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, 2017.
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Abstract—Thixoforging combined with low superheat casting (LSC) is a promising shaping process for alu-
minium casting alloys. LSC process is based on rapid solidification of an alloy which cast with low pouring
temperature. With this method, a feedstock material is produced with non-dendritic microstructure that
ready for spherisation in reheating sequence of further semi-solid process. Al-Si alloys are still castable even
at low temperatures due to their excellent fluidities. This study subjects to present spherisation of A356 and
A380 alloy billets cast with LSC process that provides appropriate beginning material with relatively high
sphericity. Obtained billet parts were reheated for different times at a semi-solid state temperature. Some of
these billets were directly quenched for observing the effects of reheating and the others were thixoforged.
With sufficient reheating time, deformation of thixoforging process did not significantly affect on the spher-
ical microstructure. Unnecessarily long reheating period caused excessive grain growth. A356 alloy had
higher spherisation tendency than A380 alloy under similar process conditions.
Keywords: Thixoforging, low superheat casting (LSC), A356 alloy, A380 alloy
DOI: 10.3103/S1067821217050066
489
490 GULER et al.
EXPERIMENTAL PROCEDURE ing temperature and the other ones were thixoforged
in a preheated open die by a hydraulic workshop press
Recycled A356 and A380 alloy ingots were supplied with 50% deformation ratio. The macrographs of as
from a local producer company. Chemical composi- cast and thixoforged specimens were given in Fig. 1.
tions of these alloys were given in Table 1. 1000 g of After grinding and polishing, specimens were etched
both alloys were melted with electric resistant furnace with 0.5% HF solution. Microstructural observations
and cast into cylindrical steel mould to produce billets and required measurements were carried out by using
with the dimension of 40 mm diameter and 310 mm Nikon Eclipse MA100 image analyser assisted light
height. For LSC process, A356 and A380 alloys were microscope. Brinell hardness of specimens were also
melted at 635 and 615°C, respectively. Those tempera- measured by a universal test device with 62.5 kg load
tures represent 20°C above their liquidus temperatures and 2.5 mm tip diameter.
(615°C for A356, 595°C for A380) [15]. Cast billets
were cut off into parts in 40 mm length and one as cast
specimen was earmarked from each alloy. Reheating RESULTS AND DISCUSSION
temperatures of alloys were determined 20°C below LSC process suppresses the dendritic structure of
liquidus temperatures, thusly, A356 and A380 alloy conventional casting and prevents formation of long
billet parts were reheated at 595 and 575°C, respec- dendrite arms. In Fig. 2, as cast microstructures of
tively. Two billet parts were reheated in 20, 40, 60 and A356 and A380 alloys cast with LSC technique were
80 min for each alloy. One of these parts were directly given. These alloys are hypoeutectic Al-Si alloys
quenched (in water at room temperature) from reheat- namely, light areas imply α-Al phase while darker grey
zones imply the Al-Si eutectic structure. Al-Si casting
alloys have sufficient fluidity even under low super-
heat conditions, as a result of this, billet castings were
performed without any pouring problem.
With LSC process, alloys were prepared to further
semi-solid processes by formation of non-dendritic
and relatively spherical microstructure. Post reheating
process increased sphericity gradually. The micro-
structures of quenched and thixoforged A356 alloy bil-
lets, which were reheated at 595°C for 20, 40, 60 and
Fig. 1. From left to right: as cast, 20, 40, 60 and 80 min 80 min respectively, were given in Fig. 3. 20 min
reheated then thixoforged round billet specimens. reheating time did not change the as cast structure
200 µm 200 µm