Mitja Petrič

The paper describes the graphite nuclei constitution for spheroidal graphite cast iron melted in a cupola furnace, which is treated by the addition of magnesium and inoculated with a barium-based inoculant. Two samples of spheroidal cast iron were analysed, differing only in tin content. Field-emission scanning electron microscopy (FE -SEM) with energy-dispersive X-ray spectroscopy (EDS) was used to analyse the nuclei. The thermodynamic calculation of the phase equilibria and the associated free formation energies of the alloys were calculated and compared with metallographic observations. It was found that the nuclei in the spheroidal graphite are different in shape and composition. Spherical and rectangular ones were found, and in many cases the porosity was present at the nuclei. The nuclei consisted of different compounds such as (Mg,Ca)S, MgO, (Mg,Al,Si)N. The amount of Sn only affected the pearlite content, and there were no Ba and rare earths present in the nuclei.

The paper describes the production of an AlSi7Mg cast alloy with Li additions and the reactions of the melt with different moulding materials. It is known that Li is very reactive and tends to form various reaction products such as oxides, gases, etc., which can influence the casting quality. The aim of the research was to find a suitable way to produce such an alloy and to describe the reaction products that are formed between the melt and the moulding material and thus to find a suitable moulding material for processing Al cast alloys with Li additions. The melt was produced in an induction furnace under an inert atmosphere. After melting, 1 w/% Li was added and the melt was cast into five different mould materials consisting of graphite, steel, a CO2 sand mixture, Croning mixture and calcium silicate materials. In the last three cases, various alcohol-based coatings were also used, such as graphite, zirconium oxide-graphite coating and aluminate-graphite filler coating. The results showed that the reaction products in the form of powder on the casting surfaces and the gas porosity in the castings occurred in the cast of a calcium silicate mould and sand mould mixtures. In the case of graphite and steel moulds, the casting surfaces were not oxidised, with no reaction products, and no gas porosity.

The utilization of aluminum-lithium-magnesium (Al-Li-Mg) alloys in the transportation industry is enabled by excellent engineering properties. The mechanical properties and corrosion resistance are influenced by the microstructure development comprehending the solidification of coherent strengthening precipitates, precipitation of course and angular equilibrium phases as well as the formation and widening of the Precipitate-free zone. The research was performed to determine the microstructure degradation of Al-2.18Mg-1.92Li alloy in a corrosive environment using electrochemical measurements. The solidification sequence of the Al-2.18Mg-1.92Li alloy, obtained using Thermo–Calc software support, indicated the transformation of the α_Al dendritic network and precipitation of AlLi (δ), Al₂LiMg (T), and Al₈Mg₅ (β) phase. All of the phases are anodic with respect to the α_Al enabling microstructure degradation. To achieve higher microstructure stability, the sample was solution hardened at 520 °C. However, the sample in as-cast condition showed a lower corrosion potential (−749.84 mV) and corrosion rate (17.01 mm/year) with respect to the solution-hardened sample (−752.52 mV, 51.24 mm/year). Higher microstructure degradation of the solution-hardened sample is a consequence of δ phase precipitation at the grain boundaries and inside the grain of α_Al, leading to intergranular corrosion and cavity formation. The δ phase precipitates from the Li and Mg enriched the α_Al solid solution at the solution-hardening temperature.

The aim of this study was to determine the correlation between the size and the distribution of microstructural constituents and their cooling rate, as well as the correlation between the mechanical properties and the cooling rate of AlSi9Cu3 aluminum alloy when cast in high-pressure die casting (HPDC) conditions. In other words, the ultimate goal of the research was to determine the mechanical properties for a casting at different cooling rates. Castings with different wall thicknesses were chosen, and different cooling rates were assumed for each one. Castings from industrial technological practice were systematically chosen, and probes were extracted from those castings for the characterization of their mechanical properties. Special non-standard cylinders were created on which compressive tests were carried out. The uniqueness of this research lies in the fact that the diameters of the designed cylinders were in direct correlation to the actual wall thickness of the castings. This is important because the solidification of metal in the die cavity is complex, in that the cooling rates are higher on the surface of the casting than in the center. Local in-casting cooling rates were determined using numerical simulations. It was discovered that with increasing cooling rates from 60 K/s to 125 K/s the values for strength at 5% deformation increased on average from 261 MPa to 335 MPa.

Lithium additions to Al offer the promise of substantially reducing the weight of alloys, since each 1 wt. % Li added to Al reduces density by 3 % and increases elastic modulus. In the present work, the effect of 1.46 wt. % Li addition to AlSi7Mg (containing 7.05 wt. % Si and 0.35 wt. % Mg) was studied. The alloy showed reduced density and higher hardness after natural ageing. Experimental work showed that micro-structural and mechanical properties changed with Li addition. It was observed that 0.80 wt. % Li addition resulted in formation of new phase AlLiSi which has a great effect to increase hardness of AlSi7Mg. According to Scanning Electron Microscope (SEM) and X-ray diffraction analysis it was confirmed that the addition of Li causes formation of different phases which are: α-Al, β-Si and AlLiSi.