 0.125 3.7 10.5 2.64 a Computed using image analysis. b 1 / 2 Computed using the formula suggested by Nardone and Prewo [22]: l5(lt /V ) where l is the interparticle spacing and t, l and V are the thickness, f f length and volume fraction of the secondary phases, respectively. M. Gupta, S. Ling / Journal of Alloys and Compounds 287 (1999) 284294 289 Fig. 7. SEM fractograph showing the fracture surface features in the case of Al7Si samples. and the evidence of signicant matrix plastic deformation, in contrast to the predominantly brittle behavior exhibited by the as-processed Al19Si samples (see Figs. 9 and 10). 4. Discussion 4.1. Processing The results of the disintegrated melt deposition process- ing revealed three salient features in the as-processed condition: high yield of the hypo- and hypereutectic alloys low volume fraction of porosity complete retention of elemental silicon in aluminum in Fig. 9. SEM fractographs showing: (a) general fracture surface features the case of hypoeutectic formulations and 95% re- and (b) presence of cracked primary silicon particles in the case of Al19Si samples. tention by weight in the case of hypereutectic formula- tion In the present study, DMD processed AlSi alloys revealed high values of yield in both the as-processed ($86%) and nally machined ($80%) conditions irre- spective of the lower volume of starting elemental materi- als. In the as-processed condition, high yield of alloys can be attributed to the low gas ow rate associated dis- integration of molten stream of alloy resulting in the complete absence of overspray powders which are normal- ly associated with conventional spray processing tech- niques adopted by other investigators [1315]. In ma- chined condition, high yield of AlSi alloys can be attributed to the formation of a shallow shrinkage cavity as Fig. 8. SEM fractograph showing the fracture surface features in the case a result of enhanced solidication of the molten alloy on of Al10Si samples. 290 M. Gupta, S. Ling / Journal of Alloys and Compounds 287 (1999) 284294 phases predicted by binary AlSi phase diagram [17]. The eutectic phase exhibited divorced morphology as a result of high interfacial energy between the two component phases and is consistent with the similar observations reported elsewhere [18]. In the case of hypereutectic Al19Si alloy, microstruc- ture characterization results revealed the presence of primary silicon and acicular eutectic silicon phases in both the as-processed and extruded conditions. The presence of these phases along with the microstructural characteristics exhibited by hypoeutectic alloys establishes the existence of predominantly equilibrium solidication conditions during disintegrated melt deposition processing of materi- als. The results of quantitative microstructural characteriza- tion conducted on hypoeutectic AlSi alloys revealed an Fig. 10. SEM fractograph showing fracture surface features in the case of increase in the volume fraction of eutectic silicon phase Al19Si(Ext) samples. and a marginal increase in its size with an increase in silicon content (see Table 3). The increase in volume the deposition surface. The enhanced solidication can be fraction of eutectic silicon phase with an increase in silicon attributed to the convectional heat transfer associated with content is in accordance with the Levers rule [19] while a the disintegration step of the DMD processing when marginal increase in the size of eutectic silicon can be compared to the conventional casting techniques. The attributed to an increase in the probability of silicon atoms results also revealed that the yield of the alloys in both the to attach themselves on the growing eutectic silicon phase. as-processed and nally machined conditions decreases The higher probability of silicon atoms to attach them- with an increase in the silicon content. selves to the growing eutectic silicon phase can be Another characteristic feature associated with the DMD attributed to their higher number and shorter travel dis- processed AlSi alloys was the presence of low ($2.65%) tances as a result of higher weight percentage of silicon in volume fraction of porosity (see Table 1) indicating the the aluminum melt [18]. This is further supported by the near-net shape forming capabilities of the DMD technique. fact that the room temperature solid solubility of silicon in The presence of lower volume fraction of porosity in the aluminum will be the same in the case of both the Al7Si as-processed condition ensures the realization of near- and Al10Si alloys due to the same processing parameters optimum properties from the material precluding the and the near-equilibrium nature of the DMD processing necessity to employ secondary processing techniques at technique. least for conventional engineering applications [16]. It may Regarding the hypereutectic Al19Si alloy in the as- further be noted that the volume fractions of porosity processed and extruded condition, the results of quantita- revealed by AlSi alloys synthesized in the present study tive microstructural characterization revealed that the are similar to the porosity levels reported in cases of other extrusion process leads to an increase in microstructural near-net shape forming techniques [13]. uniformity by decreasing the average size, interparticle Finally, the complete retention of silicon in the case of spacing and roundness of the primary and eutectic silicon hypoeutectic alloys and 95% by weight in the case of phases (see Table 3). The decrease in average size and Al19Si alloy can be attributed to the coupled effects of roundness of the primary and eutectic silicon phases can be the ability of aluminum to dissolve silicon completely at attributed to the partial dissolution of these phases during 9508C [17] and the kinetics of dissolution accomplished by hot extrusion and subsequent reprecipitation following stirring conditions used in the present study. The stirring extrusion. It may further be noted that the dissolution of procedure that involved stirring at 596 rpm for a time not silicon at the sharp tips and edges can be attributed to the exceeding 10 min also helped to ensure uniform dis- high solute concentration gradients in these regions in tribution of silicon in the ingot following solidication. accordance with the FreundlichThomson equation [20,21] leading to the reduction in roundness. The decrease in 4.2. Microstructure interparticle spacing of primary and eutectic silicon phases can primarily be attributed to the decrease in their average 1 / 2 The results of microstructural characterization conducted size in accordance with the formula, l 5(lt /V ) , pro- f on hypoeutectic Al7Si and Al10Si alloys revealed, in posed by Nardone and Prewo [22]. Finally, the increase in common, the presence of a-Al dendrites and eutectic the volume fraction of primary and eutectic silicon phases silicon (see Figs. 2 and 3). The presence of these phases (studied at magnication levels of up to 20003; see Table are in accordance with the equilibrium microstructural 3) following extrusion may be attributed to the coalescence M. Gupta, S. Ling / Journal of Alloys and Compounds 287 (1999) 284294 291 of ner distribution of these phases at the extrusion elsewhere [27]. It may further be noted that the increased temperature leading to their increased presence at magni- precipitation of the secondary phases and hence the cations up to 20003. It may be noted that the coalescence increase in magnitude of age hardening may be attributed of ner phases assists in reducing the particle/ matrix to the ability of the defect structure to serve as a heteroge- interfacial area and the relaxation of mist strains in the neous nucleation site during aging treatment. In related matrix [23]. Further work is continuing to establish the studies, for example, investigators have shown using variation in distribution pattern of these phases (especially transmission electron microscopy the precipitation of in the ner size range) as a function of extrusion step using strengthening phases on the lattice defects such as disloca- high magnication metallography techniques. tions [28]. The progressive increase in the peak hardness Another interesting feature observed in the case of when compared to as-solutionized hardness with an in- hypereutectic Al19Si samples was the presence of silicon crease in weight percentage of silicon also indicates that segregation in the immediate vicinity of primary Si much superior mechanical properties can be realized particles (see Fig. 6). This can be attributed to the localized following aging heat treatment. This is also consistent with presence of point defects and line defects in the interfacial the work reported elsewhere [16] which suggest a clear region of primary Si particles during solid state quenching correlation between hardness and strength. The results are as a result of a difference in the coefcient of thermal also consistent with the similar ndings made on an expansion between the aluminum matrix and Si particles Al7Si based alloy supplied by Duralcan, USA [6]. (CTE (Al) / CTE (Si) : 3.1 [24]). The presence of an Regarding the inuence of silicon content on the aging increased number of defects assists in promoting the kinetic, the results of the aging studies suggest that the diffusion of alloying elements from the adjacent region variation in silicon content in the range of 719 wt % was leading to the segregation in the interfacial region. These not sufcient to bring the microstructural changes capable results are also consistent with the similar studies con- of altering the aging kinetics of the aluminum matrix. This ducted on the conventionally cast A390 alloy [4]. is consistent with the work of other investigators who suggested that the aging kinetics of the metallic matrix 4.3. Aging studies containing the secondary phases with different CTE can only be inuenced if the variation in microstructure as a The results of aging studies conducted on as-processed result of their presence is signicant [29]. AlSi alloys revealed three salient features: Regarding the effect of extrusion, the results show that the hot extrusion step used in the present study increases an increase in as-solutionized and peak hardness with the as-solutionized hardness signicantly while maintain- an increase in the weight percent of silicon, ing the peak hardness similar to that observed in the case an increase in the magnitude of age hardening with an of as-processed Al19Si samples (see Fig. 1). The increase increase in the weight percent of silicon, and in as-solutionized hardness of the extruded samples may be an aging kinetics independent of weight percent of attributed to the reduction in the volume fraction of silicon porosity as a result of the extrusion (see Table 1) and a minimal amount of age hardening suggests that the hot The increase in the as-solutionized and peak hardness of extrusion step assists in establishing a uniform distribution AlSi alloys with an increase in the weight percent of pattern of silicon based phases as a result of high tempera- silicon can be attributed to an increase in the volume ture exposure (3508C) during extrusion and subsequent fraction of harder silicon based phases in the aluminum cooling to room temperature resulting into partial dissolu- matrix (see Table 3). The silicon based phases refer to tion and reprecipitation of silicon based phases in the eutectic silicon in the case of hypoeutectic AlSi alloys matrix. As a result of this, the effect of age hardening are and primary and eutectic silicon in the case of hypereutec- minimized as reected in only a 5.65% increase in tic AlSi alloys. It may be noted that the hardness of hardness of the Al19Si(Ext) samples when compared to 9 22 silicon (10 kg m ) [25] is signicantly higher when 29.9% in the case of the as-processed Al19Si samples in 6 22 compared to that of aluminum (19310 kg m for 99.6% the peak aged condition. Al) [26]. The increase in the magnitude of age hardening with 4.4. Mechanical behavior silicon content may be attributed to the capability of increasing volume fraction of silicon based phases to The results of the mechanical properties characterization generate increasing volume fraction of the defect structure revealed an increase in the matrix microhardness with an in the matrix (see Table 3). The formation of defect increase in the weight percentage of silicon in the as- structure can be attributed to a signicant difference in processed AlSi alloys (see Table 4). This is consistent coefcients of thermal expansion of aluminum and silicon with the increase in the cumulative volume fraction of the phases (CTE (Al) / CTE (Si) : 3.1 [24]). Such a correlation harder silicon based phases (see Table 3). It may be noted has been convincingly established by the researchers that an increase in the volume fraction of the harder silicon 292 M. Gupta, S. Ling / Journal of Alloys and Compounds 287 (1999) 284294 based phases and the associated defect structure will lead [16,34]. Bocchini [16] and Payne et al. [34], for example, to higher constraint in the localized deformation of softer asserted that the presence of pores lead to weakening of a matrix under the application of indentational load. In the material by reducing the amount of stress bearing area and case of Al19Si(Ext) samples, however, a signicant therefore lowers the amount of stress the material is able to increase in microhardness when compared to the Al19Si withstand. Similarly, the presence of plastically incompat- samples can be attributed to the signicant microstructural ible phases lead to the stress accumulation at the interface renement and enhanced microstructural uniformity com- with the ductile matrix and under conventional tensile monly achieved following extrusion process [30]. loading microcracks/ microvoids may appear either at the The results of tensile properties characterization re- pole or equator locations depending on the mechanical vealed an increase in 0.2% YS and a decrease in ductility properties of the strengthening phase [35], thus preventing with an increase in silicon content. An increase in 0.2% the optimum realization of UTS by the material. YS with an increase in the amount of silicon can be The results of the tensile properties characterization attributed to the relatively higher constraint exerted by an conducted on Al19Si(Ext) samples revealing an increase increasing volume fraction of the silicon based phases in in ultimate tensile strength and ductility when compared to the aluminum matrix for the onset of the slip process. It the as-processed Al19Si samples are consistent with the may be noted that an increase in the dislocation pinning dependence of these properties on the morphology of sites (such as silicon based phases and the associated plastically incompatible phases and the volume fraction of defect structure) delays the onset of plastic deformation porosity. Since the constitution of Al19Si and Al which is reected in the values of the 0.2% YS obtained in 19Si(Ext) samples is the same, the volume fraction of this study for AlSi alloys [31]. In a related work [26], for silicon based phases will also be the same since the example, it has been shown that general yield stress (s ) identical near-equilibrium primary processing technique is o can be expressed as: used to synthesize them [17]. The only difference may be in the shift in the distribution pattern of the silicon based s 5s 1s (1) o s i phases towards the coarser side due to the hot extrusion where s is the stress to operate the dislocation sources and step used in the case of Al19Si(Ext) samples. This is s s is the friction stress representing the combined effect of consistent with the results of the microstructural characteri- i all the obstacles to the motion of dislocations arising from zation studies (Table 3) which show an increase in the the sources. In the present study, based on microstructural volume fraction of micron-size silicon based phases and characterization results (see Table 3), it is evident that an more interestingly show the lower roundness (indicating increase in the amount of silicon leads to an increase in the increasing equiaxed nature) values. The decrease in the s as a result of an increase in the volume fraction of roundness value of the silicon based phases will be i silicon based phases. This is also consistent with the instrumental in increasing the resistance of the aluminum similar 0.2% YS values obtained in the case of Al19Si matrix to microcracking as a result of the decrease in the and Al19Si(Ext) samples (see Table 4). The same stress concentration at the sharp edges, thus leading to amount of silicon in these two different category of superior values of UTS and ductility. Similarly, a reduction samples is indicative of the similar volume fraction of in porosity from 2.65 to 0.65% (see Table 1) may also be silicon based phases [17] and hence the similar values of attributed to an increase in UTS and ductility values of 0.2% YS (within each others standard deviation) arising Al19Si(Ext) samples when compared to Al19Si sam- from similar s . ples. This is consistent with the work of other investigators i The decrease in ductility with the increasing amount of [25] who reported an increase in the value of UTS by silicon may be attributed to the increasing volume fraction about 51 MPa as a result of reduction in porosity by about of plastically incompatible silicon based phases in the soft 2% in the case of Al5Si samples heat treated to T6 and ductile aluminum matrix. It has been, for example, condition. It may be noted that in the present study an established that the increasing volume fraction of plastical- increase in UTS by about 51 MPa was realized as a result ly incompatible phases decreases the cavitation resistance of a reduction in porosity by about 2% in the case of T6 of the matrix leading to early microcracking and hence the heat treated Al19Si samples. The tensile testing results reduced ductility under the application of tensile loads thus obtained are consistent with the microstructural [3133]. characterization results obtained in the present study and The inferior ultimate tensile strength exhibited by Al the work of other investigators [25]. 19Si samples when compared to Al7Si and Al10Si samples may be primarily attributed to the coupled effects 4.5. Fracture behavior of the presence of primary Si and an increase in the porosity and volume fraction of plastically incompatible The results of fractographic studies conducted on the silicon based phases. The porosity associated reduction in hypoeutectic Al7Si and Al10Si samples revealed similar strength has been previously established by other inves- fracture surface features exhibiting ample evidence of tigators for steels, copper and aluminum based alloys matrix plastic deformation (see Figs. 7 and 8). The fracture M. Gupta, S. Ling / Journal of Alloys and Compounds 287 (1999) 284294 293 surfaces, in common, also showed the presence of rela- cant increase in the degree of brittleness in the hy- tively at and featureless zones which may be indicative of pereutectic samples when compared to the hypoeutectic crack propagation along the embrittled boundaries of a-Al samples. The results also revealed that the fracture dendrites/ grains. This may be attributed to the presence of mode can be changed from predominantly brittle to the hard and brittle eutectic silicon phase as shown in Figs. predominantly ductile following extrusion. 2 and 3. The fracture surface of Al19Si samples was signicantly different when compared to Al7Si and Al 10Si samples and exhibited a high degree of brittleness and Acknowledgements cracked primary silicon particles (see Fig. 9). This may be attributed to the reduced ability of metallic matrix to The authors would like to thank Mr. Tham Leung Mun deform due to the increased number of crack nucleation and Mr. Tung Siew Kong (National University of Singa- sites such as increased volume fraction of hard and brittle pore, Singapore) for their valuable experimental assistance silicon based phases and porosity. On the contrary, the and for many useful discussions and to Ms Neerja Gupta fracture surface of Al19Si(Ext) samples revealed evi- for improving the readability of this manuscript. dence of signicant matrix plastic deformation (see Fig. 10) and the presence of cracked and/ or partially debonded primary silicon particles. 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