Effect of Ti-V and Nb Addition on the Properties of Almg7cu1.2 Alloy

Abstract

In the development of aluminum casting alloys, considerable attention is given to the impact of various alloying elements, with numerous studies exploring how these elements influence the material's properties. However, the selection of alloying elements alone does not ensure optimal final quality. The casting process and melt treatment methods also play a critical role in achieving a defect-free structure, particularly when paired with defect characterization and final property assessment. Therefore, it is essential to investigate the interplay between alloying element choice, melt treatment, and defect evaluation in tandem. In this study, copper and magnesium main alloying elements have been chosen along with master alloys of Ti-V-Nb as grain refiners for the aluminum cast alloy. Phase formations have been investigated by simulated phase diagrams. Casting experiments have been done using a tilt pouring method into sand molds, and small bubble degassing equipment has been used to ensure the alloying and melt quality satisfying required mechanical strength. Composition and alloying have been validated by spectral analysis and XRF measurements. Microstructural analyses have been performed by both digital microscopy and scanning electron microscopy. EDS mappings have been carried out for alloying elements distributions. Internal defect distribution and defect structure have been evaluated by computed tomography (CT) scans. Both as-cast and heat-treated specimens have undergone tensile and hardness tests to characterize the mechanical behaviors. CT scans and mechanical behaviors have beencorrelated, and defect metrics have been investigated and classified according to defect surface, defect volumes and projected areas on XY-XZ-YZ planes. Contour maps of defect metrics and tensile properties have been analyzed to generate input to finite element simulations for latter stages studies, and correlation of strength-defect regressions has yielded parametric results to understand structural defects-mechanical performance relations. GTN and Beremin localization models capable of depicting material behavior in the presence of defects have been used to link the experimental and virtual validation assessments. In view of test results, a maximum of 0.125 wt% Nb content in AlMgCu-TiV alloy has been proposed having a tensile strength reaching 300 MPa-7.5% elongation at 0.75% Nb content with grain refinement effect owing to Al-Nb, Al-Ti, Al-V aluminide particles and good dispersion of Nb, Ti, V elements on the microstructure as assessed by EDS mapping. CT scan reconstruction images and metrics have successfully connected tensile strength and elongation with defect volume and defect surface area for the proposed alloy. In this context, the volume and surface area of defects have been evaluated as critical metrics in evaluating the mechanical properties of Al7MgCu1.2 cast alloys. Defect localization and failure point detection during plastic deformation zone have been demonstrated by Beremin model which can lead to future studies leveraging these metrics to validate material strength using damage models such as Gurson, GTN or Beremin for crack initiation and propagation methodologies.