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Introduction
High pressure die-casting (HPDC) is widely used as a cost effective way to mass produce metal components that are required to have close dimensional tolerances and smooth surface finishes. Standard HPDC components cannot however be conventionally heat treated to improve mechanical properties because the castings are relatively porous. During conventional solution treatment (e.g. at 500C), the pores expand resulting in the unacceptable surface blisters, distortion and lower mechanical properties. Recent work within the CSIRO Light Metals Flagship has revealed a heat treatment for HPDC aluminium alloys which avoids these problems. As a result, large improvements in tensile properties have been achieved as compared with the as-cast condition. One heat treatment may double yield strengths and another significantly increases elongation. Aluminium alloys used for high pressure die-casting are mostly those based on the alloys AA360 (Al-9.5Si0.52Mg) and AA380 (Al-8.5Si-3.5Cu), and their close variants such as Australian Designation alloys CA605 and CA313 respectively (See Table 1). All respond to the heat treatment. This paper describes the results of novel treatments that have been developed whereby these alloys may now be fully age hardened and strengthened by heat treatment without incurring problems with blistering or dimensional instability. Alloy wt% (balance Al)
Si Fe Cu Mn Mg Cr Ni Zn Sn Pb Ti Other elements (each) Other elements (total)
360
A380
B380
C380
D380
9-10 2.0 max 0.6 max 0.35 max 0.4-0.6 -------0.5 max 0.5 max 0.15 max -------------------
7.5-9.5 1.3 max 3.0-4.0 0.5 max 0.1 max ------0.5 max 3.0 max 0.35 max -------------------
7.5-9.5 1.3 max 3.0-4.0 0.5 max 0.1 max ------0.5 max 1.0 max 0.35 max -------------------
7.5-9.5 1.3 max 3.0-4.0 0.5 max 0.1-0.3 ------0.5 max 3.0 max 0.35 max -------------------
7.5-9.5 1.3 max 3.0-4.0 0.5 max 0.1-0.3 ------0.5 max 1.0 max 0.35 max -------------------
0.25 max
0.25 max
0.5 max
0.5 max
0.5 max
0.5 max
0.25 max
This technology is proprietary to CSIRO and accordingly, a license is required for its use.
(a)
(b)
(c)
Figure 1 compares the surface and interior microstructures of an as-cast specimen of 360 alloy and specimens that were heat treated using either conventional or novel CSIRO heat treatments compared to the as-cast condition. Figure 1(a) shows the as-cast specimen and a comparison with Figure 1(b) highlights the severe surface blistering, discoloration, internal porosity and dimensional change resulting from a conventional solution treatment. Figure 1(c) shows the outcome of the CSIRO heat treatment showing that blistering, dimensional instability and pore expansion have been prevented.
Figure 1. (a) as-cast, (b) conventional heat treatment leading to blistering and dimensional instability, and (c), the novel CSIRO heat treatment for HPDCs.
Figure 2 demonstrates the effectiveness of the HT2 heat treatment by comparing hardness results for it with equivalent results for the common permanent mold cast alloy 357 and the wrought alloy 6061, both in the T6 condition. The heat treatment response varies with alloy composition within the specification ranges. Table 3 shows mechanical properties for the alloys in Table 2. For the alloy 360, the HT2 properties display yield strength levels around 80% higher than for as-cast alloy. Alternately, for the HT1 treatment, the strength is little changed but the elongation is substantially increased compared to the as-cast material.
Alloy
1 360 spec 2 380 spec 3 380 spec 4 380 spec 5 380 spec 6 380 spec
Treatment
As cast HT1 HT2 As cast HT1 HT2 As cast HT1 HT2 As cast HT1 HT2 As cast HT1 HT2 As cast HT1 HT2
Tensile strength
310 MPa (45ksi) 310 MPa (45ksi) 373 MPa (54ksi) 354 MPa (51ksi) 387 MPa (56ksi) 431 MPa (63ksi) 347 MPa (50ksi) 405 MPa (59ksi) 442 MPa (64ksi) 358 MPa (52ksi) 411 MPa (60ksi) 458 MPa (66ksi) 358 MPa (52ksi) 397 MPa (58ksi) 457 MPa (66ksi) 362 MPa (53ksi) 411 MPa (60ksi) 481 MPa (70ksi)
Elongation
3.5% 6% 2.5% 4% 6% 3% 4% 7% 3% 3% 5% 2% 4% 5% 3% 3% 4% 2%
Table 3. Mechanical properties of 360 and 380 type alloys in as-cast and heat treated conditions.
200 190 180 Hardness (VHN) 170 160 150 140 130 120 110 100
ca s
ht
al lo y
al lo y
al lo y
w ro ug
PM
al lo y
al lo y
36
38
38
38
35
61
38
60
PD
PD
PD
PD
Figure 2. Comparative hardness of HT2 treated 360 alloy and 380 alloy variants, and T6 heat treated permanent mold cast 357 alloy, and wrought 6061 alloy.
For the various compositions of alloy 380, the HT1 treatment substantially increased the elongations and the yield strengths were also around 30% higher than those for the as-cast alloy. For the HT2 treatment, the increases in yield strength usually exceeded 100%. For example, with alloy 380 type 6, the yield strength in
PD
PD
38
al lo y
For more information please contact: Sam Tartaglia, Business Development Manager Private Bag 33, Clayton South MDC Victoria 3169, Australia Ph: +613 9545 2964 Fax: +613 9544 1128 e-mail: Sam.Tartaglia@csiro.au Roger Lumley, Project Leader: Light Metals Flagship Private Bag 33, Clayton South MDC Victoria 3169, Australia Ph: +613 9545 2894 Fax: +613 9544 1128 e-mail: Roger.Lumley@csiro.au