Aluminum Alloy Selection for In Situ Composite Production by Oxygen Blowing

We considered the possibility of using AlMg10, AlCu5, AlCu5Cd, AlSi12, and AlSi7Zn9 as initial alloys for in situ composites production via oxygen blowing of hydrogen pre-saturated melts as an alternative to AlSi7Fe. The production process provides the destruction of the oxide film on the melt surface. It was demonstrated that oxide film on AlMg10 alloy did not get destroyed due to the heavy thickness because of the porous structure that contributed to its kinetically based growth. Copper-bearing alloys AlCu5 and AlCu5Cd were characterized by the low-strength oxide film and got destroyed before floating, causing the oxide porosity. Silicon-bearing alloys AlSi12 and AlSi7Zn9 provide the dense structure, which makes it clear that to understand the Pilling–Bedworth ratio for basic alloying elements is required for a non-destructed oxide void floating and shall exceed the range of 1.64–1.77. However, the oxide film in silicon-bearing alloys under investigation did not get destroyed into fine particles. AlSi7Zn9 alloy had inclusions of smaller sizes as compared to AlSi12 alloy due to the ZnO that embrittled the film, but which were grouped to form oxide islands. Moreover, zinc was evaporated during blowing. The mechanical properties of the produced composites were based on the alloys under investigation which were in line with their structures. A higher value of the Pilling–Bedworth ratio of impurities was required for fine crushing: The conventionally used AlSi7Fe alloy met this requirement and was therefore considered to be the optimum version.

Dehydrogenation of AlSi7Fe1 Melt during In Situ Composite Production by Oxygen Blowing

The technology of producing a composite material in situ envisages the pre-saturation of an AlSi7Fe1 melt with hydrogen; afterwards, the melt is blown with oxygen until the hydrogen dissolved in the melt is burned out. The hydrogen content was researched during the manufacturing process of the composite material; before oxygen blowing, and at incomplete and complete burning out of the dissolved hydrogen. The interrelation between the absorbed hydrogen content and the aluminum oxide fraction was identified. A mathematical model was proposed which demonstrated that during the saturation process of the melt with oxide particles, hydrogen was absorbed on their surface as a layer close to monoatomic, which does not lead to the realization of the pores’ heterogeneous nucleation mechanism. Due to this, castings produced from the researched composite material are leakless. Incomplete burning out of hydrogen dissolved in the melt leads to the formation of significant hydrogen porosity. The proposed method of prevention of gas porosity in cast composites is an alternative to the conventional one and offers not only the purging of the melt from oxide inclusions but, on the contrary, a significant increase in their specific surface, which allows for the reduction in hydrogen content on the inclusion surface to the monoatomic level.