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Library | Item Barcode | Call Number | Material Type | Item Category 1 | Status |
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Searching... | 30000010186056 | TN775 E748 2008 | Open Access Book | Book | Searching... |
Searching... | 30000003505140 | TN775 E748 2008 | Open Access Book | Book | Searching... |
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Summary
Summary
Pulling together information previously scattered throughout numerous research articles into one detailed resource, Physical Metallurgy of Direct Chill Casting of Aluminum Alloys connects the fundamentals of structure formation during solidification with the practically observed structure and defect patterns in billets and ingots. The author examines the formation of a structure, properties, and defects in the as-cast material in tight correlation to the physical phenomena involved in the solidification and the process parameters.
The book draws on the author's advanced research to provide a unique application of physical metallurgy to direct chill (DC) casting technology. He examines structure and defect formation-- including macrosegregation and hot tearing. Each technology-centered chapter provides historical background before reviewing current developments. The author supports his conclusions with computer simulation results that have been correlated with highly progressive experimental data. He presents a logical system of structure and defect formation based on the specific features of the DC casting process. He also demonstrates that the seemingly controversial results reported in literature are, in fact, caused by the different ratio of the same mechanisms.
Compiling recent results and data, the book discusses the fundamentals of solidification together with metallurgical and technological aspects of DC casting. It gives new insight and perspective into DC casting research.
Table of Contents
List of Symbols and Abbreviations | p. xi |
Preface | p. xv |
Author | p. xix |
1 Direct Chill Casting: Development of the Technology | p. 1 |
References | p. 17 |
2 Solidification of Aluminum Alloys | p. 19 |
2.1 Effect of Cooling Rate and Melt Temperature on Solidification of Aluminum Alloys | p. 19 |
2.2 Microsegregation in Aluminum Alloys | p. 28 |
2.3 Solidification Reactions and Phase Composition | p. 43 |
2.3.1 Commercial Aluminum | p. 43 |
2.3.2 Wrought Alloys with Manganese (3XXX Series) | p. 46 |
2.3.3 Al-Mg-Si Wrought Alloys (6XXX Series) | p. 47 |
2.3.4 Al-Mg-Si-Cu Wrought Alloys (6XXX and 2XXX Series) | p. 50 |
2.3.5 Al-Mg-Mn Wrought Alloys (5XXX Series) | p. 51 |
2.3.6 Al-Cu-Mn (Mg, Si, Ni) Wrought Alloys (2XXX Series) | p. 54 |
2.3.7 Al-Mg-Zn-(Cu) Wrought Alloys (7XXX Series) | p. 55 |
2.3.8 Wrought Alloys Containing Lithium | p. 56 |
2.3.8.1 Al-Cu-Li Commercial Alloys | p. 56 |
2.3.8.2 Al-Li-Mg Commercial Alloys | p. 57 |
2.3.8.3 Al-Li-Cu-Mg Commercial Alloys | p. 57 |
2.4 Effect of Alloy Composition on Structure Formation: Grain Refinement | p. 59 |
2.4.1 Mechanisms of Grain Refinement | p. 59 |
2.4.2 Al-Sc-Zr Phase Diagram | p. 68 |
2.4.3 Al-Ti-B Phase Diagram | p. 70 |
2.4.4 Al-Ti-C Phase Diagram | p. 71 |
References | p. 75 |
3 Solidification Patterns and Structure Formation during Direct Chill Casting | p. 79 |
3.1 Shape and Dimensions of the Billet Sump | p. 79 |
3.2 Solidification Rate and Cooling Rate during DC Casting | p. 91 |
3.3 Effects of Process Parameters on the Formation of Grain Structure | p. 101 |
3.4 Effect of Process Parameters on the Amount of Nonequilibrium Eutectics | p. 111 |
3.5 Effect of Process Parameters and Alloy Composition on the Occurrence of Some Casting Defects | p. 115 |
References | p. 122 |
4 Macrosegregation | p. 125 |
4.1 Mechanisms of Macrosegregation | p. 125 |
4.1.1 Historic Overview | p. 125 |
4.1.2 Permeability | p. 132 |
4.1.3 Convection-Driven Macrosegregation | p. 136 |
4.1.4 Shrinkage-Driven Macrosegregation | p. 141 |
4.1.5 Floating Grains and Macrosegregation | p. 145 |
4.1.6 Deformation-Driven Macrosegregation | p. 151 |
4.2 Effects of Process Parameters on Macrosegregation during DC Casting | p. 152 |
4.2.1 Effect of Casting Speed on Macrosegregation during DC Casting | p. 152 |
4.2.2 Effect of Melt Temperature on Macrosegregation during DC Casting | p. 159 |
4.2.3 Dimensions of the Billet: Scaling Rule of Macrosegregation | p. 159 |
4.2.4 Effect of Forced Convection on Macrosegregation during DC Casting | p. 169 |
4.3 Effect of Composition on Macrosegregation: Macrosegregation in Commercial Aluminum Alloys | p. 170 |
References | p. 179 |
5 Hot Tearing | p. 183 |
5.1 Thermal Contraction during Solidification | p. 185 |
5.2 Mechanical Properties of Semi-Solid Alloys | p. 200 |
5.2.1 Testing Techniques | p. 200 |
5.2.2 Strength Properties of Aluminum Alloys in the Semi-Solid State | p. 205 |
5.2.3 Ductility of Aluminum Alloys in the Semi-Solid State | p. 208 |
5.3 Mechanisms and Criteria for Hot Tearing | p. 216 |
5.3.1 Historic Overview of Hot Tearing Research and Suggested Mechanisms | p. 216 |
5.3.2 Hot Tearing Criteria | p. 225 |
5.3.2.1 Stress-Based Criteria | p. 225 |
5.3.2.2 Strain-Based Criteria | p. 229 |
5.3.2.3 Strain Rate-Based Criteria | p. 231 |
5.3.2.4 Criteria Based on Other Principles | p. 234 |
5.3.3 Application of Hot Tearing Criteria to DC Casting of Aluminum Alloys | p. 236 |
5.3.4 Quest for a New Hot Tearing Criterion | p. 240 |
5.4 Effects of Process Parameters on Hot Tearing during DC Casting | p. 245 |
5.4.1 Thermo-Mechanical Behavior of a DC-Cast Billet (Ingot) | p. 246 |
5.4.2 Effects of Composition and Casting Speed on Hot Tearing during DC Casting | p. 251 |
5.4.3 Effect of Melt Temperature on Hot Tearing during DC Casting | p. 259 |
5.4.4 Structural Features Associated with Hot Tearing in DC Casting | p. 262 |
References | p. 269 |
Concluding Remarks | p. 275 |
Subject Index | p. 289 |