ABSTRACT The effect of heat and strain during the semisolid processing route on the microstructural evolution and mechanical performance of the Al-5.5wt%Si-5wt%Zn-0.2wt%Mg alloy was evaluated. The as cast alloy was heated and partially melted to 588 °C (fs = 0.40), thixoformed (in an open die forged) and solution heat-treated (SHT) at 525 °C for 1 to 6 h. The microstructural evolution and chemical distribution (SEM-EDS) of the main alloying elements were evaluated at each step of the processing route. The SHT for 2.5 h after thixoforming showed to be adequate considering (a) the spheroidization of Si crystals, (b) the formation of Fe- and Mn-rich platelet-like particles in the eutectic phase, (c) the Mg dissolution from the Mg2Si conglomerates and (d) the homogeneous Zn diffusion along the entire part. As a consequence of the higher circularity of secondary particles, the possibility of crack formation and propagation under stress was minimized. The possible formation of solute clusters and GP zones containing Zn, Mg, Si and Cu was enabled due to the dissolution and diffusion of secondary elements during SHT, which increased the alloy’s mechanical strength. Larger Si crystals and the homogeneous spatial spread of Zn resulted in the hardness increase of the SHT alloy.

Abstract Al-Si-Zn-Mg quaternary alloys represent a potential range of feedstock's for semisolid processing (SSM) that combine the advantages of the thixoforming process with the possibility of heat treatment to improve mechanical performance. In this work, the suitability of the Al-5wt%Si-5wt%Zn-0.5wt%Mg alloy for use in thixoforming was assessed by thermodynamic characterization and by an analysis of its microstructural evolution and rheological behavior. Thermodynamic analysis was performed by numerical simulation and by application of the differentiation method to Differential Scanning Calorimetry (DSC) curves for heating cycles up to 700 °C at 5 and 25 °C/min. Microstructural evolution during partial melting at 594 °C for 0, 30, 60 and 90 s and the corresponding rheological behavior were analyzed. The findings indicate good agreement between the thermodynamic behavior predicted by DSC and Calculation of Phase Diagrams (CALPHAD) and the data obtained from semisolid forging. Although the alloy has a coarse microstructure (GSmax = 200 μm), its rheological behavior is appropriate for thixoforming (σmax = 1.06 MPa and μmax = 1.79x104 Pa.s), indicating that the microstructure only plays a secondary role in determining viscosity when enough liquid (fl = 0.63) is present in the slurry to enhance the flow. The alloy is suitable for use as raw material for semisolid processing.

Abstract This work describes the design, construction and testing of a continuous casting device coupled to an electromagnetic stirring system for the production of thixoforming feedstock using Al-Si alloys. The following processing and construction parameters were tested: pouring temperature (660-800 °C), mould cavity roughness (Ra = 0.17-1.06 µm), casting speed (2-4 mm/s), use of a combined (primary and secondary) cooling system and the intensity and radial penetration of electromagnetic stirring (0, 1500 and 3000 W stator power). The macro-appearance of the ingots and the longitudinal and radial microstructural parameters were then evaluated. The results indicate that the surface finish of the mould cavity was an important construction parameter as it had a strong influence on heat transfer and, consequently, feed speed; use of a secondary cooling system for the mould allowed greater grain refinement and microstructural homogeneity to be achieved for all the conditions tested; optimal electromagnetic stirring power was 1500 W (EMFmax = 22 Gauss); this resulted in a grain size-to-dendritic arm spacing ratio of close to 1, which is suitable for subsequent SSM processing.

Os aços inoxidáveis austeníticos são materiais de alto valor agregado, representando uma parcela importante das ligas usadas, principalmente, nas indústrias aeronáutica, química, naval, alimentícia e biomecânica. Apresentam boas propriedades mecânicas aliadas à elevada resistência à corrosão. Quando submetido à deformação a frio, esses aços exibem uma fase metaestável denominada martensita induzida por deformação (ferromagnética), cuja formação aumenta a resistência mecânica e conformabilidade, permitindo sua ampla gama de aplicações. Aquecida acima da temperatura ambiente, a martensita induzida por deformação se transforma em austenita. Existem dados na literatura sobre a formação da martensita induzida por deformação em aços austeníticos 18Cr/8Ni, mas não há essa informação em ligas de alto teor de níquel como A286 (26Ni, 15Cr), Incoloy 800 (30-40 Ni, 21Cr) e Inconel (50Ni, 19Cr). Portanto esse trabalho foi realizado para verificar a formação de martensita induzida por deformação, após o trabalho a frio de ligas Fe-18Cr base com adição de até 60% Ni. A reversão dessa fase para austenita, após recozimento até 600ºC, também foi estudada. Microscopia óptica, ensaios de caracterização magnética e difração de raios X foram usados para analisar as transformações.

Austenitic stainless steels represent a significant portion of the alloys used in the aeronautical, chemical, shipbuilding, food processing and biomechanical industries. They combine good mechanical properties with high corrosion resistance. When subjected to cold deformation, these steels exhibit a metastable phase called: strain induced martensite (ferromagnetic), whose formation increases mechanical strength and formability, allowing for a wide range of applications. Heated from room temperature, the strain induced martensite transforms to austenite (non-magnetic). It is easy to find information in literature about the strain induced martensite for 18Cr/8Ni austenitic steels, but there is no data for high nickel alloys like A286 (26Ni, 15Cr), Incoloy 800 (30-40 Ni, 21Cr) and Inconel (50Ni, 19Cr). Therefore, this study aimed to verify the formation of strain induced martensite after cold working in Fe-18Cr base alloys with the addition of up to 60 %Ni. The reversion of this phase to austenite after annealing up to 600 ºC was also studied. Optical microscopy, magnetic characterization tests, and x-ray diffraction were used to analyze the transformations.

O material estudado consiste de uma série de ligas com composição base (% em peso) de 18Cr - 0,01C - 0,2Si - 0,4Mn e teores de níquel variando de zero a 60%. Analisou-se a microestrutura por microscopia ótica das ligas no estado recozido e após deformação à temperatura ambiente, 350 e 700ºC, de modo a simular as altas temperaturas alcançadas na usinagem dessas ligas. Foram também gerados diagramas de equilíbrio das ligas por termodinâmica computacional (Thermocalc) para se prever o comportamento dessas ligas em uma larga faixa de temperaturas. As condições teóricas de equilíbrio termodinâmico do sistema foram comparadas às microestruturas observadas, indicando que a fase CFC nas ligas com teor de níquel entre 10% e 30% em peso está, na realidade, em uma condição metaestável à temperatura ambiente. Foi observada transformação martensítica induzida por trabalho a frio na liga com 10%Ni, validando os cálculos computacionais.

The material studied consists of a series of alloys with a basic composition (weight %): 18Cr - 0.01 C - 0.2 Si - 0.4 Mn, and levels of nickel varying from zero to 60%. Alloys in the annealed condition and after deformation at room temperature, 350 and 700°C to simulate the high temperatures achieved during machining were observed by optical microscopy. Equilibrium diagrams were generated by computational thermodynamics (Thermocalc) to predict the behavior of these alloys in a wide range of temperatures. The theoretical thermodynamic equilibrium conditions of the system were compared to the observed microstructures, indicating that the CFC phase in alloys with nickel content between 10% and 30% is, in fact, in a metastable condition at room temperature. Martensitic transformation induced by cold work in the alloy with 10% Ni was observed, validating the computer calculations.

Foram realizados ensaios de tração na temperatura ambiente em ligas Fe-18%Cr, com teor de níquel variando entre zero e 60% e correlacionaram-se as propriedades obtidas com os resultados de usinabilidade obtidos anteriormente pelo grupo. As ligas foram ensaiadas, também, a 350 e 700ºC, de modo a determinar suas propriedades, na faixa de temperatura alcançada, no local da usinagem. A liga ferrítica apresentou alongamento e limite de resistência menores que as ligas austeníticas, tanto à temperatura ambiente, como a 350°C, o que explica porque, na usinagem dessas ligas, a vida da ferramenta foi muito maior que nas ligas austeníticas (100 contra 20 a 50 minutos, respectivamente). No ensaio a 350ºC, temperatura atingida pela peça na região de usinagem, o aumento do teor de níquel elevou, tanto o limite de resistência das ligas austeníticas, o que dificulta a usinagem, como, também, elevou a ductilidade (alongamento), facilitando a adesão da liga sobre a ferramenta de corte e exigindo maior esforço na usinagem, com conseqüente redução da vida da ferramenta.

Tensile tests were carried out at room temperature in Fe-18% Cr alloys, with nickel content varying between zero and 60%, and the properties obtained were correlated with the results of machinability previously obtained by the group. The alloys were also tested at 350 and 700°C in order to obtain these properties in the range of temperature compatible with the machining process. The ferritic alloy presented lower elongation and UTS (ultimate tensile strength) than austenitic alloys at room temperature and 350°C, which explains why, in the machining process, the ferritic alloy shows much greater tool life if compared to austenitic alloys (100 against 20 to 50 minutes, respectively). In the test at 350°C, the temperature reached during machining, the increase in nickel content increased the UTS of austenitic alloys, hampering the machining, and also elevated the ductility (elongation) that produces a higher volume of material adhered on the tool. This higher adhesion capacity, allied to a higher mechanical strength, explains the increase of tool wear as a function of increasing nickel content in the alloy with a consequent reduction in the life of the tool.