Trans. Nonferrous Met. Soc.

China 27(2017) 1264−1272

Influence of rheo-diecasting processing parameters on microstructure and

mechanical properties of hypereutectic Al−30%Si alloy

Zhi-kai ZHENG1, Yong-jian JI1, Wei-min MAO1, Rui YUE1, Zhi-yong LIU2
1. School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, China;
2. Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China
Received 19 May 2016; accepted 9 October 2016

Abstract: The effects of pouring temperature, vibration frequency, and the number of curves in a serpentine channel, on the
microstructure and mechanical properties of Al−30%Si alloy processed by rheo-diecasting (RDC) were investigated. The semisolid
Al−30%Si alloy slurry was prepared by vibration serpentine channel pouring (VSCP) process in the RDC process. The results show
that the pouring temperature, the vibration frequency, and the number of the curves strongly affect the microstructure and mechanical
properties of Al−30%Si alloy. Under experimental conditions of a pouring temperature of 850 °C, a twelve-curve copper channel and
a vibration frequency of 80 Hz, the primary Si grains are refined into fine compact grains with average grain size of about 24.6 μm in
the RDC samples assisted with VSCP. Moreover, the ultimate tensile strength (UTS), elongation and hardness of the RDC sample are
296 MPa, 0.87% and HB 155, respectively. It is concluded that the VSCP process can effectively refine the primary Si grains. The
refinement of primary Si grains is the major cause for the improvement of the mechanical properties of the RDC sample.
Key words: hypereutectic Al−Si alloy; primary Si; vibration serpentine channel; pouring process; rheo-diecasting; microstructure;
mechanical properties

microstructure and phase morphology of hypereutectic

1 Introduction Al−Si alloys. However, the mechanical properties of
high silicon (w(Si)>22%) Al−Si alloys are rarely
High silicon (w(Si)>22%) aluminium alloys are reported. Diecasting is an efficient and economical
widely used for making heat-resistant parts such as process offering a broader range of shapes and
pistons of high speed engines, engine blocks, aircraft components than any other manufacturing technique.
components and military applications due to the superior However, the traditional diecasting process will produce
performances of high specific strength, excellent wear a great amount of entrapped gas during the two first
resistance and corrosion resistance, as well as low filling stages of die casting process. The presence of gas
coefficient of thermal expansion [1−4]. In general, the porosity in castings is harmful because the mechanical
mechanical properties of hypereutectic Al−Si alloys properties and pressure tightness are adversely
largely depend on the morphology and size of the affected [7,8]. Rheo-diecasting (RDC) can produce high
primary Si grains. However, the morphology of primary quality components with high integrity and improved the
Si grains is mainly star-like, or plate-like, or penniform performance [9,10]. The RDC process has a lot of
and the Si grain size is very large after traditional advantages such as extremely low porosity, fine and
solidification. So, it is difficult to improve the uniform microstructure and improved mechanical
morphology of primary Si grains and refine the Si grain properties. More importantly, the resulting RDC products
size through the conventional casting process. If the size have close-to-zero porosity and therefore can be heat-
and morphology of primary Si grains can be refined, the treated [11]. In the rheo-forming process, molten alloy is
properties of hypereutectic Al−Si alloys with high Si stirred as the temperature is decreased in order to create
content will be greatly improved [5,6]. semi-solid slurry with a controlled grain size, which
The present investigations mainly focus on the is then injected into a die and formed with a press, as

Foundation item: Project (5077400) supported by the National Natural Science Foundation of China
Corresponding author: Wei-min MAO; Tel: +86-13911069562; E-mail: weiminmao@263.net
DOI: 10.1016/S1003-6326(17)60147-X
 Zhi-kai ZHENG, et al/Trans. Nonferrous Met. Soc. China 27(2017) 1264−1272 1265
reported by JIN et al [12]. There have been many new diameter of 80 mm and a height of 150 mm, was made of
developed techniques to prepare semisolid alloy slurry. red copper. The pouring temperatures and the
Among these new techniques, serpentine channel temperature of the melt in the copper collection crucible
pouring (SCP) process is an environmentally safe were measured with a K-model handset thermocouple.
technology with simple process and low cost [13−15]. In The applied mechanical vibration power in this study
this study, we propose a novel method to prepare was 3 kW, and the amplitude was 150 μm [20].
semi-solid Al−30%Si alloy slurry through a vibrated
serpentine channel pouring (VSCP) process and
investigate the mechanical properties of the Al−30%Si
alloy processed by rheo-diecasting (RDC).
In recent years, the rheological forming process of
semi-solid slurry has attracted more and more attention
for its merits, such as simple process and low cost. The
A356 alloy formed directly by rheo-squeeze casting of
semi-solid slurry made with rotating magnetic field
method showed excellent mechanical properties, as
reported by ZHANG et al [16]. Recently, LIN et al [17]
have used ultrasonic vibration (USV) to make semi-solid
slurry, and it has significant effects on refining the Fig. 1 Schematic diagram of VSCP system (A—Melting stage;
B — Pouring stage; 1 — Graphite clay melting crucible;
primary Si grains of hypereutectic Al−Si alloy and
2 — K-type thermocouple; 3 — Water inlet; 4 — Studdle;
modifying the intermetallic compounds such as
5—Bracket; 6—Pouring cup; 7—Water outlet; 8—Water jacket;
Fe-containing phase. CAO et al [18] reported that heat
9—Serpentine channel; 10—Slurry; 11—Copper collection
treatment and P modifier could be used to prepare
crucible; 12—Vibration table; 13—Copper serpentine channel;
hypereutectic Al−50%Si alloy, and it could make the size
14—Control cabinet)
of primary Si grains reduce to 48 μm. ZHENG et al [19]
prepared semi-solid A390 alloy slurry through serpentine
The newly produced cast alloy investigated had the
channel pouring (SCP) process near the liquidus
composition shown in Table 1 and was prepared with
temperature, and the fine primary Si grains with average
commercial A390 aluminum alloy and Al−43%Si (mass
grain size of about 20 μm were obtained in the A390
fraction, the same in the following) master alloy,
alloy.
commercial pure Al (99.8%), pure Cu (99.99%) and pure
The object of this paper is to investigate the effects
Mg (99.9%). Differential scanning calorimetry (DSC)
of different process parameters on the microstructure and
(NETZSCHSTA 409C/CD) was employed to determine
mechanical properties of Al−30%Si alloy. Different
the liquidus and solidus temperatures of the Al−30%Si
process parameters (i.e., the pouring temperature, the
alloy. The liquidus and the solidus temperatures of the
number of curves in the serpentine channel, and the
alloy are 801 °C and 488 °C, respectively. The DSC
vibration frequency of the channel) were varied to obtain
curve of the alloy is shown in Fig. 2.
a favorable as-cast microstructure and better mechanical
properties. In addition, the refinement mechanism of the
Table 1 Chemical composition of Al−30%Si alloy (mass
primary Si grains in the Al−30%Si alloy samples
fraction, %)
processed by RDC assisted with the vibration serpentine
channel pouring (VSCP) process was also studied. Si Cu Mg Zn Mn Cr Ni Fe Al
30 4.5 0.55 0.02 0.01 0.02 0.01 0.17 Bal.
2 Experimental
2.2 Methods
2.1 Materials and equipments The experimental parameters are listed in Table 2.
The schematic diagram of VSCP system is shown in Firstly, the materials were melted in a graphite crucible
Fig. 1. It consists of melting stage (A) and pouring stage at 920−950 °C. And the melt was degassed for 15 min
(B). All experimental materials were melted in a 5 kW with argon gas introduced through a graphite lance. The
resistance furnace. The melt and isothermal holding melt was allowed to cool down to a chosen pouring
temperatures were controlled by a PID temperature temperature near liquidus after degassing. The collection
controller. The Al−30%Si alloy was melted in a crucible was preheated to 430−450 °C by the heating
clay-bonded graphite crucible. The vibration frequency furnace. Subsequently, the alloy melt was poured through
and amplitude of the vibration table could be adjusted by a vibration serpentine channel that was continuously
the control cabinet. The collection crucible, with a cooled with cooling water flow of 500 L/h and was
1266 Zhi-kai ZHENG, et al/Trans. Nonferrous Met. Soc. China 27(2017) 1264−1272

Fig. 2 DSC curves of Al−30%Si alloy obtained during solidification (a) and solid fraction−temperature curve of Al−30%Si alloy (b)

Table 2 Process parameters and characteristic sizes of semi-solid slurry

Pouring Vibration Outlet Equivalent grain Shape
Channel
temperature/°C frequency/Hz temperature/°C diameter/μm coefficient
Four-curve copper 850 80 789 32.1 0.61
Eight-curve copper 830 80 710 30.3 0.75
Eight-curve copper 850 80 746 27.2 0.85
Eight-curve copper 870 80 758 31.9 0.80
Eight-curve copper 890 80 772 35.5 0.75
Twelve-curve copper 850 0 725 32.3 0.59
Twelve-curve copper 850 40 722 28.1 0.73
Twelve-curve copper 850 80 725 24.6 0.87
Twelve-curve copper 850 120 726 27.1 0.79

allowed to flow into a collection crucible, and the were cut from the ends of tensile test samples. After the
semisolid slurry with a certain solid fraction was samples were subjected to rough grinding, fine grinding,
obtained. Finally, the semisolid slurry was transferred and polishing, the transverse of each sample was
into a YYC180 machine with a 180 t clamping force, immersed into 0.5% HF (volume fraction) aqueous
which was used to form standard tensile samples. The solution for 20 s for etching. The microstructures were
injection speed and injection pressure were 5 m/s and examined using a Neuphoto21 optical microscope.
70 MPa, respectively. The die used for casting test Meanwhile, each of the primary Si grains was marked
samples had six cavities, of which three had been using professional image-analysis software (Image-Pro
subjected to solution treatment at 510 °C for 6 h and then Plus), the area A and the perimeter P were also
artificial aging at 190 °C for 12 h (T6 heat-treated). The measured. Finally, the equivalent grain diameter D and
temperature of the die was kept at 210 °C during the shape coefficient F of the primary Si grains were
processing. The shape and dimensions of the tensile respectively calculated using Eqs. (1) and (2) [21]:
samples are shown in Fig. 3, and the standard tensile N
samples are based on GB/T228.1−2010.  4 Ai /π
The specimens for the metallographic examination i 1
D (1)
N
N
Fs  (2)
N
Pi 2
 4πA
i 1 i

where D, Fs, A, N, and P are the equivalent grain

diameter, the average shape coefficient, the area, the
Fig. 3 Schematic of tensile samples (unit: mm) number and the perimeter of the primary Si grains,
 Zhi-kai ZHENG, et al/Trans. Nonferrous Met. Soc. China 27(2017) 1264−1272 1267
respectively. When the value of Fs approaches 1, the
primary Si grains are more globular. The tensile tests
were carried out using a CMT4105 testing machine at a
corresponding speed of 1 mm/min. The average UTS
was obtained from three tensile specimens for each
specified experimental condition. The average Brinell
hardness of five points on the sample surface was tested
by HB−3000B Brinell hardness tester.

3 Results and discussion

3.1 Effects of pouring temperature on RDC samples

For the sake of contrast, the Al−30%Si alloy liquid Fig. 4 Microstructure of as-cast DC Al−30%Si alloy poured at
was poured directly into the shot chamber of the die 850 °C
casting machine at 850 °C. Figure 4 shows the
microstructure of the as-cast samples. The lightgray properties of the RDC samples, an eight-curve copper
regions, the darkgray grains and the black regions in serpentine channel and four different pouring
Fig. 4 refer to α(Al), primary Si grains and Al−Si eutectic temperatures were used under a vibration frequency of
phase, respectively. The primary Si grains are very 80 Hz, as listed in Table 2. Figure 5(a) shows that almost
coarse and their average grain size is 87.6 μm. The all of the primary Si grains are coarse plate-like grains
distribution of the primary Si grains is also non-uniform when the pouring temperature is 890 °C. However, the
and the primary Si grains exhibit thicker plate-like and size of the primary Si grains in Fig. 5(a) is decreased
five-petal star-shape morphology. So, the UTS of the DC significantly compared with that of the conventional DC
sample is only 133 MPa. microstructure in Fig. 4, and the average grain size of the
When Al−30%Si alloy melt flows through the primary Si grains is 35.5 μm. Figure 5(b) shows that the
vibration serpentine channel, the melt temperatures out blocky or polygonal primary Si grains begin to appear
of the outlet will be below the liquidus temperature, when the pouring temperature is 870 °C, and the average
which means that the Al−30%Si alloy melt has become grain size of the primary Si grains is reduced to 31.9 μm.
the semi-solid slurry. To study the effects of the pouring Figure 5(c) shows that when the pouring temperature is
temperature on the microstructures and mechanical decreased to 850 °C, almost all of the primary Si grains

Fig. 5 Microstructures of as-cast samples processed by RDC assisted with VSCP at different pouring temperatures with vibration
frequency of 80 Hz and eight-curve serpentine channel: (a) 890 °C; (b) 870 °C; (c) 850 °C; (d) 830 °C
1268 Zhi-kai ZHENG, et al/Trans. Nonferrous Met. Soc. China 27(2017) 1264−1272
are refined into blocky or polygonal ones with an grain size is small. Meanwhile, the rapid cooling of the
average grain size of 27.2 μm. Figure 5(d) shows that copper serpentine channel and the mold of die casting
when the pouring temperature is 830 °C, the average machine can restrain the growth of the primary Si grains.
grain size of the primary Si grains is 30.3 μm and the The combined action of the promotion of nucleation and
number of the fine plate-like primary Si grains increases the restriction of growth results in the refinement of the
gradually. In summary, with decreasing pouring primary Si grains. Besides, the shape factor of all of the
temperature of VSCP, the average grain size of the primary Si grains is about 0.8, which indicates that the
primary Si grains reaches a minimum value when the effect of pouring temperature on the shape factor of the
pouring temperature is 850 °C, and then increases again primary Si grains is relatively small.
slightly. The obtained mechanical properties of the
The result may be attributed to the survival of the Al−30%Si alloy processed by DC and RDC assisted with
primary Si nuclei induced by VSCP in the alloy melt. VSCP at different pouring temperatures are tabulated in
LIN et al [17] and LIU et al [22] suggested that the Table 3. In T6 heat treatment state, the mechanical
degree of supercooling of the alloy melt strongly properties of the Al−30%Si alloy processed by RDC at
influences the final microstructure. According to the the pouring temperature of 850 °C are the best. The UTS,
principle of nucleation kinetics, the relationship between elongation and hardness of the RDC sample are
the degree of supercooling, ΔT, and the critical 278 MPa, 0.80% and HB 152, respectively. Compared
nucleation radius, Rk, can be calculated by [23] with the conventional DC process, RDC samples have
much improved UTS and tensile elongation. The UTS,
Rk=(2σSLTm)/(ΔHmΔT) (3) elongation and hardness of the RDC samples are
where σSL, Tm and ΔHm can be considered as constants approximately 57.9%, 42.9% and 20.6% higher than
for a certain alloy. Therefore, the greater the degree of those of the DC samples, respectively. It might be
supercooling is, the smaller the critical nucleation radius because the coarse plate-like primary Si grains which can
is and the lower the nucleation energy is. The low crack the Al matrix give rise to the crack initiation and
nucleation energy can promote the increase of the shrinkage porosity in the DC sample [25]. While the
number of crystal nuclei, which results in the grain primary Si grains in the RDC sample are refined into fine
refinement. In general, when the pouring temperature is compact particles, which can reduce or even eliminate
high, more physical heat contains in the Al−30%Si alloy the crack initiation and shrinkage porosity. Thus, good
liquid. When higher temperature Al−30%Si alloy liquid combination of strength and elongation of RDC samples
flows through the serpentine channel, more heat will is mainly dependent on the extremely low porosity, fine
inevitably transfer to the channel wall. As a result, the size and granular morphology of the primary Si grains.
chilling effect of the channel wall is diminished, which
results in a higher outlet temperature. Because the Table 3 Mechanical properties of Al−30%Si alloy processed by
chilling effect is constantly being diminished, the speed RDC assisted with VSCP at different pouring temperatures
at which the whole Al−30%Si alloy liquid temperature UTS at room Elongation Hardness
decreases is also diminished, which can reduce the temperature/MPa at room (T6 heat-
Process
possibility of primary Si precipitation in the supercooled T6 heat- temperature (T6 treated)
As-cast
region of the alloy melt and consequently decrease the treated heat-treated)/% (HB)
number of primary Si crystal nuclei. Meanwhile, the DC 133 176 0.56 126
primary Si crystal nuclei may be remelted under the RDC
171 213 0.63 137
conditions of the subsequent overheated alloy liquid (890 °C)
through the serpentine channel. The lower pouring RDC
202 247 0.69 143
temperatures can cause a greater degree of supercooling, (870 °C)
which is beneficial to the nucleation of the primary Si RDC
234 278 0.80 152
grains and results in the generation of a mass of primary (850 °C)
Si crystal nuclei in the alloy melt. However, KANG RDC
221 266 0.73 146
et al [24] discovered that when the pouring temperature (830 °C)
is too low, the primary Si grains can precipitate out
before or during the pouring process, which provides 3.2 Effects of vibration frequency on RDC samples
more time to grow up for these part of primary Si grains, As is well known, the mechanical properties are
finally leading to an increase in the size of the primary Si largely determined by the microstructure. In order to
grains. In summary, the greater the nucleation rate is, the decrease the size and promote a granular morphology of
more the number of crystal nucleus of unit volume is, the primary Si grains, the vibration frequency of the
smaller the room for each grain growing up is, so the VSCP is particularly important. Figure 6 shows the
 Zhi-kai ZHENG, et al/Trans. Nonferrous Met. Soc. China 27(2017) 1264−1272 1269
microstructures of the RDC samples, where an twelve- precipitate easily and grow up along the inner wall of the
curve copper serpentine channel and four different channel. Meanwhile, the vibration of the serpentine
vibration frequencies were used under a pouring channel can accelerate the exfoliation of primary Si
temperature of 850 °C. Compared with the conventional grains and provide the kinetic energy for them to move
DC microstructure in Fig. 4, the average grain size of the to the solid−liquid interface. Due to the scouring effect
primary Si grains in Fig. 6 is obviously decreased. of the subsequent alloy melt, the exfoliated primary Si
Figure 6(a) shows that, when the VSCP is applied grains at the solid−liquid interface can be taken away,
without vibration, almost all of the primary Si grains are which results in the continual proliferation of primary Si
coarse plate-like grains and the average grain size of crystal nuclei within the Al−30%Si alloy melt. Based on
primary Si grains is 32.3 μm. Figure 6(b) shows that, the above two points, a large amount primary Si crystal
when the VSCP is applied with the vibration frequency nuclei and free primary Si grains can be brought into the
of 40 Hz, the coarse plate-like primary Si grains are collection crucible, the primary Si grains are refined
refined into fine plate-like grains, and the average grain eventually.
size of primary Si grains reduces to 28.1 μm. Figure 6(c) As shown in Fig. 6, at a certain pouring temperature
shows that when the vibration frequency is increased to and number of curves in the serpentine channel, with
80 Hz, almost all of the primary Si grains are refined into increasing the vibration frequency of VSCP, the average
fine compact particles with the average grain size of grain size of the primary Si grains reaches a minimum
24.6 μm. The average grain size increases to 27.1 μm value when the vibration frequency is 80 Hz, and then
when the vibration frequency is increased to 120 Hz, increases slightly. The relationship between the vibration
even some primary Si grains exhibit a fine plate-like energy, E, and the vibration frequency, f, was studied by
morphology, as shown in Fig. 6(d). CAMPBELL [26], which can be defined by
Compared with the microstructure without the
E=8π2ma2f 3
(4)
vibration in Fig. 6(a), the primary Si grains in the
microstructures with the vibration are refined where m is the mass and a is the amplitude of the
significantly. This could be mainly attributed to the vibration table, which can be considered as constants for
chilling effect induced by VSCP. Due to the intense this study. It is clear that the vibration energy increases
chilling effect of the copper serpentine channel, the with increasing the vibration frequency. When the
Al−30%Si alloy liquid which is close to the channel vibration frequency is 40 Hz, the vibration energy may
inner wall, can be prone to cool below the liquidus be insufficient, which results in a small amount of
temperature. So, the primary Si crystal nuclei can primary Si grains to be exfoliated and cannot make all of

Fig. 6 Microstructures of as-cast samples processed by RDC assisted with VSCP at 850 °C, with twelve-curve serpentine channel and
different vibration frequencies: (a) 0 Hz; (b) 40 Hz; (c) 80 Hz; (d) 120 Hz
1270 Zhi-kai ZHENG, et al/Trans. Nonferrous Met. Soc. China 27(2017) 1264−1272
them move to the solid−liquid interface. So, the average grains are refined to fine plate-like grains and the
grain size of the primary Si grains is relatively large. average grain size of the primary Si grains reduces to
When the vibration frequency increases to 80 Hz, the 27.2 μm, as shown in Fig. 7(b). Figure 7(c) shows that
enhanced vibration energy increases the number of the when the number of curves increases to 12, almost all of
exfoliated primary Si grains. The sufficient kinetic the primary Si grains are refined into fine compact
energy maybe makes all the exfoliated primary Si grains particles with the average grain size of 24.6 μm.
move to the solid−liquid interface, so, the subsequent
Al−30%Si alloy melt can bring them into the collection
crucible. When the vibration frequency continues to
increase to 120 Hz, the vibration energy is further
enhanced. However, due to the excessive kinetic energy,
some part of the exfoliated primary Si grains maybe
move to the superheated liquid region. Consequently, this
part of the exfoliated primary Si grains may be remelted,
which decreases the effective nucleation rate of the
primary Si crystal nuclei within the Al−30%Si alloy melt.
As a result, with increasing the vibration frequency of
VSCP, the average grain size of the primary Si grains
decreases at first and then increases slightly.
Table 4 shows a comparison of mechanical
properties of the Al−30%Si alloy samples processed by
RDC assisted with VSCP at different vibration
frequencies. As can be seen, when the VSCP is applied at
a vibration frequency of 80 Hz, the mechanical
properties of the RDC samples are the best. The UTS,
elongation and hardness of the RDC sample are 296 MPa,
0.87% and HB 155, respectively. This is mainly because
the fine compact primary Si grains can enhance the
mechanical properties of the RDC samples.

Table 4 Mechanical properties of Al−30%Si alloy processed by

RDC assisted with VSCP at different vibration frequencies
UTS at room Hardness
Elongation at room
temperature/MPa (T6 heat-
Process temperature
As- T6 heat- treated)
(T6 heat-treated)/%
cast treated (HB)
RDC
183 221 0.63 139
(0 Hz)
RDC
237 276 0.72 146
(40 Hz) Fig. 7 Microstructures of as-cast samples processed by RDC
RDC assisted with VSCP at 850 °C, vibration frequency of 80 Hz
251 296 0.87 155
(80 Hz) and different numbers of curves: (a) Four-curve channel;
RDC (b) Eight-curve channel; (c) Twelve-curve channel
(120 246 283 0.81 149
Hz) As shown in Fig. 8, under the same other
conditions, the average grain size of the primary Si
3.3 Effects of number of curves on RDC samples grains decreases with increasing the number of curves in
Figure 7 shows the microstructures of the RDC the serpentine channel. As the number of curves in the
samples, of which three different numbers of curves in serpentine channel increases, the area of the serpentine
the serpentine channel were used under a pouring channel inner wall which is directly in contact with the
temperature of 850 °C and a vibration frequency of alloy melt is enlarged. This is beneficial to
80 Hz. Figure 7(a) shows that almost all of the primary heterogeneous nucleation and chilling nucleation of the
Si grains are coarse plate-like grains with the average alloy melt. With increasing the area of heterogeneous
grain size of 32.1 μm. The coarse plate-like primary Si nucleation and chilling nucleation substrate, more crystal
 Zhi-kai ZHENG, et al/Trans. Nonferrous Met. Soc. China 27(2017) 1264−1272 1271
nuclei are generated. Meanwhile, as the area of the with VSCP and the twelve-curve copper serpentine
serpentine channel inner wall increases, the superheat channel are the best. Besides, T6 heat treatment can
and latent heat of the alloy melt are more easily absorbed significantly improve the mechanical properties of the
by the copper serpentine channel, thereby the crystal RDC sample, as shown in Fig. 8(b).
nuclei are also easily preserved. Moreover, with
increasing the number of curves in the serpentine 4 Conclusions
channel, the collision frequency among the primary Si
grains and between primary Si grains and the serpentine 1) The primary Si grains in the Al−30%Si alloy
channel inner walls can be constantly enhanced, which samples processed by RDC assisted with VSCP can be
effectively promotes the refinement and regularization of successfully refined. The primary Si grains are refined to
the plate-like grains. Finally, the average grain size of the the greatest extent and the plate-like grains are changed
primary Si grains is substantially decreased. into fine compact particles with the average grain size of
24.6 μm when the VSCP is applied at a pouring
temperature of 850 °C, a twelve-curve copper serpentine
channel and a vibration frequency of 80 Hz. It is
considered that the chilling effect induced by VSCP
results in the refinement of primary Si grains.
2) Under the same other conditions, with increasing
the vibration frequency and decreasing the pouring
temperature, the average grain size of the primary Si
grains firstly decreases and then increases slightly.
Furthermore, the average grain size of the primary Si
grains decreases with increasing the number of curves in
the serpentine channel.
3) The obtained mechanical properties of the RDC
Al−30%Si alloy processed by RDC assisted with VSCP
at different process parameters change in accordance
with the effects of the process parameters on the
microstructure. The mechanical properties of the RDC
sample assisted with VSCP at a pouring temperature of
850 °C, a twelve-curve copper channel and a vibration
frequency of 80 Hz are the best. The UTS, elongation
and hardness of the RDC sample are 296 MPa, 0.87%
and HB 155, respectively.
4) In T6 heat treatment state, compared with the DC
sample, the UTS, elongation and hardness of the RDC
sample are increased by 57.9%, 42.9% and 20.6%,
respectively.
Fig. 8 Average grain size and shape factor versus number of
curves (a) and tensile strength versus number of curves (b) References
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流变压铸工艺参数对过共晶 Al−30%Si 合金
显微组织和力学性能的影响
郑志凯 1，吉永健 1，毛卫民 1，岳 锐 1，刘志勇 2

1. 北京科技大学 材料科学与工程学院，北京 100083；2. 清华大学 机械工程系，北京 100084

摘 要：研究流变压铸工艺参数浇注温度、振动频率和蛇形通道弯道数量对 Al−30%Si 合金的显微组织和力学性

能的影响。流变压铸过程中的半固态 Al−30%Si 合金浆料采用振动蛇形通道浇注工艺制备。实验结果表明：浇注
温度、振动频率和通道数量对 Al−30%Si 合金显微组织和力学性能的影响较大。在浇注温度为 850 °C、通道弯道
数量为 12 和振动频率为 80 Hz 的条件下，流变压铸工艺制备的样品组织的初生硅晶粒被细化成平均粒径约为
24.6 μm 的块状颗粒；此外，流变压铸样品的抗拉强度、伸长率和硬度分别为 296 MPa、0.87%和 HB 155。因此，
振动蛇形通道浇注工艺能有效地细化组织中的初生 Si 晶粒。初生 Si 晶粒的细化是流变压铸样品力学性能改善的
主要原因。
关键词：过共晶铝硅合金；初生 Si；振动蛇形通道；浇注工艺；流变压铸；显微组织；力学性能
(Edited by Wei-ping CHEN)