Revealing Microstructure Characteristics in High Pressure Die Cast Alloys with X-ray Microtomography: A Handbook Overview

This introduction paper is based on the paper "Characteristics and distribution of microstructures in high pressure die cast alloys with X-ray microtomography: A review" published by "China Foundry".

Fig. 1: Reconstructed pores in HPDC AE44 alloys based on a serial sectioning technique [18]
Fig. 1: Reconstructed pores in HPDC AE44 alloys based on a serial sectioning technique [18]

1. Overview:

  • Title: Characteristics and distribution of microstructures in high pressure die cast alloys with X-ray microtomography: A review
  • Author: Hai-dong Zhao, Xue-ling Wang, Qian Wan, Wen-hui Bai, and Fei Liu
  • Year of publication: 2024
  • Journal/academic society of publication: China Foundry
  • Keywords: high pressure die casting; microstructure; three-dimensional characteristics; distribution; Al and Mg alloys

2. Abstract:

Al and Mg alloy high pressure die castings (HPDC) are increasingly used in automotive industries. The microstructures in the castings have decisive effect on the casting mechanical properties, in which the microstructure characteristics are fundamental for the investigation of the microstructure-property relation. During the past decade, the microstructure characteristics of HPDC Al and Mg alloys, especially micro-pores and a-Fe, have been investigated from two-dimensional (2D) to three-dimensional with X-ray micro-computed tomography (μ-CT). This paper provides an overview of the current understanding regarding the 3D characteristics and formation mechanisms of microstructures in HPDC alloys, their spatial distributions, and the impact on mechanical properties. Additionally, it outlines future research directions for the formation and control of heterogeneous microstructures in HPDC alloys.

3. Introduction:

Global industrialization drives the demand for lightweighting in automobiles, leading to increased utilization of Al and Mg alloy high pressure die castings (HPDC) due to their near net-shape forming capability, high production efficiency, and low production costs. While HPDC offers advantages, conventional HPDC components often contain pores resulting from turbulent flow during mold filling. These pores are detrimental to mechanical properties. High vacuum die casting (HVDC) technologies have been developed to mitigate porosity, but impurity elements like Fe can still form brittle intermetallics, impacting mechanical properties. Microalloying and controlling intermetallic characteristics are crucial for optimizing casting properties. Traditional 2D analysis techniques are limited in revealing the spatial distribution of microstructures. X-ray microtomography (μ-CT) has emerged as a powerful 3D technique, enriching the understanding of phase characteristics and formation in HPDC Al and Mg alloys. This review summarizes current knowledge on the characteristics and distribution of phases in HPDC alloys using X-ray microtomography and highlights future research directions.

4. Summary of the study:

Background of the research topic:

The increasing demand for lightweight vehicles in the automotive industry necessitates the use of Al and Mg alloy HPDC components. Microstructures within these castings critically determine their mechanical properties. Understanding the microstructure-property relationship is essential for optimizing casting performance. Porosity and intermetallic phases are key microstructural features influencing the mechanical behavior of HPDC alloys.

Status of previous research:

Conventional methods like Archimedes' Law, optical microscopy (OM), and scanning electron microscopy (SEM) provided 2D sectional microstructure characterization, which is insufficient to reveal the spatial distribution and morphology of phases within HPDC alloys. These 2D techniques may underestimate pore complexity and volume and overestimate pore numbers.

Purpose of the study:

This study aims to provide a comprehensive overview of the current understanding of 3D microstructure characteristics in HPDC Al and Mg alloys, specifically focusing on micro-pores and Fe-rich intermetallics, using X-ray micro-computed tomography (μ-CT). The review encompasses the formation mechanisms, spatial distributions, and impact of these microstructures on mechanical properties.

Core study:

The core of this review focuses on summarizing research that utilizes X-ray microtomography to investigate:

  • Micro-pores: Classification (gas porosity, shrinkage porosity, gas-shrinkage porosity), morphology, formation mechanisms related to gas entrapment and solidification shrinkage, and quantitative characteristics.
  • Fe-rich intermetallics: Morphology (primary and secondary phases, polyhedral, compact, Chinese script-type), formation mechanisms related to solidification conditions and alloying elements (Fe, Mn), and clustering behavior.
  • Impact on Mechanical Properties: Correlation of micro-pores and Fe-rich intermetallics with tensile and fatigue properties, crack initiation, and propagation.
  • Microstructure Evolution Simulation: Numerical simulation approaches for predicting microstructure formation and heterogeneity in HPDC alloys.

5. Research Methodology

Research Design:

This study is a review paper that synthesizes findings from various research articles focusing on the application of X-ray microtomography to characterize microstructures in HPDC Al and Mg alloys.

Data Collection and Analysis Methods:

The data for this review were collected through a comprehensive literature search of publications that have employed X-ray microtomography to study microstructures in HPDC Al and Mg alloys. The analysis method involves summarizing and synthesizing the key findings, methodologies, and conclusions from these selected publications.

Research Topics and Scope:

The review focuses on the following topics within the scope of HPDC Al and Mg alloys microstructure characterization using X-ray microtomography:

  • 3D characteristics of micro-pores (morphology, classification, quantitative analysis).
  • 3D characteristics of Fe-rich intermetallics (morphology, classification, quantitative analysis, clustering).
  • Influence of micro-pores and Fe-rich intermetallics on mechanical properties (tensile strength, fatigue life, fracture mechanisms).
  • Simulation of microstructure evolution in HPDC alloys.

6. Key Results:

Key Results:

  • Micro-pores: X-ray microtomography enables 3D characterization and classification of micro-pores into gas porosity, gas-shrinkage porosity, and shrinkage porosity, each exhibiting distinct morphologies and formation mechanisms. Quantitative analysis reveals volume, sphericity, and surface area differences among pore types (Table 1). Micro-pores, especially larger and irregular pores, are detrimental to tensile and fatigue properties, acting as stress concentrators and crack initiation sites. Volume distribution of micro-pores is well described by a three-parameter lognormal distribution.
  • Fe-rich Intermetallics: X-ray microtomography elucidates the 3D morphology and clustering of Fe-rich intermetallics. Primary and secondary Fe-rich phases exhibit different shapes (blocky, network-like, polyhedral, Chinese script-type). Clustering of Fe-rich intermetallics is observed, particularly for alloys with primary α-Fe phase, impacting mechanical properties by acting as crack initiation sites. The morphology and distribution of Fe-rich intermetallics are influenced by alloy composition (Fe, Mn content) and solidification conditions.
  • Microstructure Heterogeneity and Simulation: HPDC components exhibit microstructure heterogeneity across skin layer, segregation band, and core regions. Numerical simulation based on cellular automaton (CA) coupled with process simulation is being developed to predict grain size and microstructure evolution, showing promising agreement with experimental observations.
  • In-situ Microtomography: In-situ X-ray microtomography coupled with tensile testing allows for dynamic observation of damage evolution, crack nucleation and growth, revealing that eutectic Fe-rich intermetallics and small pores are initial damage sites in some alloys, while clustered primary intermetallics fracture at low strains in others.
Fig. 4: 3D morphology of porosity in HPDC AM60 alloys: (a) overall view of porosities in specimen; (b) a zoom-in area showing four types of porosities, such as gas-shrinkage pore (c), gas-pore (d), net-shrinkage (e), and island-shrinkage (f) [25]
Fig. 4: 3D morphology of porosity in HPDC AM60 alloys: (a) overall view of porosities in specimen; (b) a zoom-in area showing four types of porosities, such as gas-shrinkage pore (c), gas-pore (d), net-shrinkage (e), and island-shrinkage (f) [25]
Fig. 5: (a) Distribution of Fe-rich phases along the radial direction from surface to center; (b), (c) and (d) 3D morphology of Fe-rich phases in HPDC; (e), (f) and (g) SEM results of the morphology of Fe-rich phases corresponding to (b), (c) and (d), respectively [31]
Fig. 5: (a) Distribution of Fe-rich phases along the radial direction from surface to center; (b), (c) and (d) 3D morphology of Fe-rich phases in HPDC; (e), (f) and (g) SEM results of the morphology of Fe-rich phases corresponding to (b), (c) and (d), respectively [31]
Fig. 8: Fe-rich intermetallics with equivalent diameter over 10 µm: (a-d) in the skin layer and (e-h) the core of HVDC AISI10-0.1Fe0.6Mn (a) and (e), AlSi10-0.16Fe0.6Mn (b) and (f), AlSi10-0.20Fe0.6Mn (c) and (g), and AlSi10-0.15Fe0.82Mn (d) and (h) alloys
Fig. 8: Fe-rich intermetallics with equivalent diameter over 10 µm: (a-d) in the skin layer and (e-h) the core of HVDC AISI10-0.1Fe0.6Mn (a) and (e), AlSi10-0.16Fe0.6Mn (b) and (f), AlSi10-0.20Fe0.6Mn (c) and (g), and AlSi10-0.15Fe0.82Mn (d) and (h) alloys
Fig. 9: Distribution of Fe-rich intermetallic number based on equivalent diameter in the skin layer (a) and the core (b) of HVDC AISI10-0.10Fe0.6Mn, AlSi10-0.16Fe0.6Mn, AlSi10-0.20Fe0.6Mn and AlSi10-0.15Fe0.82Mn alloys
Fig. 9: Distribution of Fe-rich intermetallic number based on equivalent diameter in the skin layer (a) and the core (b) of HVDC AISI10-0.10Fe0.6Mn, AlSi10-0.16Fe0.6Mn, AlSi10-0.20Fe0.6Mn and AlSi10-0.15Fe0.82Mn alloys
Fig. 10: Primary a-Fe intermetallics with increased volumes in the HVDC AlSi10-0.15Fe0.82Mn alloy (a-f) [34]
Fig. 10: Primary a-Fe intermetallics with increased volumes in the HVDC AlSi10-0.15Fe0.82Mn alloy (a-f) [34]
Fig. 11: Schematic of growth pattern of the primary a-Fe phase in die-cast AlSiMgMn alloys (a-e) [34]
Fig. 11: Schematic of growth pattern of the primary a-Fe phase in die-cast AlSiMgMn alloys (a-e) [34]
Fig. 15: Comparison of pore size and distribution between CT images (a) and fracture surface (b) [44]
Fig. 15: Comparison of pore size and distribution between CT images (a) and fracture surface (b) [44]
Fig. 18: Polyhedral Fe-rich phases (a) and their fracture morphologies (b)-(d), polyhedral Fe-rich phase under 0 N (e) and 410 N (f), and shrinkage under 410 N (g) [31]
Fig. 18: Polyhedral Fe-rich phases (a) and their fracture morphologies (b)-(d), polyhedral Fe-rich phase under 0 N (e) and 410 N (f), and shrinkage under 410 N (g) [31]

Figure Name List:

  • Fig. 1: Reconstructed pores in HPDC AE44 alloys based on a serial sectioning technique [18]
  • Fig. 2: Fatigue specimens with different pore fractions by X-ray microtomography inspection: (a) 0.12%; (b) 0.34%; (c) 0.73%; and (d) 1.01%
  • Fig. 3: Typical gas pores (a), gas-shrinkage pores (b), and shrinkage pores (c) in practical ADC12 die castings
  • Fig. 4: 3D morphology of porosity in HPDC AM60 alloys: (a) overall view of porosities in specimen; (b) a zoom-in area showing four types of porosities, such as gas-shrinkage pore (c), gas-pore (d), net-shrinkage (e), and island-shrinkage (f) [25]
  • Fig. 5: (a) Distribution of Fe-rich phases along the radial direction from surface to center; (b), (c) and (d) 3D morphology of Fe-rich phases in HPDC; (e), (f) and (g) SEM results of the morphology of Fe-rich phases corresponding to (b), (c) and (d), respectively [31]
  • Fig. 6: Equivalent diameter for Fe-rich phase less than 10 µm (a), and no less than 15 µm (b), as well as the in-cavity solidified Fe-rich phase (c)-(e), externally solidified primary Fe-rich phase (f)-(h), and the corresponding SEM results (c1)-(e1), (f1)-(h1), respectively [35]
  • Fig. 7: Morphological transformation of externally solidified primary Fe-rich phase and its corresponding geometric parameters (a-f) [35]
  • Fig. 8: Fe-rich intermetallics with equivalent diameter over 10 µm: (a-d) in the skin layer and (e-h) the core of HVDC AISI10-0.1Fe0.6Mn (a) and (e), AlSi10-0.16Fe0.6Mn (b) and (f), AlSi10-0.20Fe0.6Mn (c) and (g), and AlSi10-0.15Fe0.82Mn (d) and (h) alloys
  • Fig. 9: Distribution of Fe-rich intermetallic number based on equivalent diameter in the skin layer (a) and the core (b) of HVDC AISI10-0.10Fe0.6Mn, AlSi10-0.16Fe0.6Mn, AlSi10-0.20Fe0.6Mn and AlSi10-0.15Fe0.82Mn alloys
  • Fig. 10: Primary a-Fe intermetallics with increased volumes in the HVDC AlSi10-0.15Fe0.82Mn alloy (a-f) [34]
  • Fig. 11: Schematic of growth pattern of the primary a-Fe phase in die-cast AlSiMgMn alloys (a-e) [34]
  • Fig. 12: Volume distribution of micro pores in ADC12 die casting: (a) Weibull distribution; (b) two-parameter lognormal distribution; and (c) three-parameter lognormal distribution
  • Fig. 13: Clusters of Fe-rich intermetallics in core of the HVDC AISi10-0.16Fe0.6Mn (a) and AlSi10-0.15Fe0.82Mn (b) alloys
  • Fig. 14: Distances between intermetallic centroids (black arrow) and the intra-distance (red arrow) the HVDC AlSi10-0.16Fe0.6Mn (a) and AlSi10-0.15Fe0.82Mn (b) alloys
  • Fig. 15: Comparison of pore size and distribution between CT images (a) and fracture surface (b) [44]
  • Fig. 16: Pore changes in HPDC AISi10MgMn alloys under different loading conditions: (a) 0% distortion; (b) 2% distortion; and (c) fractured condition [51]
  • Fig. 17: Stress-fatigue life of specimens with different porosities from ADC 12 die castings
  • Fig. 18: Polyhedral Fe-rich phases (a) and their fracture morphologies (b)-(d), polyhedral Fe-rich phase under 0 N (e) and 410 N (f), and shrinkage under 410 N (g) [31]
  • Fig. 19: Damage and fracture of HVDC AISi10-0.16Fe0.6Mn (a) and AlSi10-0.15Fe0.82Mn (b) alloys with 3D X-rays microtomography in-situ tensile test
  • Fig. 20: HPDC experiment results at the center region of a sample with a 5 mm wall thickness: (a) EBSD image; (b) EBSD grain map; and (c) simulated grain morphology [65]
  • Fig. 21: Reconstructed microstructure of HVDC AlSi10Mg0.2Cu0.1 (a), AlSi10Mg0.2Cu0.6 (b), AlSi10Mg0.2Cu0.6 (c), and AlSi10Mg0.4Cu0.6 (d) with SBFSEM at nano-scale
  • Fig. 22: Stress concentration factors (maximum and average values) calculated using FEA for shrinkage pore (a) and β-Al5FeSi intermetallics (b) of gravity cast AlSiCu alloys [72]

7. Conclusion:

X-ray microtomography has become an indispensable tool for characterizing 3D microstructures in HPDC Al and Mg alloys, providing insights into pores and Fe-rich intermetallics. It enables quantitative analysis of morphology, distribution, and clustering, which are crucial for understanding their impact on mechanical properties. Future research should focus on integrating X-ray microtomography with advanced simulation techniques to predict and control microstructure formation and optimize alloy design and casting processes for enhanced performance of HPDC components. Multi-phase and multi-physical simulations incorporating actual microstructure characteristics are crucial for establishing robust microstructure-property relationships in HVDC Al and Mg alloys.

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9. Copyright:

  • This material is a paper by "Hai-dong Zhao, Xue-ling Wang, Qian Wan, Wen-hui Bai, and Fei Liu". Based on "Characteristics and distribution of microstructures in high pressure die cast alloys with X-ray microtomography: A review".
  • Source of the paper: https://doi.org/10.1007/s41230-024-4109-3

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