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Group Members
1) Rashid Humayun2) Muhammad Adeel Rauf3) Ehsan Ali Shaikh4) Asad Alamgir5) Tarique Ahmed Baig6) Munib-Ur-Rehman
Investigation and Research
ACTION PLAN OF INVESTIGATION AND RESEARCH
1. The impact of Thermal Treatment (T6 of a suitable grade of Al-Si alloy on the microstructure and properties . Also matches the results before and after treatment
2. Investigate on
The effect of solutionizing time The effect of Aging time The effect of cooling rate on the the properties and microstructure of LM-13 during
T6 treatment
Investigation and Research1. The impact of Thermal Treatment (T6 of a suitable grade
of Al-Si alloy on the microstructure and properties . Also matches the results before and after treatment
1.1 Grade selection 1.2 Grade Specification 1.3 Melt preparation 1.4 Mould preparation 1.5 Pouring 1.6 Heat Treatment 1.7 Sample preparation 1.8 Results of analysis before and after treatment 1.9 Conclusion
Investigation and Research 1.1 Grade selection
LM -13 --- I am selecting such grade because due to the minute %age of Cu and Mg it good compromise on the properties due to formation of beta and theta phase which makes results more interesting to research.
1.2 Grade Specification
Chemical composition
Properties.% Si %Fe %Cu %Ni %Mg11.5 – 12.5% < O.6% O.85 – 1.3% O.85 – 1.5% 1.1 – 1.5%
Hardness Tensile Strength
Elongation Impact strength
Hardness
65 – 75 HRB 15 – 25 Kg/mm2
3 – 5 % 8 – 10 joules
65 – 75 HRB
Investigation and Research 1.6 Heat Treatment
In above treatment solutionizing and aging both are processed at electrical bell type furnace
Treatment methodSolutionizing temperature 480 – 510oC
Solutionizing time 6 HrsCooling medium water
Cooling temperature 60oC Aging temperature 160 - 180oC
Aging time 5 Hrs Cooling medium Air
1.8 Results of analysis before and after treatment
way of treatment
Mechanical Properties Microstructure 100X
Hardness Tensile Strength
Elongation Impact strength
Before T6 Treatment
32 HRB 10 Kg/mm2
1 % 3.4 joules
way of treatment
Mechanical Properties Microstructure 100X
Hardness Tensile Strengt
h
Elongation Impact strength
After T6 Treatment
60 HRB 15 Kg/mm2
3 % 8.5 joules
Investigation and Research 1.9 Conclusion
Structure 1 .shows the very coarse particals of eutectic silicon and dentritic structure
Structure 2. shows the very fine particles of eutectic silicon and fine dendrite is also obtained with very homogeneity
Due to fine structure all properties became enhanced which shows the effect of treatment
Investigation and Research2. Investigate on
2.1 The effect of solutionizing time
2.2 The effect of Aging time
2.3 The effect of cooling rate
2.4 The comparison between T6 and Hardening
on the properties and microstructure of LM-13 during T6 treatment
Investigation and Research 2.1 The effect of solutionizing time The solution treatment temperature was carried out at 490oC with various
solution treatment times for 0.5hr, 1hr, 1.5hrs, 2hrs and 4 hrs, followed by water quenching
Subsequent aging treatment was carried out at 175oC for 5 hrs (T6 condition)
Investigation and ResearchSolutionizing time Hardness HRB
0.5 hr 59 1 hr 54
1.5 hrs 45 2 hrs 39 4 hrs 32
0
10
20
30
40
50
60
70
0.5 hr 1 hr 1.5 hrs 2 hrs 4 hrs
AGE HARDING CURVE
2.1.2 Results
2.1.3 Drawing Age hardening curve
2.1.4 Microstructure evolutions
Microstructure of sample after solution treatment for 30 min. ( at 100X
Microstructure of sample after solution treatment for 1 hr
Microstructure of sample after solution treatment for 1.5 hrs
Microstructure of sample after solution treatment for 2 hrs
Microstructure of sample after solution treatment for 4 hrs
Investigation and Research 2.1.5 Conclusion . Structure 1. Spherical particles of eutectic Si is in very low range while the dentritic
alpha aluminum in higher range
• Structure 2. the dentritic alpha aluminum is still present
Structure 3. Short range of eutectic silicon on the left side
Structure 4. Slightly higher range of spherical particles of eutectic Si
Structure 5. Higher range of spherical particles of eutectic Si
The HRB values are continuously decrease from 59 to 32 HRB as resulted from the coarsening of eutectic silicon, increasing of inter particle spacing and dissolution of the NiAl3 phase
Investigation and Research 2.2 The effect of Aging time Prepared test pieces were cleaned from impurity then were
realized the heat treatment which first were solutionizing and then ageing with different rates
Results:
Heat treatment operation
Temperature oC
Hour Hrs Cooling medium
Solutioning 480±5 6 Water – 20°Cquenching
Ageing 180±10 1 , 3, 5, 9,,
Air cooling
Heat treatment operation
Hour Hrs hardness [HRB] Tensile strength
Kg/mm2
Ageing180±10 oC
1 29 143 41 155 50 179 51 15
Investigation and Research 2.2.3 Drawing different curves & obtaining
Microstructure:
Microstructure of sample after Microstructure of sample after
Aging treatment for 1 hr at 100X Aging treatment for 3 hr at 400X
Microstructure of sample after Microstructure of sample after
Aging treatment for 5hrs Aging treatment for 9hrs
Investigation and Research 2.2.5 Conclusion Structure 1. The dentritic alpha aluminum and spherical eutectic silicon is
present
• Structure 2. The dentritic alpha aluminum is improving while spherical eutectic
silicon is still present
Structure 3. It shows the sharp needles of dentritic alpha aluminum while the
spherical eutectic silicon in slightly lower in range which shows that structure going to age and hard
Structure 4. Here we can see the final structure where the uniformity in
dentritic structure while spherical eutectic silicon are in very lower range
Investigation and Research 2.2.5 Conclusion
According to the microstructure results on each aging time the dentritic structure of alpha aluminium was going to uniform with aging time and spherical eutectic structure was going to minimize in range
But here we see that the last value of hardness at aging time 9 hrs i.e 51 HRB is not very much increase in comparison with the 5 hrs aging value i.e 50 HRB while the value of tensile strength of 9 hrs aging became decreased to 15 Kg/mm2 in comparison with the 5 hrs treatment i.e 17 Kg/mm2
Over aging is due to prolong aging time the θ and β precipitate i.e Al2Cu and Mg2Si precipitate may slightly dissolve in the structure.
Investigation and Research 2.3 The effect of cooling rate The solution treatment temperature was carried out at 490oC for 6 hrs
then, followed by water quenching
Subsequent aging treatment was carried out at 175oC for 5 hrs (complete T6 condition)
After aging treatment first sample cools in water , second sample cools at oil while third sample cools in air
Results:COOLING MEDIAM HARDNESS HRB
AIR 65
OIL 74
WATER 85
Investigation and Research
Hardness obtained upon different mediums SEM Microgrape at 20micron - Air quenched
SEM Microgrape at 20micron - Oil quenched SEM Microgrape at 20micron – Water quenched
Investigation and Research 2.3.5 Conclusion
• Structure 1. The Si phase is colored dark gray and appears
in the shape of very irregular, longitudinal sharp-edged structure while the Al2Cu phase appears light gray which is less in range
• Structure 2. The Si phase is colored dark gray and appears in the shape of very
irregular, longitudinal sharp-edged structure while the Al2Cu phase appears light gray which is slightly higher in range then before
Structure 3. The Si phase is colored dark gray and appears in the shape of
very irregular, longitudinal sharp-edged structure while the Al2Cu phase appears light gray which is higher in range in comparison of other two
Investigation and Research 2.3.5 Conclusion
According to above results and Scanning electron microstructure micrograph we see that with the increase of cooling rate the precipitation of Al2Cu phase increased
So its mean we can say that hardness value of Aluminum Silicon LM-13 grade alloy relay on the range of precipitation of Al2Cu phase and other phases like Mg2Si.
RESEARCH AND DEVELOPMENT IN CURRENT
PROCESS
RESEARCH AND DEVELOPMENT
After all above investigation and research on aluminum alloy we can alter our current process of heat treatment
Our current Procedure of Heat treatment consist of solution treatment ------------- takes 6 hours aging treatment ------------- takes 5 hours
• After changing the process we can achieve same properties and microstructure results
solution treatment ------------- takes 2 hours aging treatment ------------- takes 5 hours + quenched at cold water 15 min
RESEARCH AND DEVELOPMENT
Benefits on the implementation of new developed process
Huge cost benefits to company Low Production Time Fulfillment of Targets & objectives on time Comparatively low consumption of Energy
& Time.
Thank You