Pre project

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


Before T6 Treatment

32 HRB 10 Kg/mm2

1 % 3.4 joules

way of treatment

Mechanical Properties Microstructure 100X

Hardness Tensile Strengt

h


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


• 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


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

Pre project

Engineering

Transcript of Pre project