CharacterizationoftheRoleofSqueezeCastingonthe...

Research ArticleCharacterization of the Role of Squeeze Casting on theMicrostructure andMechanical Properties of the T6 Heat Treated2017A Aluminum Alloy

S. Souissi ,1 N. Souissi,2 H. Barhoumi,2 M. ben Amar,1 C. Bradai,1 and F. Elhalouani1

1Laboratory LASEM, National Engineering School of Sfax (ENIS), University of Sfax, B.P. 1173-3038 Sfax, Tunisia2Faculty of Sciences of Sfax, University of Sfax, Sfax, Tunisia

Correspondence should be addressed to S. Souissi; [email protected]

Received 29 October 2018; Accepted 24 December 2018; Published 22 January 2019

Academic Editor: Pavel Lejcek

Copyright © 2019 S. Souissi et al. *is is an open access article distributed under the Creative Commons Attribution License,which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

In this study, the effects of squeeze casting process and T6 heat treatment on the microstructure and mechanical properties of2017A aluminum alloy were investigated with scanning electron microscopy (SEM), energy dispersive X-ray spectrometry (EDS),differential scanning calorimetry (DSC), and microhardness and tensile tests. *e results showed that this alloy contained αmatrix, θ-Al2Cu, and other phases. Furthermore, the applied pressure and heat treatment refines the microstructure and improvethe ultimate tensile strength (UTS) to 296MPa and the microhardness to 106HV with the pressure 90MPa after ageing at 180°Cfor 6 h. With ageing temperature increasing to 320°C for 6 h, the strength of the alloy declines slightly to 27MPa. *en, the yieldstrength drops quickly when temperature reaches over 320°C. *e high strength of the alloy in peak-aged condition is caused by aconsiderable amount of θ′ precipitates. *e growth of θ′ precipitates and the generation of θ phase lead to a rapid drop of thestrength when temperature is over 180°C.

1. Introduction

Due to their excellent mechanical and physical properties,Al-Cu cast alloys are used in automobile and military in-dustries, aerospace, and in applications such as floor beams,engine pistons, wing box, covers, brake components, fueltanks, slot tracks wheel, fittings, fuel systems, body skinconnectors [1–3].

However, the major problems in casting these alloysconsist in their high tendency to form casting defects such ashot tearing, solidification shrinkage, porosity [2], and theirbad fluidity in conventional casting processes. *eseproblems have negative effects on the mechanical propertiesand have greatly limited the application of Al-Cu cast alloys.Nowadays, for improved alloy properties, themicrostructurerefinement of Al-Cu cast alloys has become an importantresearch field because mechanical properties can be sig-nificantly enhanced by microstructure refinement.

Squeeze casting is one of the modern casting processeswhich have been invented to address these imperfections

and has a high potential to produce sound castings. It is ametal-forming process which combines permanent mouldcasting with die forging into a single operation where moltenmetal is solidified under applied hydrostatic pressure [4–6].

*e process, which is suitable for shaping both cast andwrought alloys, improves product quality by pressurizedsolidification, which prevents the formation of shrinkagedefects, retains dissolved gases in solution until freezing hascompleted, and has the priority to form the equiaxed grainstructure [7, 8]. Many research works on the advantages ofsqueeze casting process have been discussed. Souissi et al. [9]have shown that squeeze casting caused the refinement ofthe microstructure and reduction in the dendrite armspacing (DAS) of the cast structure possibly due to in-creasing the cooling rate of 2017A aluminum alloy. *eyfound that the gravity cast specimens have the lowest UTScompared with the squeeze cast specimens. However, theincrease of UTS and YS is obvious at the 50MPa and100MPa pressure. In the same way, Souissi et al. [10] havestudied Al-13% Si alloy and found that the dendrite size of

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the alloy decreases with the increase of the squeezingpressure in the center and the edge of specimens. Malekiet al. [11] have investigated considerably the effects ofsqueeze casting parameters on the microstructure andmechanical properties of aluminum alloys.

Moreover, another method for improving the me-chanical properties of the cast Al-Cu alloys is the heattreatment; the most used method for these alloys is the T6heat treatment. A typical precipitation hardening treatmentinvolves three steps: (1) the solution treatment that brings allthe elements into solid solution state; (2) rapid quenching inorder to avoid diffusion and to retain supersaturated solidsolution at room temperature; and (3) ageing treatment toform fine precipitates by controlled decomposition ofmetastable supersaturated solid solution.

In this regard, Panuskova et al. [12] have investigated theeffects of the heat treatment solution of Al-Si-Cu cast alloyson the microstructure of the alloy in three aspects, namely,the dissolution of coarse Al2Cu, homogenization of themicrostructure, and improvement of eutectic silicon mor-phology (fragmentation, spheroidization, and coarsening).In addition, Barhoumi et al. [13] have studied the effect ofthe T6 heat treatment on Al9Si3Cu alloy that caused changesin the morphology of eutectic silicon, the Cu-rich, and Fe-rich phases. *e eutectic is converted into fine spherodisedSi-phases uniformly distributed in the aluminum matrix.*e dissolution of Cu-rich phases during heat treatmentincreases the concentration of Cu and other alloying ele-ments (Mg and Si) in the aluminum matrix. In this regard,Muzaffer et al. [14] found that the ageing heat treatmentmechanisms responsible for the strengthening effect arebased on the formation of intermetallic phases during thedecomposition of a metastable supersaturated solid solutionobtained by solution treatment and quenching. *us, themechanical properties (UTS, YS, El%, and microhardnessHV) of these alloys are influenced by the presence ofprecipitates.

In this work, the influence of pressure and T6 treatmentswith different ageing temperatures was carried out on castaluminum alloy 2017A. *e microstructure and pre-cipitation behavior obtained under different squeeze pres-sures and heat treatment conditions were also investigated toprovide theoretical support for the evolution of strength.*is is to find the relationship between the microstructure ofalloy and the mechanical properties under the peak ageing ofvarious heat treatment conditions.

2. Experimental

*e material investigated in this study is 2017A wroughtaluminum alloy. *e material provides average tensilestrength and good machinability. It is widely used in me-chanical applications. *e alloy is received as an extrudedbar of 80mm diameter. *e chemical composition is pre-sented in Table 1, and it was analyzed by using an opticalemission spectrometer (ICP-MS). *e material was meltedin an electric resistance furnace using a graphite crucible.Squeeze casting was performed using experimental setup asshown in Figure 1. *e melt was poured into the die

preheated to 250°C. *e pressure was applied to the meltafter pouring by using a 50-ton vertical hydraulic press usinga ram until solidification was completed. *e appliedpressures were 0, 30, 60, and 90MPa. *e cast billets werecylindrical in shape with 23mm in diameter and about100mm in height.

*e casting was subjected to heat treatment T6 con-sisting of solution treatment and ageing treatment. Firstly,the temperature of homogenization treatment of the alloywas performed at 500°C for 8 h and then quenched intowater at room temperature and ageing at 180°C for 6 h and320°C at 6 h in order to further prove that the second phaseswere dissolved into the matrix after solution heat treatment.After heat treatment, samples were subjected to the mi-crostructural and mechanical test; all samples for metallo-graphic analysis were cut in the middle of the specimens.Metallographic samples were polished and then etched withthe Keller solution for 10 seconds before rinsing with dis-tilled water. For the specimens morphology, observationswere performed by using an optical microscope LEICADMLP with a digital camera JVC. A PHILIPS-XL30 ESEMscanning electron microscope (SEM) equipped with energydispersive X-ray spectrometry (EDS) was used to quanti-tatively analyze the sizes of the intermetallic compounds andthe α (Al) dendrite in the as-cast and heat-treated samples.*e intermetallic particles were identified by using X-raydiffraction analysis and differential scanning calorimetry(DSC) at a heating rate of 10°C/min.

To evaluate tensile tests on the specimens of the gravitydie cast (0MPa) and squeeze cast for each experimentalcondition, an INSTRON universal testingmachine was used.*e tests were performed under displacement control with astrain rate starting at 1mm/min. An extensometer (gagelength of 14.3mm) is attached with two rubber bands to the

Table 1: Chemical composition of 2017A aluminum alloy (wt.%).

Cu Mg Si Mn Ni Fe Cr Zn Pb Al4.47 0.45 0.86 0.36 0.36 0.49 0.1 0.25 0.03 Rest

Punch

Billet

Controlled pressure

Figure 1: Schematic presentation of squeeze casting setup.

2 Advances in Materials Science and Engineering

central part of the specimen. �ree specimen samples wereprepared.

A Micro-Vickers hardness analysis HV was performedemploying a MEKTON Vickers Hardness Tester with adiamond pyramidal indenter. �ree measurements weretaken at randomly selected points with a load of 300 g ap-plied for 30 s.

3. Results and Discussion

3.1. Microstructural Characterization of As-Cast Alloy.Figure 2 shows the DSC analysis of the samples in dierentpressures, which exhibits three exothermic peaks (A, C, andD) and two endothermic peaks (B and E): peak A corre-sponds to the formation of Guinier–Preston (GP) zones,followed by an endothermic (peak B) in the interval[145–195°C] which corresponds to the formation of the θ″phase (coherent precipitate). �e larger exothermic (peak C)signies the precipitation of the θ′ phase (semicoherentprecipitate). However, the dissolution peak of the pre-cipitates of peak C was not detected; this can be explained bythe overlap of the peaks due to the rapidity of the trans-formations. A third exothermic (peak D), located in thetemperature range 447–510°C, is related to the formation ofthe θ-Al2Cu phase. �is is followed by a last and moreintense endothermic (peak E) at the temperature range510–560°C; it signies the dissolution of the θ-Al2Cu phase[15], and there is a slight displacement of the peak E, for die-cast alloy under 90MPa, at low temperatures. �is dis-crepancy can be explained by the increase in the temperatureof the eutectic transformation under the eect of thepressure [16].

Figure 3(a) shows the as-cast microstructure of 2017Aalloy under 90MPa squeeze pressure. It is clear that thesample mainly consisted of dendritic α-Al grains and in-termetallic phases. Analyzing the microstructures along thedierent transverse sections of the samples, an α–rich alu-minum dendritic matrix and interdendritic structures can beobserved from the results of the micrograph. �e EDXqualitative analysis allowed us to identify the intermetallicphases. From the chemical composition of the alloy, andbased on the results of Birol [17, 18], the two phases areassociated, respectively, with the two intermetallic com-pounds θ-Al2Cu and Al12(FeMnCu)3Si. However, it seemsthat the distribution of the θ-Al2Cu phase after the T6 heattreatment is strongly modied compared to the initialcasting state. Indeed, its distribution becomes thinner anduniform at grain boundary levels as shown in Figure 3(b).

�e results of SEM are conrmed with X-ray diraction.Furthermore, XRD technique was utilized to help establishthe results of the phase classication based on the metal-lographic study. �e X-ray diraction spectra of 2017A alloyof the 90MPa under squeeze pressure in the as-cast and heattreatment conditions are shown in Figure 4. During heattreatment, no new phase was precipitated. Indeed, theprecipitates (θ-Al2Cu and Al12(FeMnCu)3Si) as indicated bythe XRD patterns already revealed by SEM are identied.

3.2. As-Cast and Heat Treatment Microstructure. Figure 5displays the microstructure of the as-cast alloy prepared atdierent squeezing pressures. It is clear that the squeezingpressure has signicant in£uence on the microstructure ofthe alloy. �e results show that the secondary dendrite armspacing (SDAS) will be reduced to some extent when thesqueeze pressure of 90MPa is applied. In this study, it wasfound that microporosity was eliminated completely whenthe pressure was up to 60MPa. Furthermore, the in-termetallic phases in the alloy with no applied pressure arecoarser than those under high squeezing pressure. In-creasing the freezing point causes undercooling in the alloythat is already superheated. However, such change infreezing temperature with the increasing pressure is ex-pected due to the reduction in interatomic distance and thusthe restriction of atomic movement. �e higher freezingpoint brings about the larger undercooling in the initiallysuperheated alloy and thus elevates the nucleation fre-quency, resulting in a more ne-grained structure. Apartfrom the changes in undercooling of the molten alloy causedby applied pressure, greater cooling rates for the solidifyingalloy can be realized due to reduction in the air gap betweenthe alloy and the die wall and thus larger eective contactarea [9, 19, 20].

�is is because squeeze pressure plays an active role inthe diusion of heat and thus enlarges the solidication rate.Obviously, the increase of undercooling degree and heat-transfer coe¤cient will result in the renement of the grainsize of squeeze casting alloy. In addition, the increase indensity of the alloy will be obtained due to reduction ofmicroporosity [11].

�e microstructure for the heat-treated alloy (as-quenched, aged at 6 h at 180°C and aged at 320°C) condi-tions is presented in Figure 6.

0.4

0.2

0.0

–0.2

–0.4

100

Exo

200 300Temperature (°C)

Hea

t flo

w (m

W/m

g)

400 500

90 MPa60 MPa

30 MPa0 MPa

Figure 2: DSC analysis of squeeze cast specimens at dierentspecic pressures.

Advances in Materials Science and Engineering 3

�e microstructure reveals a signicant dierence be-tween gravity casting and 90MPa pressure casting in theheat treatment conditions of the alloy. From these opticalmicrographs, we can notice that all the microstructuresconsist of equiaxial grains but are of homogeneous sizecompared with Figure 5. We also distinguish the micro-structure of the as-quenched sample (Figure 6(a)). It showsthat only α-Al matrix was observed because the intermetallicphases dissolved in the matrix after the homogenizationtreatment. �erefore, the alloy components were evenlydistributed despite some residual participants at the grainboundaries [21]. Compared to the microstructure of dif-ferent ageing conditions, it can be found that when theageing temperature of microstructure is 180°C (Figures 6(c)and 6(d)), there are a large number of precipitation phase inthe matrix. Indeed, the presence of the precipitates andalloying elements causes braking of the grain boundaries inmigration. �e growth of precipitates is governed by thediusion of the solute atoms towards the germs, which arethermally activated. At the same time, these precipitates areevenly distributed. All this is benecial to improve themechanical properties of the alloy. In addition, when theageing temperature is 180°C, the precipitates observed

showed a higher volume fraction than that of the hardenedand quenched alloy that has returned to 320°C. Compared tothe microstructure of dierent ageing conditions, along withthe ageing temperature increase, the quantity of the coarseequilibrium precipitates also increased. It is not conducive toimprovement in the mechanical properties, which is con-sistent with other reported studies [22–24].

3.3.E�ectofAgeingTemperatureon theMechanicalProperties.�e variation curves of the ageing microhardness of the alloyin various pressure levels are shown in Figure 7. As can beseen from the curves, the peak microhardness increases atrst and then decreases as ageing temperature increasesunder the dierent pressures. �e hardness peak is attainedwhen ageing at 180°C for 6 h. �e hardening achieved isattributed to the formation of GP zones and the precipitationof phase θ′ [17]. �e 2017A aluminum alloy has now begunto nucleate heterogeneously on dislocations, as the homo-genously nucleated GP zones have developed within thedislocation-free volumes of the alloy. �us, the micro-structure was found to consist of a high density CuAl2 (θ′) inthe α-Al matrix [25, 26]. In this case, the dislocations will

θ-Al2Cu

α-Al

Al12(FeMnCu)3Si

10 μm

(a)

Al12(FeMnCu)3Si

θ-Al2Cu α-Al

10 μm

(b)

Figure 3: SEM micrographs of 2017A alloy under 90MPa squeeze pressure: (a) as-cast state; (b) after T6 heat treatment.

Inte

nsity

(a.u

.)

2θ (°)50454035302520

α-Al θ-Al2Cu Al12(FeMnCu)3Si

(a)

2θ (°)

Inte

nsity

(a.u

.)

50454035302520

α-Al θ-Al2Cu Al12(FeMnCu)3Si

(b)

Figure 4: XRD patterns of the 90MPa squeeze pressure in the (a) as-cast state and (b) after T6 heat treatment.


0MPa

100 μm

As-

quen

ched

(a)

100 μm

90MPa

As-

quen

ched

(b)

Figure 6: Continued.

100μm

(a)

100μm

(b)

100μm

(c)

100μm

(d)

Figure 5: Microstructure of 2017A alloy in as-cast conditions: (a) P � 0MPa, (b) P � 30MPa, (c) P � 60MPa, and (d) P � 90MPa.


shear these precipitates by destroying their order. Indeed,generally the precipitates oppose the phenomena of sliding,which explain the increase of microhardness. In ageingtreatment at 210°C, the microhardness of the alloy increasesrapidly to a peak in a shorter time. �erefore, the secondpeak occurs, and with the extension of ageing time, themicrohardness of the alloy declines due to overageing.Ageing of the test samples has been carried out at tem-peratures of 180°C. Every ageing temperature reached twopeaks. �is is called the “double peaks” phenomenon.

Between these two peaks, there is a remarkable decrease ofmicrohardness. For temperatures above 320°C, the micro-hardness increases again. �is increase is apparently relatedto high concentration of the solute atoms in the aluminummatrix. �is can precipitate during cooling, which leads tohigh microhardness values.

Results of tensile tests for the samples in the as-cast state,as-quenched state, and dierent ageing time at 180°C and320°C after the solution treatment at 500°C for 8 h aresummarized in Figures 8 and 9. As can be noticed from

100 μm

0MPa

Age

d at

180

°C in

6h

(c)

100 μm

90MPa

Age

d at

180

°C in

6h

(d)

100 μm

0MPa

Age

d at

320

°C in

6h

(e)

100 μm

90MPa

Age

d at

320

°C in

6h

(f )

Figure 6: Optical micrographs of the 2017A alloy in heat treatment conditions.

65707580859095

100105

35 85 135 170 190 225 275 310 330 375

Mic

roha

rdne

ss (H

V)

Temperature (°C)

0 MPa30 MPa

60 MPa90 MPa

Figure 7: Graphical representation of microhardness values of alloy in heat treatment conditions with various pressures.


Figure 8, the gravity cast specimens have the lowest ultimatetensile stress (UTS) and yield stress (YS) compared withsamples when squeeze pressure from 90MPa is applied.Evidently, the tensile properties of the alloy are obviouslyimproved because of the application of pressure. Actually, thestrength of the alloy can be in£uenced by the grain size, thedistribution, morphology as well as the intermetallic phases.

�e improvement of mechanical properties results es-sentially from the microstructure renement produced bythe squeeze pressure during solidication. Furthermore, anincrease of applied pressure contributes to the increase insolidication temperature of the alloy, which bringsundercooling in a superheated alloy and increases nucle-ation ratio in the melt, resulting in a ner grain size [27–31].

�e results of the heat treatment conditions showedhigher values for tensile properties than the as-cast condi-tion. For instance, in the case of this alloy, the ageingtemperature at 180°C for 6 h leads to an increase in the YSand UTS of the squeeze cast samples from 107 to 218MPaand 215 to 296MPa, respectively. Also, an obvious im-provement in elongation compared with the values in the as-quenched state and ageing temperature was observed at320°C at 6 h. �is variation is associated with the homog-enization of solute atoms and the variation of the dissolution

of intermetallics. After ageing treatment, due to the pre-cipitation of nanosize phases, the strength especially (YS) issignicantly improved and the elongation decreases. Fur-thermore, the eect of microstructural coarseness on themechanical properties is re£ected by comparing the tensileproperties of each step. In fact, the tensile properties vary as afunction of the morphology and the size of the micro-structural constituents as well as porosity. �e present re-sults are conrmed by Barhoumi et al. [32], Tao et al. [21],and Jahangiri et al. [33]. As a result, the research conrmedthat squeeze casting technique and the T6 heat treatmentwith ageing at 180°C at 6h has the potential to enhance thequality of casted parts.

4. Conclusion

�e following conclusions are established for eect of ap-plied pressure and ageing treatments on microstructure andthe mechanical properties of squeeze casting 2017A alloy:

(1) �e dierential calorimetric study shows us thetransformations of the dierent phases dissolved inthe α-Al matrix. �e results have shown that theapplication of pressure (90MPa) has a signicanteect on the morphology of the phases. On the otherhand, the morphology of T6 heat treatment variesremarkably according to the ageing temperature.

(2) �e microstructure was altered with the ageingtreatment. Also, it was observed that the precipitatephases dispersed denser in structure with the in-creasing of the ageing temperature. In fact, theprecipitates observed show a higher volume fractionin ageing at 180°C than as-quenched conditions andageing at 320°C. �ese results are validated by tensiletests that are in good agreement with the results ofmicrohardness and optical microstructure.

Data Availability

No data were used to support this study.

92

153

107

215

125

200 199

278

175

219 218

296

88

175

121

276

YS (MPa) UTS (MPa) YS (MPa) UTS (MPa)Gravity Squeeze casting

As-castAs-quenched

Aging at 180°CAging at 320°C

Figure 8: YS and UTS of the gravity die cast and the squeeze cast alloy under 90MPa pressure in the dierent treatment conditions.

0.82

1.7

0.4

2.52.35 2.21.85

3.1

As-cast As-quenched Aging at 180°C Aging at 320°C

GravitySqueeze casting

Figure 9: Elongation (%) of the gravity cast and the squeeze castalloy under 90MPa pressure in the dierent treatment conditions.


Conflicts of Interest

*e authors declare that they have no conflicts of interest.

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