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Materials Science & Engineering A 597 (2014) 237–244

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Materials Science & Engineering A


journal homepage: www.elsevier.com/locate/msea

Effects of rare earth elements addition on microstructures, tensile


properties and fractography of A357 alloy
Wenming Jiang a,b,n, Zitian Fan a, Yucheng Dai a, Chi Li a
a
State Key Lab of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, PR China
b
School of Mechanical & Electrical Engineering, Wuhan Institute of Technology, Wuhan 430073, PR China

ar t ic l e i nf o a b s t r a c t

Article history: The effects of rare earth (RE) containing Ce and La elements addition on the microstructures
Received 10 December 2013 characteristics, tensile properties and fracture behavior of A357 alloy under as-cast and T6 conditions
Received in revised form were systematically investigated in this study. Obtained results showed that the addition of RE obviously
1 January 2014
reduced the sizes of the α-Al primary phase and eutectic silicon particles as well as SDAS value and
Accepted 3 January 2014
improved the morphology of eutectic silicon particles. The optimum level of added RE content were
Available online 10 January 2014
0.2 wt%, and the aspect ratio of eutectic silicon particles of the A357 modified alloy under as-cast and T6
Keywords: conditions decreased 142% and 174%, respectively, compared with the unmodified alloy. In addition, the
A357 aluminum alloy addition of RE greatly improved the tensile properties of A357 alloy as result of the significant
Rare earth
improvement in microstructure, especially in elongation under T6 condition. The fracture surfaces of
Microstructure characteristics
the A357 unmodified alloy tensile samples showed a clear brittle fracture nature, and its fracture path
Tensile properties
Fractography passed through the eutectic silicon particles and displayed a transgranular fracture mode, leading to
poorer ductility. The fracture path of the A357 modified alloys passed through the eutectic phase along
the grain boundaries of the α-Al primary phase, and the fracture generated by dimple rupture with
cracked eutectic silicon particles, and it showed an intergranular fracture mode, resulting in superior
ductility.
& 2014 Elsevier B.V. All rights reserved.

1. Introduction particles exhibit coarse acicular needles. As a result, the mechan-


ical properties of Al–Si cast alloys are remarkably weaken. There-
Currently, the aluminum–silicon (Al–Si) cast alloys are exten- fore, there are many methods to improve the morphology and size
sively used in the aerospace and automotive industries because of of α-Al primary phase and eutectic silicon particles, such as
its many advantages including excellent castability, corrosion chemical modification [7–9], outfield modification [10,11] as well
resistance, high strength to weight ratio as well as low coefficient as thermal modification [12–14], etc.
of thermal expansion, etc [1–3]. The mechanical properties of The chemical modification is regarded as an economical and
aluminum–silicon cast alloys mainly depend on the chemical effective modification method for the improvement of the mor-
composition and microstructure, etc [4,5]. And the microstructure phology and size of α-Al primary phase and eutectic silicon
of the Al–Si cast alloys mainly consists of α-Al primary phase, Al–Si particles. Generally, many chemical elements are known to be
eutectic, intermetallics and other precipitate phases. The morphol- used in the chemical modification method, such as Ti, B, Sr, Na,
ogy and size of α-Al primary phase and Al–Si eutectic have a Sb and rare earth (RE) elements including Ce, La, Yb, Eu and Sc [15–
significant effect on mechanical properties of the Al–Si cast alloys. 18], etc. However, many chemical elements are only responsible for
The tensile properties of the Al–Si cast alloys, especially in the the modification of α-Al primary phase from coarse dendrites to fine
ductility, are mainly controlled by the dendrites cell size of α-Al grains, such as Ti, B, etc, or for the modification of eutectic silicon
primary phase. Moreover, the eutectic silicon particles also play an particles from coarse acicular needles to fine fibrous structure, such
important role in the fracture behavior and tensile ductility of Al– as Sr, Na, Sb, etc. The RE elements containing Ce and La not only can
Si cast alloys [6]. Generally, in the normal casting condition, α-Al fine α-Al primary phase, but also can fine eutectic silicon particles
primary phases grow coarse dendrites, and the eutectic silicon [1,19]. Furthermore, the hydrogen content in the aluminum molten
metal can also be decreased. Nevertheless, few literatures system-
n
atically reported that the effects of RE addition containing Ce and La
Corresponding author at: Huazhong University of Science and Technology, State
Key Lab of Materials Processing and Die & Mould Technology, Luoyu, Wuhan
elements on the microstructures characteristics, tensile properties
430074, PR China. Tel.: þ 86 27 87540094; fax: þ 86 27 87558252. and fracture behavior of A357 alloy, especially in investigations of the
E-mail address: jwenming@163.com (W. Jiang). quantitative metallography of microstructure including α-Al primary

0921-5093/$ - see front matter & 2014 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.msea.2014.01.009
238 W. Jiang et al. / Materials Science & Engineering A 597 (2014) 237–244

Table 1 tensile specimens, which were prepared according to the ASTM E-


The nominal chemical composition of experimental alloys (wt%). 8 standard. The solution treatment was firstly performed at 540 1C
for 8 h, and then quenched into hot water at 80 1C. The aging
Alloy Si Mg Ti Fe RE Al
treatment was then carried out at 165 1C for 6 h, and the samples
Alloy 1 (unmodified) 6.75 0.63 0.14 0.084 0 Bal. were finally cooled in air.
Alloy 2 6.75 0.63 0.14 0.084 0.1 Bal. The tensile tests were carried out by using the AG-IC100KN
Alloy 3 6.75 0.63 0.14 0.084 0.2 Bal. universal testing machine at a crosshead speed of 1.5 mm/min. The
Alloy 4 6.75 0.63 0.14 0.084 0.3 Bal.
hardness of A357 alloy was measured using a HB-3000 hardness
test machine. The fractured surfaces of tensile samples were
observed and analyzed using the JSM-7600F scanning electron
microscope (SEM) equipped with facilities for energy dispersive
spectroscopy (EDS). Phases analyses were performed using a X-ray
diffraction (XRD) analysis with Cu Kα radiation.

Fig. 1. Shape and dimensions of tensile specimens (unit: mm).

3. Results and discussion

phase, secondary dendrite arm spacing (SDAS) and eutectic silicon 3.1. Microstructural characterization
particles as well as the correlation of microstructure with mechanical
properties and fracture behavior of A357 alloy. Fig. 2 shows the optical microstructures of A357 alloys with
In this study, the mixed RE containing Ce and La elements were different additions of RE under as-cast and T6 heat treatment
added into A357 Al–Si alloy. The aim of present work at system- conditions, and the optical microstructures of the eutectic zone are
atically investigated the effects of mixed RE elements addition on also exhibited in order to demonstrate a substantial microstruc-
the microstructures characteristics including the morphology and ture difference in the morphology and size of eutectic silicon
size of α-Al primary phase and eutectic silicon phase as well as particles.
SDAS, tensile properties and fracture behavior of A357 Al–Si alloy In the microstructures of the A357 unmodified alloys under as-
under as-cast and T6 conditions. Moreover, the correlation of cast and T6 conditions, it is evident that the coarse dendrite are
microstructure with mechanical properties and fracture behavior observed, as shown in Fig. 2(a and e). Meanwhile, it can also be
of A357 alloy were also studied. seen from Fig. 2(a and e) that the plate-like silicon particles are
showed. In contrast, the microstructures are significantly
improved when the A357 alloys are modified with the addition
2. Experimental procedures of RE, and the coarse dendrites are fined and the plate-like silicon
particles become fine fibrous structure. Because the spheroidiza-
The chemical composition of A357 Al–Si alloy used in this study tion efficiency of eutectic silicon particles mainly depends on the
is shown in Table 1, named Alloy 1. The RE containing 65 wt% Ce initial size of eutectic silicon particles [1], the eutectic silicon
and 35 wt% La elements was added as Al-10%RE master alloy. particles of the A357 modified alloys are obviously spheroidized
Firstly, the A357 aluminum ingot was placed inside a graphite and homogeneously distributed in the grain boundary after T6
crucible and melted at 730 1C by using the electrical resistance heat treatment, as shown in Fig. 2(f–h). Nevertheless, when the RE
furnace. The Al-10%RE master alloys with different additions (0.1, addition is 0.1 wt%, some the plate-like silicon particles can also be
0.2 and 0.3) were then added into the molten melt at 740 1C, seen in microstructure. With the addition of Re up to 0.2 wt%, the
named Alloy 2, Alloy 3 and Alloy 4, respectively. Subsequently, the morphology and size of α-Al primary phase and eutectic silicon
molten metal was refined using argon gas for 15 min using a particles are further improved, and the α-Al primary phases
rotary graphite degasser when the temperature reached 750 1C, display a finer structure, and the eutectic silicon particles exhibit
and the slag was then skimmed. When the melting temperature a granular and globular structure, as shown in Fig. 2(g). With the
was 720 1C, the molten metal was finally poured into a metal further increase of addition of RE content, the morphology and
mould, which was preheated for 250 1C. size of α-Al primary phase and eutectic silicon particles are
The metallographic samples were etched using 0.5% hydrofluoric deteriorated, and some eutectic silicon particles with acicular
acid solution after polishing. Microstructures were observed using needles morphology are observed, as shown in Fig. 2(h).
the OLYMPUS-MG3 metallographic microscope. The secondary Table 2 depicts the quantitative metallography results of
dendrite arm spacing (SDAS), average length of silicon particles as microstructure features including α-Al primary phase, eutectic
well as average width of silicon particles were measured by using silicon particles as well as SDAS of A357 alloys with different RE
the ImageTool metallographic analysis software. The measurement additions. According to the results obtained from the microstruc-
was done on 50 different areas of each microstructure in order to tural parameters in Table 2, it is clear that the addition of RE
minimize the errors. The aspect ratio of silicon particles was remarkably reduces the size of α-Al primary phase and SDAS value.
calculated according to the ratio of the average length of silicon Meanwhile, the average length, average width and aspect ratio of
particles to the average width of silicon particles. The grain size of eutectic silicon particles are also greatly decreased compared to
the α-Al primary phase was defined according to the following the unmodified condition, and the morphology of eutectic silicon
equation [20]: particles looks more round. With the 0.2 wt% addition of RE, the
pffiffiffiffiffiffiffiffi reductions under as-cast and T6 heat treatment conditions in the
D ¼ 2 A=π ð1Þ
size of α-Al primary phase and SDAS value are 48.1%, 162.2%, and
where A is the average area of the α-Al primary phase, which was 26.6%, 84.4%, respectively, compared to the unmodified condition.
measured using the ImageTool software. Furthermore, the aspect ratio of eutectic silicon particles of the
The as-cast and T6 heat treatment specimens were subjected to A357 modified alloy under as-cast and T6 conditions decrease
investigate in this study. Fig. 1 depicts the shape and dimensions of 142% and 174%, respectively, compared with the unmodified alloy.
W. Jiang et al. / Materials Science & Engineering A 597 (2014) 237–244 239

Fig. 2. Optical microstructures of A357 alloys with different additions of RE: (a and e) unmodified, Alloy 1; (b and f) 0.1 wt% RE, Alloy 2; (c and g) 0.2 wt% RE, Alloy 3; (d and
h) 0.3 wt% RE, Alloy 4; (a–d) As-cast condition and (e–h) T6 heat treatment condition.

It can be noted that the T6 heat treatment has a profound effect on The mechanism of RE modification on the α-Al primary phase
the spheroidization of eutectic silicon, and it is consist with the can be explained by follows. The eutectic reaction of RE occurs
previous studies [21–23]. at 637–642 1C, and the reaction equation is presented in the
240 W. Jiang et al. / Materials Science & Engineering A 597 (2014) 237–244

Table 2
Quantitative metallography results for the microstructures of A357 aluminum alloy with different RE additions.

Sample Alloy Grain size of α-Al SDAS (μm) Average length Average width Aspect ratio
primary phase (μm) of silicon particles (μm) of silicon particles (μm) of silicon particles

as-cast Alloy 1 (unmodified) 118.82 7 7.1 37.65 7 2.8 39.517 3.6 3.79 7 0.7 10.4 7 1.8
Alloy 2 100.05 7 4.1 23.16 7 2.0 24.777 3.1 3.17 0.2 8.0 7 1.4
Alloy 3 80.22 7 2.8 14.36 7 1.1 14.86 7 1.4 3.42 7 0.3 4.3 7 0.5
Alloy 4 97.81 7 3.5 23.78 7 2.0 19.95 7 2.0 3.667 0.4 5.5 7 0.6
T6 Alloy 1 (unmodified) 117.89 7 6.8 38.78 7 2.5 23.717 2.8 3.79 7 0.7 6.3 7 0.9
Alloy 2 110.277 4.7 31.97 7 2.9 17.067 1.7 4.517 0.8 3.8 7 0.3
Alloy 3 93.157 3.9 21.03 7 2.0 10.707 1.2 4.65 7 0.7 2.3 7 0.2
Alloy 4 106.107 4.2 25.83 7 2.8 15.09 7 1.9 4.677 0.8 3.2 7 0.4

Fig. 3. SEM microstructure and EDS analysis of the A357 modified alloy with 0.2 wt% RE: (a) morphology and (b) EDS of the intermetallic compound containing Al, Si and RE.

following: restricted. Thereby, the morphology of the eutectic silicon phases


presents fine fibrous structure. The modified silicon fibers contain
L-ðα  AlÞ þ Al4 ðLa; CeÞ ð2Þ
more twins than the unmodified silicon particles and have a rough
The precipitation phases of α-Al due to the eutectic reaction microfaceted surface [25]. Therefore, the silicon fibers are crystal-
supply a large number of nucleation cores for the α-Al primary lographically very imperfect, and each surface imperfection is a
phases. Meanwhile, the intermetallic compounds containing Al potential site to occur branching. In this case, the silicon fibers in
and Re have a very high melting point, above 1200 1C, and the the modified eutectic are prone to bend, curve and split to give rise
lattices constant of the intermetallic compounds are similar with to a further finer structure. As a consequence, the morphology and
α-Al. The EDS analysis and X-ray diffraction patterns of the A357 size of α-Al primary phase and eutectic silicon particles are
modified alloy also confirm the reaction products of above eutectic evidently improved with the addition of RE.
reaction, and the intermetallic compounds containing Al and RE
are observed, as shown in Figs. 3 and 4, especially in higher
addition content of RE. Consequently, the intermetallic compounds 3.2. Tensile properties
can also supply some nucleation cores for the α-Al primary phases.
As a result, the grain size of α-Al primary phase and SDAS are Table 3 presents the tensile properties including tensile
greatly decreased because of the large number of nucleation cores strength, yield strength, elongation and hardness of A357 alloys
in the Al liquid. with different additions of RE under as-cast and T6 conditions. It is
It is well known that the Sr also has a remarkable effect on the evident that the tensile strength, yield strength, elongation and
morphology and size of the eutectic silicon particles [1]. However, hardness of A357 modified alloys in both as-cast condition
the Sr cannot modify the size and morphology of the α-Al primary and T6 condition show a significant improvement compared to
phase as well as SDAS. The mechanism of RE modification on the the unmodified alloy. With the addition of 0.2% RE, the tensile
eutectic silicon phases is might attributed to the concentration of strength, yield strength, elongation and hardness of the A357
RE elements on the surface of eutectic silicon particles, and it is modified alloy reach 228.1 MPa, 160.2 MPa, 2.97% and 80 HB in as-
similar to the mechanism of Sr modification on the eutectic silicon cast condition, 349.1 MPa, 312.2 MPa, 3.89% and 120 HB in T6
phases because of their adjacently diagonal relationship in the condition, respectively. They are respectively 15.4%, 4.5%, 25.9%
Periodic Table of the elements, and the widely accepted recent and 6.3% higher than those of the unmodified alloy under as-cast
theory is the impurity-induced twinning theory [24]. In general, condition, and 11.2%, 8.4%, 34.2% and 8.3% higher than that of the
the Ce and La elements hardly dissolve in the α-Al or eutectic unmodified alloy under T6 condition, in particularly, elongation,
silicon phases because the atomic radius of the Ce and La elements and it is agreement with the previous study [23]. The advantages
are much larger than that of α-Al and silicon. As a result, the Ce of morphology and size of the α-Al primary phase and eutectic
and La elements mainly concentrate on the surface of eutectic silicon particles as well as SDAS are responsible for the improve-
silicon phases, and the growths of eutectic silicon phases are then ment of tensile properties of the A357 modified alloys [22,26].
W. Jiang et al. / Materials Science & Engineering A 597 (2014) 237–244 241

3.3. Fractography containing Al and RE are prone to act as crack initiators and
weaken the mechanical properties of the A357 modified alloy
Fig. 5 exhibits the SEM fractographs of A357 alloys tensile [4,23].
samples with different additions of RE under as-cast and T6 heat Fig. 7 shows the optical micrographs of side views of fractured
treatment conditions. As can be seen, the fracture surfaces of the A357 alloys tensile tested samples with and without modification.
A357 unmodified alloy tensile samples in both as-cast and T6 It can be evidently seen from Fig. 7(a) that many elongated
conditions show a clear brittle fracture nature, and the quasi- eutectic silicon particles present in the microstructure of the
cleavage feature can be observed, as shown in Fig. 5(a and e), A357 unmodified alloy. The eutectic silicon phases as a brittle
leading to lower elongation value. After T6 heat treatment, few phase are easily to crack and separate from Al matrix under
dimples exhibit in the fracture surfaces of the A357 unmodified applied loads, particular the elongated eutectic silicon particles,
alloy tensile samples. It is noted that the addition of RE obviously as they are the main sources of stress concentration [27–29]. For
increases the number of dimples, and the fracture surfaces of the the A357 unmodified alloy, the elongated eutectic silicon particles
A357 modified alloy tensile samples with the addition of 0.1 wt% are prone to rupture compared to the modified alloy with finer
RE display a mixed quasi-cleavage and dimple morphology. With eutectic silicon particles, as indicated by the arrows in Fig. 7(a).
the RE addition increasing, the number of dimples sharply On the other hand, the A357 unmodified alloy has larger SDAS
increase. When the addition of RE reach 0.2 wt%, the SEM value than that of the A357 modified alloy. The elongated eutectic
fractographs of the A357 modified alloy tensile tested samples silicon particles cluster along both cell and grain boundaries so
exhibit an obvious morphology of dimple fracture, and the that there is a nearly continuous wall of eutectic silicon particles
dimples are very deep and distributed uniformly with high around the dendrite cell. The dendrite cells behave similar to
density, as shown in Fig. 5(c and g), resulting in a significant grains and strong interaction between particles and slip bands
improvement of elongation. In addition, the fracture surface of the giving rise to at the cell boundaries when the plastic deformation
T6 heat treated alloy also indicates a much more ductile failure generates. The final fracture paths then tend to pass through the
mode compared to that of the as-cast alloy. With the addition of eutectic silicon particles. As a consequence, the tensile sample
RE up to 0.3 wt%, the SEM fractographs give rise to deterioration. without modification shows a transgranular fracture mode.
The EDS spectra in Fig. 6(b), presenting the presence of alloying For the A357 modified alloy, the smaller SDAS value and
elements in the intermetallic compounds, implies the existence of finer eutectic silicon particles make the grain cell boundaries more
the intermetallic compounds containing Al and RE in the fracture discontinuous, compared with the A357 unmodified alloy.
surface of the modified alloy. The intermetallic compounds Thereby, a stronger interaction between slip bands and plastic
flow produces in the grain boundaries. The fracture of eutectic
silicon particles generates in the grain boundaries, and the final
fracture path tends to pass through the eutectic phase along the
grain boundaries of the α-Al primary phases [27,30]. Thereby, the
fracture take places mostly by dimple rupture with cracked
eutectic silicon particles, and it exhibits an intergranular fracture
mode, leading to superior ductility [31].

4. Conclusions

In the present work, the effects of RE addition on the micro-


structures characteristics, tensile properties and fracture behavior
of A357 alloy under as-cast and T6 conditions were investigated.
Based on the experimental results obtained, the following conclu-
sions were drawn:

(1) The addition of RE greatly reduced the sizes of the α-Al primary
phase and eutectic silicon particles as well as SDAS value. And
the morphology of eutectic silicon particles was also clearly
improved, especially in T6 heat treatment. When the addition of
Fig. 4. X-ray diffraction patterns of the A357 alloys with different additions of RE: RE up to 0.2 wt%, compared with the unmodified alloy under as-
(a) unmodified; (b) 0.1 wt% RE; (c) 0.2 wt% RE; (d) 0.3 wt% RE. cast and T6 conditions, the reductions in the size of α-Al primary

Table 3
Tensile properties of the A357 alloys with different additions of RE under as-cast and T6 heat treatment conditions.

Sample Alloy Tensile strength (MPa) Yield strength (MPa) Elongation (%) Hardness (HBS)

as-cast Alloy 1 (unmodified) 1937 9.2 1537 10.6 2.2 7 0.2 75 78


Alloy 2 208.5 7 10.5 1527 10.3 2.75 7 0.3 78 77
Alloy 3 228.17 11.6 160.2 7 10.9 2.977 0.4 80 79
Alloy 4 226.0 7 10.8 1537 10.2 2.83 7 0.3 79 75
T6 Alloy 1 (unmodified) 3107 13.7 286 7 11.5 2.56 7 0.2 110 710
Alloy 2 322.3 7 14.1 290 7 11.7 3.127 0.4 115 711
Alloy 3 349.17 15.2 312.2 7 12.0 3.89 7 0.6 120 712
Alloy 4 324.2 7 14.5 287 7 11.3 3.36 7 0.5 116 710
242 W. Jiang et al. / Materials Science & Engineering A 597 (2014) 237–244

Fig. 5. SEM fractographs of A357 alloy tensile samples with different additions of RE: (a and e) unmodified, Alloy 1; (b and f) 0.1 wt% RE, Alloy 2; (c and g) 0.2 wt% RE, Alloy 3;
(d and h) 0.3 wt% RE, Alloy 4; (a–d) as-cast condition and (e–h) T6 heat treatment condition.

phase and SDAS value were 48.1%, 162.2%, and 26.6%, 84.4%, (2) The addition of RE significantly improved the tensile proper-
respectively, and the aspect ratio of eutectic silicon particles ties of A357 alloy owing to the remarkable improvement in
decreased 142% and 174%, respectively. microstructure. Compared to the unmodified A357 alloy, the
W. Jiang et al. / Materials Science & Engineering A 597 (2014) 237–244 243

Fig. 6. SEM fractograph and EDS analysis of the intermetallic compound in the A357 modified alloy with 0.3 wt% RE: (a) fractograph and (b) EDS of the intermetallic
compound.

Fig. 7. Optical micrographs of side views of fractured A357 alloy tensile samples with different additions of RE: (a) unmodified and (b) 0.2 wt% RE.

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