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Wednesday, November 2, 2011 - 9:30 AM

Development and Assessment of Short Cycle Tempers for Heat Resistant Aluminum Cast Alloy

W. Kasprzak, Natural Resources Canada, Ottawa, ON, Canada

Existing heat treatment standards do not properly address aluminum cast components manufactured using permanent mold technologies. Recently emerged casting processes such vacuum HPDC (High Pressure Die Casting) should not required long solution treatment times due to their fine microstructures caused by rapid solidification rates. Consequently, long and expensive T6 and T7 tempers could be avoided. The heat treatment studies involving rapidly solidified samples were conducted for various parameters including solution time between 30 minutes to 9 hours, 1-step or 2-steps solution temperatures (480 to 525oC) and were carried out for various aging parameters (T5, T6 and T7). The T5 temper analysis suggested that rapidly solidified alloy having SDAS between 10 to 35mm showed ~20% hardness increase after aging operation without prior quenching indicating that solidification process alone could cause some saturation of solid solution. The T6 and T7 analysis revealed that increase in microstructure refinement enabled reduction of solution time from 9 hours to 30 minutes without compromising alloy’s mechanical properties. The highest strength, i.e., 360/310 MPa for UTS and YS respectively was achieved for 2-step solution treatment and T6 peak aging conditions. Additionally, thermal analysis and dilatometer results are presented to assess phase’s dissolution during solution treatment, aging kinetics as well as dimensional stability analysis.