Advanced Materials Research Vols.

189-193 (2011) pp 3862-3865

Online available since 2011/Feb/21 at www.scientific.net
© (2011) Trans Tech Publications, Switzerland
doi:10.4028/www.scientific.net/AMR.189-193.3862

Study on Defects of A356 Aluminum Alloy Wheel

Weimin Zhao1,a, Liang Zhang1,b, Zhifeng Wang1,c, Hongji Yan2,d

1
School of Materials Science and Engineering, Hebei University of Technology,
Tianjin 300130, China
2
Citic Dicastal Wheel Manufacturing Co., Ltd, Qinhuangdao 066003, China
a b c
wmzhao@hebut.edu.cn, zl3713@yahoo.cn, zhifeng_wang@yahoo.com,
d
yanhongji@dicastal.com

Keywords: A356 Alloy; Rate Of Defect; Inclusion; Slag

Abstract. This paper studied the effects of inclusion and slag on properties of a die cast A356 alloy
wheel. The result showed that the rate of defect is important for the mechanical properties. The tensile
strength and extension was not dropped but the rate of defect is increased about 2%. The variation
trend of tensile strength and extension is linear, while the area of porosity on tensile fracture is
between 2% and 6%. However, the tensile strength and extension was dropped with the increasing
rate of defect. The variation trend of mechanical properties of the sample with inclusion is stable, but
the sample with slag is not stable. The mechanical properties of samples with inclusion are drastically
changed, while the rate of defect is increased. The mechanical properties of samples with slag are
smoothly. The EDS analysis indicated that the defects consist of Al-Ti-B compound, α-phase
(Al12FeSi), β-phase (Al9Fe2Si2) and Al2O3. These oxides form the compact composite oxide film
expand into first cracks. The fracture mode of sample with defects is brittle fracture. The values of the
Secondary dendrite arm spacing (DAS) in the inclusion and the matrix are the same, while the values
of DAS in the slag and the matrix are different.

Introduction
A356 alloy have many excellent properties such as high specific strength, high specific rigidity.
They are used to be the lightest structural material and widely used in automobile and aircraft industry
[1-3]. The A356 alloy is widely employed in numerous applications for structural components such as
the alloy wheel, the supporting brackets and housings through various casting processes.
The recent years, the effect of Ba, Ca, Y and Yb on porosity formation in a permanent mould
casting identical to that used in the previous study. Sr presence produce a good modification rating of
the eutectic phase in the case of Al-7Si cast alloys and their mechanical properties were increased in
as cast condition.
Given that these internal defects play a decisive factor in determining the mechanical properties of
thin-wall sectioned castings, considerable recent experimental and theoretical research has been
actively conducted to establish the effect of internal defects on mechanical properties.

Experimental
A356 alloy ingots (99.95%), Al-Ti-B master alloys (99.95%), Al-10Sr master alloys (99.90%) were
selected for the experimental material (wt. %). A356 alloy (nominal compositions: 6.5~7.5%Si,
0.2~0.4% Mg, 0.135%Ti, 0.09Sr, balance Al) were melted and were used to be the smelting furnace.
The furnace was heated to 740°C, and then the melt was poured as cast condition. The alloy wheel
were solution treated at 560°C for 350min, quenched into the water with 334°C temperature, and aged
at 155°C for 200min. Cast tensile test specimens were machined according to ISO6892-1 standard.
They were tested by use of Zwick/Roell Z100 machine with tensile load of 5 mm/min. The fracture is
analysised by stered microscope. Metallographic analysis was done using Axio Observer.A1m optical
microscopy to evaluate: DAS, modification rating (MR) and porosity% (%P). Also the phase presents
in the structure were analyzed by SEM equipped with EDS microanalysis technique.

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 Advanced Materials Research Vols. 189-193 3863

Results and Discussion

Analysis of mechanical properties. The mechanical properties of A356 alloy wheel is shown in
Fig.1 and Fig.2. There was an optimum regression equation between rate of defect and the mechanical
properties (Fig.1(a): y=282.6+2.5x-0.75x2; Fig.1(b): y=11.2-3.1x+0.5x2-0.5x3; Fig.2(a):
y=256-2.7x+0.34x2; Fig.2(b): y=10.7-2.3x+0.3x2). The rate of defect is important for tensile strength
and extension. The tensile strength and extension were not dropped but the rate of defect is increased
about 2%. However, The tensile strength and extension were dropped with the increasing rate of
defect, the variation trend of tensile strength and extension is linear, while the area of porosity on
tensile fracture is between 2% and 6%.The mechanical properties of the sample with inclusion is
drastically change, while the rate of defect is increased. The mechanical properties of the sample with
slag is smoothly. These can be ascribed to two aspects of reasons.
First, The tensile cracks were initially formed in the eutectic area and propagated through either
shearing or following primary alpha phases. the probability of silicon cracking strongly depends on
the aspect ratio[4]. The inclusion is a compound, which is generated by A356 alloy; it mainly focuses
on the eutectic area, so cracks were initially formed. It is combining with α-Al phase. The slag is a
substance, which is from the outside. It also mainly focus on the eutectic area, cracks were initially
formed.
Second, The number of defect play a very important role in the mechanical properties. Defects and
high aspect ratio of silicon particles caused consequently stress concentration. The tensile strength
and extension was dropped with the increasing the rate of defect, but excessive slag and inclusion
little influence tensile samples of the fracture trend, more defects not cause levels of stress
concentration. Fig. 3 shows the fracture characteristics of A356 alloy. The sample with inclusion is a
metal features, and flat. The organization is uniform and no spots appear, but the slag is black.
(a) (b)

Fig. 1 The variation trend of the mechanical properties with inclusion sample
(a) The variation trend of tensile strength (b) The variation trend of extension
(a) (b)

Fig. 2 The variation trend of the mechanical properties with slag sample
(a) The variation trend of tensile strength (b) The variation trend of extension
Fig. 4 shows the microstructure of A356 alloy. The basic microstructure of the alloy consists of
primary Al dendrites with eutectic Si-particles distributed around the α-Al dendrites to form a cell
pattern periodically repeated across the metallographic surface. A new inclusion phase uniformly
distributed in the matrix, but the slag phase is only flat line. The collective effects of low aspect ratio
of silicon particles, prevailing primary alpha phase structure and low level of porosity were
responsible for the improvement of the tensile properties[5].
3864 Manufacturing Process Technology

Fig. 3 The fracture surface of the defects sample (a) Inclusion (b) Slag

Fig. 4 The metallographs of the defects sample (a) Inclusion (b) Slag
The variation trend of mechanical properties of the sample with inclusion is stable, but the sample
with slag is not stable, which have two reasons: on the one hand, the inclusion is a part of matrix, slag
and matrix is not the same with phase; on the other hand, high ratio of silicon particles appear in the
sample with slag, silicon particles is the edges, the sample with inclusion is different. The values of
DAS in the inclusion and the matrix are the same, while the values of DAS in the slag and the matrix
are different.

Fig. 5 SEM&EDS analysis of the sample with slag (a) SEM images (b) EDS spot scanning

Fig. 6 SEM & EDS analysis of the sample with inclusion (a) SEM images (b) EDS spot scanning
Analysis of the defect. Defect analysis is an important research for A356 alloy wheel. The Fig.5
and Fig.6 indicated the surface of inclusion and slag were formed about 50µm length oxidation film
which is not smooth. The oxygen content of oxide film from the external to internal is diminishing
gradually.
The facture of inclusion sample is a falt matrix, the enrichment of B elements appears in the
inclusion, and also found the presence of Fe. Considered EDS analysis, so the oxide film consists of
Al-Ti-B compound and Al2O3. These oxides form the compact composite oxide film further expand
into first cracks[6]. Al-Ti-B compounds have two source ways. First, Al-Ti-B is not melt, it is
combining with the matrix; Second, there are new compounds, it is also combining with the matrix.
The facture have little toughness nest, but the fracture mode of sample with inclusion is brittle fracture,
the inclusion further expand into first cracks.
The facture of inclusion sample is a falt matrix, the enrichment of Si elements appears in the slag,
and also found the presence of Fe, considered EDS analysis, the oxide film consists of Al-Ti-B
compound and Al2O3. The slag is shaped by casting processes. The facture have lots of toughness nest,
the fracture mode of sample with slag is brittle fracturel, These oxides form the compact composite
 Advanced Materials Research Vols. 189-193 3865

oxide film further expand into first cracks.The Fig.7 indicated the surface of defects were formed
oxidation film. The defects also consists of Al-Ti-B compound, α-phase (Al12FeSi), β-phase
(Al9Fe2Si2) and Al2O3.

Fig. 7 SEM&EDS analysis of the defect sample

Conclusions
The rate of defect is important for the mechanical properties. The tensile strength and extension was
not dropped but the rate of defect is increased about 2%. The variation trend of tensile strength and
extension is linear, while the area of porosity on tensile fracture is between 2% and 6%. However, the
tensile strength and extension was dropped with the increasing rate of defect. The mechanical
properties of samples with inclusion are drastically changed, while the rate of defect is increased. The
mechanical properties of samples with slag are smoothly.
The EDS analysis indicated that the defects consist of Al-Ti-B compound, α-phase (Al12FeSi),
β-phase (Al9Fe2Si2) and Al2O3. These oxides form the compact composite oxide film expand into first
cracks.
The fracture mode of sample with defects is brittle fracture. The values of DAS in the inclusion and
the matrix are the same, while the values of DAS in the slag and the matrix are different.

Acknowledgements
This work was supported by the International S & T Cooperation Program of China (No.
2010DFA51850) and the Natural Science Foundation of Hebei Province, China (No. E2010000057).

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Manufacturing Process Technology
10.4028/www.scientific.net/AMR.189-193

Study on Defects of A356 Aluminum Alloy Wheel

10.4028/www.scientific.net/AMR.189-193.3862

DOI References
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doi:10.1179/026708301101510023
[2] S. Tahamtan, A.Fadavi Boostani, H. Nazemi, et al: J. Alloy. Compd. Vol.468 (2009), p. 1074
doi:10.1016/j.matdes.2008.10.003
[3] G. Ran, J.G. Zhou, Q.G. Wang, et al: J. Alloy. Compd. Vol. 42 (2006), p. 80
doi:10.1016/j.jallcom.2005.11.019
[4] Choong Do Lee: Mater. Sci. Eng. A Vol.464 (2007), p. 249-254
doi:10.1016/j.msea.2007.01.130